How Should The Internal Space Of The Pre-insulated Bushing Be Matched With The Conductor?
In electrical assembly, a fundamental step is inserting wires into connectors. The design of pre insulated sleeve revolves around this action. Its hollow internal structure is not arbitrarily formed, but precisely matched to the outer diameter of the wire and the cross-section of the core. This physical fit lays the foundation for the stability of the electrical connection. This is particularly relevant for flexible copper wires commonly used in industrial applications.
Looking at the design logic of the sleeve from the perspective of "penetration"
The pre insulated junction sleeve sleeve can be fitted onto the conductor, a characteristic that determines the smoothness of wire harness processing. Some tubular pre-insulated connectors use copper as the conductor, with an outer nylon insulation layer. The tubular structure facilitates crimping after wire insertion. In high-voltage scenarios such as 10KV line connections, the inside of the bushing is even coated with contact grease to enhance the tightness of the conductor contact. The surface of the bushing is usually clearly marked with the cross-sectional area of the applicable wire and even the number of crimping cycles, providing direct reference for operators.
The synergy between materials and crimping:
The insulated joint sleeve bushing can be fitted over the wire; after threading, it is crimped for fixation. The internal metal components of the bushing, for example, are made of electrolytic copper with a purity of 99.95% or higher, and are tin-plated to improve corrosion resistance. The outer polyamide PA6 insulating sleeve provides clear electrical isolation. When pressure is applied to the bushing using a matching crimping tool, the metal wall undergoes plastic deformation, tightly bonding with the internal conductor core. The insulation layer not only protects the connection point during this process but also constrains the crimping shape.
