CA1189690A - Electrical crimp connection with anaerobic sealant - Google Patents
Electrical crimp connection with anaerobic sealantInfo
- Publication number
- CA1189690A CA1189690A CA000395708A CA395708A CA1189690A CA 1189690 A CA1189690 A CA 1189690A CA 000395708 A CA000395708 A CA 000395708A CA 395708 A CA395708 A CA 395708A CA 1189690 A CA1189690 A CA 1189690A
- Authority
- CA
- Canada
- Prior art keywords
- wire barrel
- crimped
- setting material
- barrel
- conductor
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
- H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
- H01R4/185—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
- H01R13/5216—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases characterised by the sealing material, e.g. gels or resins
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/04—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation using electrically conductive adhesives
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
Landscapes
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Manufacturing Of Electrical Connectors (AREA)
Abstract
ELECTRICAL CRIMP CONNECTION
WITH ANAEROBIC SEALANT
Abstract of the Disclosure:
A tin plated, bronze terminal has an open wire barrel of unique design which is attached to the end of a stranded copper wire conductor. An anaerobically setting material, such as Loctite? AV, is applied to the end of the stranded wire conductor and the open wire barrel is then tightly crimped around the end producing an electrical interface inside the crimped wire barrel. The anaerobically setting material is retained inside the crimped wire barrel in a substantially air free environment where the anaerobically setting material cures to provide an air tight seal for the electrical interface.
WITH ANAEROBIC SEALANT
Abstract of the Disclosure:
A tin plated, bronze terminal has an open wire barrel of unique design which is attached to the end of a stranded copper wire conductor. An anaerobically setting material, such as Loctite? AV, is applied to the end of the stranded wire conductor and the open wire barrel is then tightly crimped around the end producing an electrical interface inside the crimped wire barrel. The anaerobically setting material is retained inside the crimped wire barrel in a substantially air free environment where the anaerobically setting material cures to provide an air tight seal for the electrical interface.
Description
C~3330 D-4,742 ELECTRICAL CRIMP CONNECTION
WITH ANAEROBIC SEALANT
This invention relates generally to electrical connections and, more particularly, to an electrical crimp connection where a wire barrel S is mechanically and electrically attached to a stranded wire conductor.
Electric terminals are commonly attached to the ends of electric ca~les by a crimp connection ~ere an open U-shaped wire barrel of the terminal is crimped or deformed tightly around the exposed end of a stranded ~ire conductor of the cable. See for instance, U.S. Patent 3,032,6Q2 granted to Samuel J. Farnell on May 1, 1962. This crimped wire ~arrel is both a mechanical and electrical connection of the terminal to the end of the stranded wire conductor. The terminals often have a second U-shaped ~arrel ~hich is crimped around the cable insulation to enhance the mechanical connection.
Electr~cal terminals are commonly made of 2a an oxidiza~le material, such as tin plated bronze and the stranded wire conductors are also commonly made o an ox.idizable material such as copper.
Consequently, the electrical crimp connection is subject to deterioration when exposed to an oxidi2ing environment because the electrical resistance increases due to oxides ~eing ~ormed at the inter~
face between t~e crimped wire barrel and the stranded wire conductor. The useful life of the electrical crimp connection, therefore, depends 3a among other things on the type of electrical circuitry involved and the environment to which the crimp connection is exposed.
A stable resistance of electrical crimp connections is particularly important in low voltage, low current appllcations such as electronic circuitry, and it is particularly challenging to S achieve in harsh environments such as automobile engine compartments where electronic engine controls are ~ecoming common.
A kno~n ~ay to sta~ilize the electrical resistance and t~us improve the life o~ electrical 1~ crimp connections is to seal t~e electrical crimp connectlon ~y a solder reflow process. In this process, the exposed end of the stranded wire conductor is dipped in liquid solder which is allowed to solidify. The wire ~arrel of the terminal is then crimped tightly ~round the solder coated end of the stranded ~ire conductor. ~fter the wire ~arrel is crimped, t~e crimp connection is then heated until the solder melts and flows to fill all the open spaces and vo~ds inside the crimpecl wire barrel.
The solder then cools and solidifies ~ormin~ an air tight seal for the inter~ace between the crimped ~ire barrel and the stranded ~ire conductor~
The solder reflow process adequately sta~ilizes the electrical resistance of the electric crimp connection ~or use in electronic circuits.
However, the solder reflow process is relatively expensive.
The o~ject of this invention is to provide an electrical crimp connection which is stabilized by a method whîch is considera~ly cheaper and simpler than the solder reflow process.
A primary feature of -the invention is the use of an anaero~ic material which forms an air tight seal for the interface between the crimped wire barrel and the stranded wire conductor In an electrical crimp connection.
Another ~eature of the invention is the advantageous use of the air exclusion produced hy t~e crimping process to oxygenate and set the anaerobic material ~hich eliminates critical timing and greatly simplîfies the processing of the electrical crîmp connection in comparîson to the solder re10w-process.
Yet another feature of the învention is t~at the anaero~îc material removes natîve oxîdes on the ~ire barrel and the stranded wire conductor during the crîmping process thus reducing the electrical resistance of the electrical crimp connection.
Yet another feature of the invention is that the anaerobic material is a tenacious adhesive which improves the mechanical connection of the crîmped wire ~arrel to the stranded wire conductor, Still yet another feature of the invention is that the wire barrel may be slotted to lower the electrical resistance of the electrical crimp connection employing the anaerobic material.
Other objects and features of the invention will ~ecome apparent to those skilled în the art as the disclosure is made in the following detailed description of a preferred embodiment of the in-vention as illustrated in the accompanying shee~ of 3~ drawing in which:
Figure 1 is a perspective view of an electric ca~le and an apparatus for appl,ving an anaerobic material to an exposed end of the stranded wire con-ductor of the electric cable, Figure 2 is a top view o~ a terminal having a slotted open ~ire ~arrel for crimping around the end of the stranded wire conductor after the anaerobic material has ~een applied thereta.
Figure 3 is a side view of the terminal shown in Figure 1.
Figure 4 is a section taken substantially along the line 4-4 of Fi~ure 2 and looking in the lQ direction of the arrows.
Figure 5 is a perspective view of the -terminal shown in Figures 2, 3 and 4 and an electric ca~le attached to each other ~y an electrical crimp connection according to our invention.
Figllre 6 is a transverse section through the cri.mped wire barrel taken substantially along the line 6 6 of Figure 5 and looking in the direction of the arrows.
Reerring now to the drawi.ng, Figure 1 shows an electric cable 12 comprising a stranded wire conductor 14 inside an insulation jacket 16.
A length o the insulation jacket 16 has been stripped rom the cable 12 to expose an end portion o the stranded wire conductor 14, which in the example illustrated, consists of seven gradually parallel copper wire strands 18.
Figure 1 also shows an apparatus for ap-plying liquid material to the exposed end portionof the stranded wire conductor 14. The apparatus comprises a sponge pad 20 which is located in a shallow reservoir 22 by four corner braces 23. The bottom portion of the sponge pad 20 lies in liquid material 24 contained in the shallow reservoir and the sponge pad 20 is filled with this liquid material 24 by a wicking action. The apparatus also includes an air cylinder which moves a ram plake 25 which presses the exposed end portion o~
the conductor 14 into the sponge pad 20 to apply the liquid material 24.
We have discovered that Loctite~ AV, which is a non-conducting, anaerobically setting, polymeric material composed mainly o~ a dimethacrylate ester, is an excellent material ~or stabilizing the resistance o~
an electrical crimp connection particularly when a stranded copper wire conductor and tin plate bronze terminal are involved. Loctite~ AV is manufactured and marketed under Product Catalogue Number 87 by I,octite Corporation ~ounded in 195LI which produces anaerobic polymeric materials o~ various ~ormulations for use as adheslves and/or sealants.
The Loctite~ AV, Product Catalogue Number 87, ls a red liquid of mild odor. It has low solubility in water, a bolling point o~ approximately 300F. and a speci~lc gravity o~ 1.068 @ 80F. The chemlcal composition comprises approximately 84% Dimethacrylate Ester, 6% Resin, 2.6% Tertiary Amine and 7% Catalyst.
The rnaterial is also believed to be described in the U.S. Patent 2,628,178 granted to Robert E.
Burnett and Birger W. Nordlander on February 10, 1953.
Since Loctite~ AV is anaerobic and does not set or polymerize until the material is in an oxygen or ~3~
air free environment3 the liquid material 24 can be applied to the end portion Or the conductor 14 without concern about premature solidification simply by keeping the electric cables 12 which have been treated with the Locti-te~ AV in a normal environment. More-over, the exclusion o~ oxygen or air which is required for solidfying the Loctite~ AV ls initiated at precisely the right time in the process as will hereinafter more fully appear.
As indicated above, Loctite~ AV is a nonconductive material. We have not only discovered its surprising utility as a sealant for electrlcal crimp connections but we have also discovered that the electrical properties o~ the crimp connection can be enhanced by the tin pla,ted bronze terminal 30, shown in Figures 2, 3 and 4, which has a unique wire barrel.
The terminal 30 has a .~emale contact portion 32 at one end and a cable attachment portion 34 at the other end and generally conforms to the termi.nal whlch is disclosed in U.S. Patent 3,267,410 (Baer et al) and U.~. Patent 3, 310, 7 72 (.Klrk).
The details o~ the contact portion 32 are not releva.nt to our invention and, consequently, the contact portion 32 need not be described in detai.l.
The cable attachment portion 34 comprises an open wire barrel 36 and larger open insulation barrel 38. The open wire barrel 36 is generally U-shaped as shown in ~igure 4 and the outer ends OI the barrel are coined at 40 in accordance with standard practice. The wire barrel 36, however, is unique in that it has -two slots 42 in each wing 44 o~ the open wire barrel 36 so that each wing 44 of the open wire barrel 36 has three narrow fingers 45, The fingers 45 deform independently of each other in the crimping process and produce a tighter crimp while minimizing the danger of cutting wire strands 18~
In an actual example, a terminal 30 was made from tin plated bronze stock which was 0~016 inches thick. The slots 42 were about 0.020 inches wide and extended down ~rom the coined ends o~ the open wire barrel 36 for about 0.0ll0 inches so that the fingers 45 10 were each about 0.034 inches wide and 0.040 inches long. The insulation barrel 38 is conventional in design.
The terminal 30 is attached to the electric cable 12 with crimping dles generally of the form shown 15 in the af`orementioned Farnell patent so that the wire barrel 36 is tightly crimped around the end portion of the stranded wire conductor 14 (which has the Loctite~
AV applied thereto) and the insulation barrel is tightly crimped around the insulation ,~acket 16 as 20 shown in :Eiigure 5.
I'he appearance o:~ a. -typical transversely cross-sectioned electrlcal crimp connection made in accordance with our inven-tion is shown in r~llgure 6.
This schematic drawing made from a scanning electron
WITH ANAEROBIC SEALANT
This invention relates generally to electrical connections and, more particularly, to an electrical crimp connection where a wire barrel S is mechanically and electrically attached to a stranded wire conductor.
Electric terminals are commonly attached to the ends of electric ca~les by a crimp connection ~ere an open U-shaped wire barrel of the terminal is crimped or deformed tightly around the exposed end of a stranded ~ire conductor of the cable. See for instance, U.S. Patent 3,032,6Q2 granted to Samuel J. Farnell on May 1, 1962. This crimped wire ~arrel is both a mechanical and electrical connection of the terminal to the end of the stranded wire conductor. The terminals often have a second U-shaped ~arrel ~hich is crimped around the cable insulation to enhance the mechanical connection.
Electr~cal terminals are commonly made of 2a an oxidiza~le material, such as tin plated bronze and the stranded wire conductors are also commonly made o an ox.idizable material such as copper.
Consequently, the electrical crimp connection is subject to deterioration when exposed to an oxidi2ing environment because the electrical resistance increases due to oxides ~eing ~ormed at the inter~
face between t~e crimped wire barrel and the stranded wire conductor. The useful life of the electrical crimp connection, therefore, depends 3a among other things on the type of electrical circuitry involved and the environment to which the crimp connection is exposed.
A stable resistance of electrical crimp connections is particularly important in low voltage, low current appllcations such as electronic circuitry, and it is particularly challenging to S achieve in harsh environments such as automobile engine compartments where electronic engine controls are ~ecoming common.
A kno~n ~ay to sta~ilize the electrical resistance and t~us improve the life o~ electrical 1~ crimp connections is to seal t~e electrical crimp connectlon ~y a solder reflow process. In this process, the exposed end of the stranded wire conductor is dipped in liquid solder which is allowed to solidify. The wire ~arrel of the terminal is then crimped tightly ~round the solder coated end of the stranded ~ire conductor. ~fter the wire ~arrel is crimped, t~e crimp connection is then heated until the solder melts and flows to fill all the open spaces and vo~ds inside the crimpecl wire barrel.
The solder then cools and solidifies ~ormin~ an air tight seal for the inter~ace between the crimped ~ire barrel and the stranded ~ire conductor~
The solder reflow process adequately sta~ilizes the electrical resistance of the electric crimp connection ~or use in electronic circuits.
However, the solder reflow process is relatively expensive.
The o~ject of this invention is to provide an electrical crimp connection which is stabilized by a method whîch is considera~ly cheaper and simpler than the solder reflow process.
A primary feature of -the invention is the use of an anaero~ic material which forms an air tight seal for the interface between the crimped wire barrel and the stranded wire conductor In an electrical crimp connection.
Another ~eature of the invention is the advantageous use of the air exclusion produced hy t~e crimping process to oxygenate and set the anaerobic material ~hich eliminates critical timing and greatly simplîfies the processing of the electrical crîmp connection in comparîson to the solder re10w-process.
Yet another feature of the învention is t~at the anaero~îc material removes natîve oxîdes on the ~ire barrel and the stranded wire conductor during the crîmping process thus reducing the electrical resistance of the electrical crimp connection.
Yet another feature of the invention is that the anaerobic material is a tenacious adhesive which improves the mechanical connection of the crîmped wire ~arrel to the stranded wire conductor, Still yet another feature of the invention is that the wire barrel may be slotted to lower the electrical resistance of the electrical crimp connection employing the anaerobic material.
Other objects and features of the invention will ~ecome apparent to those skilled în the art as the disclosure is made in the following detailed description of a preferred embodiment of the in-vention as illustrated in the accompanying shee~ of 3~ drawing in which:
Figure 1 is a perspective view of an electric ca~le and an apparatus for appl,ving an anaerobic material to an exposed end of the stranded wire con-ductor of the electric cable, Figure 2 is a top view o~ a terminal having a slotted open ~ire ~arrel for crimping around the end of the stranded wire conductor after the anaerobic material has ~een applied thereta.
Figure 3 is a side view of the terminal shown in Figure 1.
Figure 4 is a section taken substantially along the line 4-4 of Fi~ure 2 and looking in the lQ direction of the arrows.
Figure 5 is a perspective view of the -terminal shown in Figures 2, 3 and 4 and an electric ca~le attached to each other ~y an electrical crimp connection according to our invention.
Figllre 6 is a transverse section through the cri.mped wire barrel taken substantially along the line 6 6 of Figure 5 and looking in the direction of the arrows.
Reerring now to the drawi.ng, Figure 1 shows an electric cable 12 comprising a stranded wire conductor 14 inside an insulation jacket 16.
A length o the insulation jacket 16 has been stripped rom the cable 12 to expose an end portion o the stranded wire conductor 14, which in the example illustrated, consists of seven gradually parallel copper wire strands 18.
Figure 1 also shows an apparatus for ap-plying liquid material to the exposed end portionof the stranded wire conductor 14. The apparatus comprises a sponge pad 20 which is located in a shallow reservoir 22 by four corner braces 23. The bottom portion of the sponge pad 20 lies in liquid material 24 contained in the shallow reservoir and the sponge pad 20 is filled with this liquid material 24 by a wicking action. The apparatus also includes an air cylinder which moves a ram plake 25 which presses the exposed end portion o~
the conductor 14 into the sponge pad 20 to apply the liquid material 24.
We have discovered that Loctite~ AV, which is a non-conducting, anaerobically setting, polymeric material composed mainly o~ a dimethacrylate ester, is an excellent material ~or stabilizing the resistance o~
an electrical crimp connection particularly when a stranded copper wire conductor and tin plate bronze terminal are involved. Loctite~ AV is manufactured and marketed under Product Catalogue Number 87 by I,octite Corporation ~ounded in 195LI which produces anaerobic polymeric materials o~ various ~ormulations for use as adheslves and/or sealants.
The Loctite~ AV, Product Catalogue Number 87, ls a red liquid of mild odor. It has low solubility in water, a bolling point o~ approximately 300F. and a speci~lc gravity o~ 1.068 @ 80F. The chemlcal composition comprises approximately 84% Dimethacrylate Ester, 6% Resin, 2.6% Tertiary Amine and 7% Catalyst.
The rnaterial is also believed to be described in the U.S. Patent 2,628,178 granted to Robert E.
Burnett and Birger W. Nordlander on February 10, 1953.
Since Loctite~ AV is anaerobic and does not set or polymerize until the material is in an oxygen or ~3~
air free environment3 the liquid material 24 can be applied to the end portion Or the conductor 14 without concern about premature solidification simply by keeping the electric cables 12 which have been treated with the Locti-te~ AV in a normal environment. More-over, the exclusion o~ oxygen or air which is required for solidfying the Loctite~ AV ls initiated at precisely the right time in the process as will hereinafter more fully appear.
As indicated above, Loctite~ AV is a nonconductive material. We have not only discovered its surprising utility as a sealant for electrlcal crimp connections but we have also discovered that the electrical properties o~ the crimp connection can be enhanced by the tin pla,ted bronze terminal 30, shown in Figures 2, 3 and 4, which has a unique wire barrel.
The terminal 30 has a .~emale contact portion 32 at one end and a cable attachment portion 34 at the other end and generally conforms to the termi.nal whlch is disclosed in U.S. Patent 3,267,410 (Baer et al) and U.~. Patent 3, 310, 7 72 (.Klrk).
The details o~ the contact portion 32 are not releva.nt to our invention and, consequently, the contact portion 32 need not be described in detai.l.
The cable attachment portion 34 comprises an open wire barrel 36 and larger open insulation barrel 38. The open wire barrel 36 is generally U-shaped as shown in ~igure 4 and the outer ends OI the barrel are coined at 40 in accordance with standard practice. The wire barrel 36, however, is unique in that it has -two slots 42 in each wing 44 o~ the open wire barrel 36 so that each wing 44 of the open wire barrel 36 has three narrow fingers 45, The fingers 45 deform independently of each other in the crimping process and produce a tighter crimp while minimizing the danger of cutting wire strands 18~
In an actual example, a terminal 30 was made from tin plated bronze stock which was 0~016 inches thick. The slots 42 were about 0.020 inches wide and extended down ~rom the coined ends o~ the open wire barrel 36 for about 0.0ll0 inches so that the fingers 45 10 were each about 0.034 inches wide and 0.040 inches long. The insulation barrel 38 is conventional in design.
The terminal 30 is attached to the electric cable 12 with crimping dles generally of the form shown 15 in the af`orementioned Farnell patent so that the wire barrel 36 is tightly crimped around the end portion of the stranded wire conductor 14 (which has the Loctite~
AV applied thereto) and the insulation barrel is tightly crimped around the insulation ,~acket 16 as 20 shown in :Eiigure 5.
I'he appearance o:~ a. -typical transversely cross-sectioned electrlcal crimp connection made in accordance with our inven-tion is shown in r~llgure 6.
This schematic drawing made from a scanning electron
2~ m:lcrograph correctly depicts the dimensions o~ the tin plated bronze wire barrel 36 and a seven strand copper wire conductor 14. The hexagonal shape o~ the copper wire strands 18 and the predominance of' boundaries intersecting at approximately 60 indicates that the 30 copper wire strands 18 are under a high compressive stress while the areas designated 36d indicate that the tin plating on the interior wall o:E the crimped wire barrel 36 buckles severely~
The electrical crimp connections were also analyzed with an electron microprobe. The resulting micrographs of boundaries between the copper strands 18 (not shown) reveal a hlgh concentration of carbon between adJacent copper strands which indicates that the Loctite~ AV was not expelled by the crimping process.
The electrlcal properties of the electrical crimp connection, in this instance, are dominated by the interface between the copper wire strands 18 and the tin plating of the crimped wire barrel 36. Other micrographs (not shown) indicate that the Loctite~ AV
nearly forms a complete boundary layer between the tin plating and stranded copper wire conductor 14. The Loctite~ AV thus reduces the effective contact area of the electrical crimp connection.
Cross~sections taken near the ends of the crimped wire barrel 36 show that the Loctite~ AV fills the voids between the copper wire strands 18. This provides effective seal protecting the interior sur~aces from oxidation by air or other ambient gases.
The role of Loctite~ AV in the electrical crimp connectLon is believed to be as rollows. Upon application, the Loctite~ AV partially cleans the native oxide ~rom the copper wire strands 18 and the wire barrel 36. This cleaning action may be facili-tated by the temperature rise as the crimping process is initiated. As the crimp is formed, Loctite~ AV
remains inside the wire barrel 36. The Loctite~ AV
is tenacious and reduces the contact area between the crimped wire barrel 36 and the copper wire strands 18.
The slots 42 in the wire barrel 36 aid in establishing . ...
electrical contact by creating pressure gradients during the crimping process which encourage the flow of the unset Loctite~ AV. The tin plating or layer buckles and increases the area of the interface between the crimped wire barrel 36 and the copper wire strands 18. It ls also likely that the electrical contact between the crimped wire barrel 36 and the copper wire strands 18 can be enhanced by dispersing conductive particles in the Loctite~ AV.
The crimping process also excludes air ~rom inside the crlmped wire barrel 36 so that the Loctite~
AV inside the tightly crimped wire barrel 36 is in an essentially oxygen or air free environment. Conse-quently, the Loctite~ AV starts to set up or oxygenate when the wire barrel 36 is crimped.
When the Loctite~ AV is cured and forms a solid, it provides an air tight seal for the interface between the crlmped wire barrel 36 and the ~:Lre strands 18. This air tight seal, formed by the Loctite~ AV, :Ls chemically inert and prevents oxidation of the co~tact inter~ace. Consequently, the electrical resistance of crimp connectlon remains relatively constant over a prolonged life. The Loctite~ AV is also a tenacious adhesive, so that it also counters the tendency of the crimped wire barrel 36 to relax. Thus, the cured Loctite~ AV also enhances the mechanical connection between the crimped wire barrel 36 and the end portion o~ the stranded wire conductor 1llo The cure time of the Loctite~ AV is two to six hours and the cure time is enhanced in this particular instance because the wire strands are copper. The cure time can also be substantially reduced to a matter of minutes by the use of a Loquic~
primer which is also marketed by the Loctite CorporationO However, since the terminals 30 are normally attached to the cables 12 several hours before the terminals 30 and cables 12 are used~ a fast cure time is usually not necessary. Consequently~ the use of Loqulc~ or another accelerator is not necessary in most instances.
We wish it to be understood that we do not desire to be limited to the exact details of construction shown and described, for obvious modifications will occur to a person skilled in the art.
,.:
The electrical crimp connections were also analyzed with an electron microprobe. The resulting micrographs of boundaries between the copper strands 18 (not shown) reveal a hlgh concentration of carbon between adJacent copper strands which indicates that the Loctite~ AV was not expelled by the crimping process.
The electrlcal properties of the electrical crimp connection, in this instance, are dominated by the interface between the copper wire strands 18 and the tin plating of the crimped wire barrel 36. Other micrographs (not shown) indicate that the Loctite~ AV
nearly forms a complete boundary layer between the tin plating and stranded copper wire conductor 14. The Loctite~ AV thus reduces the effective contact area of the electrical crimp connection.
Cross~sections taken near the ends of the crimped wire barrel 36 show that the Loctite~ AV fills the voids between the copper wire strands 18. This provides effective seal protecting the interior sur~aces from oxidation by air or other ambient gases.
The role of Loctite~ AV in the electrical crimp connectLon is believed to be as rollows. Upon application, the Loctite~ AV partially cleans the native oxide ~rom the copper wire strands 18 and the wire barrel 36. This cleaning action may be facili-tated by the temperature rise as the crimping process is initiated. As the crimp is formed, Loctite~ AV
remains inside the wire barrel 36. The Loctite~ AV
is tenacious and reduces the contact area between the crimped wire barrel 36 and the copper wire strands 18.
The slots 42 in the wire barrel 36 aid in establishing . ...
electrical contact by creating pressure gradients during the crimping process which encourage the flow of the unset Loctite~ AV. The tin plating or layer buckles and increases the area of the interface between the crimped wire barrel 36 and the copper wire strands 18. It ls also likely that the electrical contact between the crimped wire barrel 36 and the copper wire strands 18 can be enhanced by dispersing conductive particles in the Loctite~ AV.
The crimping process also excludes air ~rom inside the crlmped wire barrel 36 so that the Loctite~
AV inside the tightly crimped wire barrel 36 is in an essentially oxygen or air free environment. Conse-quently, the Loctite~ AV starts to set up or oxygenate when the wire barrel 36 is crimped.
When the Loctite~ AV is cured and forms a solid, it provides an air tight seal for the interface between the crlmped wire barrel 36 and the ~:Lre strands 18. This air tight seal, formed by the Loctite~ AV, :Ls chemically inert and prevents oxidation of the co~tact inter~ace. Consequently, the electrical resistance of crimp connectlon remains relatively constant over a prolonged life. The Loctite~ AV is also a tenacious adhesive, so that it also counters the tendency of the crimped wire barrel 36 to relax. Thus, the cured Loctite~ AV also enhances the mechanical connection between the crimped wire barrel 36 and the end portion o~ the stranded wire conductor 1llo The cure time of the Loctite~ AV is two to six hours and the cure time is enhanced in this particular instance because the wire strands are copper. The cure time can also be substantially reduced to a matter of minutes by the use of a Loquic~
primer which is also marketed by the Loctite CorporationO However, since the terminals 30 are normally attached to the cables 12 several hours before the terminals 30 and cables 12 are used~ a fast cure time is usually not necessary. Consequently~ the use of Loqulc~ or another accelerator is not necessary in most instances.
We wish it to be understood that we do not desire to be limited to the exact details of construction shown and described, for obvious modifications will occur to a person skilled in the art.
,.:
Claims (10)
1. A method of making an electrical crimp connection in which an open wire barrel is attached to a stranded wire conductor comprising the steps of:
applying an anaerobically setting material to a portion of the stranded wire conductor, crimping the open wire barrel around the portion of the standed wire conductor so that the crimped wire barrel is mechanically connected to the portion of the stranded wire conductor and an electrical interface is produced inside the crimped wire barrel, while anaerobically setting material is retained inside the crimped wire barrel, said crimping operation being sufficient to produce a substantially air free environment inside the crimped wire barrel whereby the anaerobically setting material retained inside the crimped wire barrel polymerizes and sets to provide an air tight seal for the electrical interface.
applying an anaerobically setting material to a portion of the stranded wire conductor, crimping the open wire barrel around the portion of the standed wire conductor so that the crimped wire barrel is mechanically connected to the portion of the stranded wire conductor and an electrical interface is produced inside the crimped wire barrel, while anaerobically setting material is retained inside the crimped wire barrel, said crimping operation being sufficient to produce a substantially air free environment inside the crimped wire barrel whereby the anaerobically setting material retained inside the crimped wire barrel polymerizes and sets to provide an air tight seal for the electrical interface.
2. A method of making an electrical crimp connection in which an open wire barrel is attached to a stranded wire conductor comprising the steps of:
applying a non-conducting, anaerobically setting material to a portion of the stranded wire conductor, crimping the open wire barrel around the portion of the stranded wire conductor so that the crimped wire barrel is mechanically connected to the portion of the stranded wire conductor and an electrical interface is produced inside the crimped wire barrel, while non-conducting, anaerobically setting material is retained inside the crimped wire barrel, said crimping operation being sufficient to produce a substantially air free environment inside the crimped wire barrel whereby the anaerobically setting material retained inside the crimped wire barrel polymerizes and sets to provide an air tight seal for the electrical interface.
applying a non-conducting, anaerobically setting material to a portion of the stranded wire conductor, crimping the open wire barrel around the portion of the stranded wire conductor so that the crimped wire barrel is mechanically connected to the portion of the stranded wire conductor and an electrical interface is produced inside the crimped wire barrel, while non-conducting, anaerobically setting material is retained inside the crimped wire barrel, said crimping operation being sufficient to produce a substantially air free environment inside the crimped wire barrel whereby the anaerobically setting material retained inside the crimped wire barrel polymerizes and sets to provide an air tight seal for the electrical interface.
3. The method as defined in claim 2 wherein the non-conducting, anaerobically setting material is composed mainly of a dimethacrylate ester or esters.
4. A method of making an electrical crimp connection in which an open wire barrel is attached to a stranded wire conductor comprising the steps of:
providing a metallic, open wire barrel which has a tin layer on an interior surface, applying a tenacious, anaerobically setting material to a portion of a stranded wire conductor, crimping the open wire barrel around the portion of the stranded wire conductor so that the crimped wire barrel is mechanically connected to the portion of the stranded wire conductor and the tin layer is buckled so as to enhance the electrical interface of the crimped wire barrel and the stranded wire conductor while anaerobically setting material is retained inside the crimped wire barrel, said crimping operation being sufficient to produce a substantially air free environment inside the crimped wire barrel whereby the anaerobically setting material retained inside the crimped wire barrel polymerizes and sets to provide an air tight seal for the electrical interfaces.
providing a metallic, open wire barrel which has a tin layer on an interior surface, applying a tenacious, anaerobically setting material to a portion of a stranded wire conductor, crimping the open wire barrel around the portion of the stranded wire conductor so that the crimped wire barrel is mechanically connected to the portion of the stranded wire conductor and the tin layer is buckled so as to enhance the electrical interface of the crimped wire barrel and the stranded wire conductor while anaerobically setting material is retained inside the crimped wire barrel, said crimping operation being sufficient to produce a substantially air free environment inside the crimped wire barrel whereby the anaerobically setting material retained inside the crimped wire barrel polymerizes and sets to provide an air tight seal for the electrical interfaces.
5. The method as defined in claim 4 wherein the anaerobically setting material is non-conducting.
6. The method as defined in claim 5 wherein the anaerobically setting material is composed mainly of a dimethacrylate ester or esters.
7. The method as defined in claim 6 wherein the stranded wire conductor is made of copper.
8. A method of making an electrical crimp connection in which an open wire barrel is attached to a stranded wire conductor comprising the steps of:
providing a metallic, open wire barrel which has a tin layer on an interior surface and slots forming a plurality of narrow fingers in each wing of the open wire barrel, applying a tenacious, anaerobically setting material to a portion of the stranded wire conductor, crimping the open wire barrel around the portion of the stranded wire conductor so that the crimped wire barrel is mechanically connected to the portion of the stranded wire conductor and the tin layer is buckled so as to enhance the electrical interface of the crimped wire barrel and the stranded wire conductor while anaerobically setting material is retained inside the crimped wire barrel, said crimping operation being sufficient to produce a substantially air free environment inside the crimped wire barrel whereby the anaerobic material retained inside the crimped wire barrel polymerizes and sets to provide an air tight seal for the electrical interface.
providing a metallic, open wire barrel which has a tin layer on an interior surface and slots forming a plurality of narrow fingers in each wing of the open wire barrel, applying a tenacious, anaerobically setting material to a portion of the stranded wire conductor, crimping the open wire barrel around the portion of the stranded wire conductor so that the crimped wire barrel is mechanically connected to the portion of the stranded wire conductor and the tin layer is buckled so as to enhance the electrical interface of the crimped wire barrel and the stranded wire conductor while anaerobically setting material is retained inside the crimped wire barrel, said crimping operation being sufficient to produce a substantially air free environment inside the crimped wire barrel whereby the anaerobic material retained inside the crimped wire barrel polymerizes and sets to provide an air tight seal for the electrical interface.
9. The method as defined in claim 8 wherein the anaerobically setting material is non-conducting.
10. The method as defined in claim 8 wherein the anaerobically setting material is composed mainly of a dimethacrylate ester or esters and the stranded wire conductor is made of copper.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US28455581A | 1981-07-20 | 1981-07-20 | |
| US284,555 | 1981-07-20 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1189690A true CA1189690A (en) | 1985-07-02 |
Family
ID=23090640
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000395708A Expired CA1189690A (en) | 1981-07-20 | 1982-02-08 | Electrical crimp connection with anaerobic sealant |
Country Status (4)
| Country | Link |
|---|---|
| EP (1) | EP0070639B1 (en) |
| JP (1) | JPS5825090A (en) |
| CA (1) | CA1189690A (en) |
| DE (1) | DE3269364D1 (en) |
Families Citing this family (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02291676A (en) * | 1990-01-12 | 1990-12-03 | Yazaki Corp | Connecting method for wire harness |
| JPH0828240B2 (en) * | 1990-05-25 | 1996-03-21 | 矢崎総業株式会社 | Crimping connection structure for electric wires and crimping connection method |
| JPH04136385A (en) * | 1990-09-26 | 1992-05-11 | Mazda Motor Corp | Door lock structure of car |
| US5532433A (en) * | 1991-11-13 | 1996-07-02 | Yazaki Corporation | Waterproof-type terminal connection structure and method of producing same |
| JP2844993B2 (en) * | 1991-11-13 | 1999-01-13 | 矢崎総業株式会社 | Joint terminal waterproof connection method |
| JPH0686540U (en) * | 1993-05-27 | 1994-12-20 | 株式会社服部セイコー | Connecting device for leather bands |
| DE19727314B4 (en) * | 1997-06-27 | 2012-01-12 | Bayerische Motoren Werke Aktiengesellschaft | crimp |
| DE19906563A1 (en) * | 1999-02-17 | 2000-08-31 | Em Kunststofftechnik Gmbh | Electrical cables |
| DE19929004A1 (en) * | 1999-06-24 | 2000-12-28 | Delphi Tech Inc | Crimp connection |
| FR2928039B1 (en) * | 2008-02-25 | 2010-03-12 | Leoni Wiring Systems France | ASSEMBLY FORMING ELECTRICAL CONNECTION BY CRIMPING. |
| JP5362296B2 (en) * | 2008-09-03 | 2013-12-11 | 矢崎総業株式会社 | Terminal fitting |
| DE102013012990A1 (en) * | 2013-08-02 | 2015-02-05 | Interroll Holding Ag | Powered conveyor roller |
| EP4024617A1 (en) * | 2014-04-24 | 2022-07-06 | Molex, LLC | Terminal fitting |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2347540A (en) * | 1942-09-07 | 1944-04-25 | Nat Telephone Supply Co | Wire connecting device |
| US2551299A (en) * | 1943-10-06 | 1951-05-01 | Aircraft Marine Prod Inc | Electrical connector and method of making the same |
| US2655641A (en) * | 1948-10-29 | 1953-10-13 | Aircraft Marine Prod Inc | Electrical connector having a mercury amalgam coating on its inner surface |
| US2906987A (en) * | 1955-12-28 | 1959-09-29 | Amp Inc | Stabilized crimped connections |
| GB2041794A (en) * | 1979-02-20 | 1980-09-17 | Bicc Burndy Ltd | Improvements in or relating to ferrules |
-
1982
- 1982-02-08 CA CA000395708A patent/CA1189690A/en not_active Expired
- 1982-07-02 DE DE8282303481T patent/DE3269364D1/en not_active Expired
- 1982-07-02 EP EP19820303481 patent/EP0070639B1/en not_active Expired
- 1982-07-20 JP JP12519082A patent/JPS5825090A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5825090A (en) | 1983-02-15 |
| EP0070639A1 (en) | 1983-01-26 |
| EP0070639B1 (en) | 1986-02-26 |
| DE3269364D1 (en) | 1986-04-03 |
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