EP0356168A1 - Crimping a ferrule to the insulation of an insulated cable - Google Patents
Crimping a ferrule to the insulation of an insulated cable Download PDFInfo
- Publication number
- EP0356168A1 EP0356168A1 EP89308404A EP89308404A EP0356168A1 EP 0356168 A1 EP0356168 A1 EP 0356168A1 EP 89308404 A EP89308404 A EP 89308404A EP 89308404 A EP89308404 A EP 89308404A EP 0356168 A1 EP0356168 A1 EP 0356168A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- cable
- ferrule
- insulation
- base
- scrolls
- 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.)
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
- H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
- H01R11/20—End pieces terminating in a needle point or analogous contact for penetrating insulation or cable strands
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- 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
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- 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
- H01R43/048—Crimping apparatus or processes
Definitions
- This invention relates to a method of, and a die for use in crimping a metal ferrule about the insulation of an insulated cable and also relates to the ferrule when it has been so crimped.
- Electrical terminals to be crimped to stripped end portions of electrical cables having a central metal core surrounded by a layer of insulation comprise a first ferrule which is usually of U-shaped cross section and which is known as a wire barrel for crimping to the cable core and a second ferrule which is also of U-shaped cross section and which is known as the insulation barrel which is for crimping about the insulation of said stripped end portion.
- the purpose of the insulation barrel is to minimise strain and vibration, that could affect the integrity of the crimped connection between the wire barrel and the cable core.
- the terminal when crimped to the cable, is to be used in an environment, for example in an automotive vehicle, where considerable vibration may obtain, it is important that the connection between the insulation barrel and the insulation of the cable should remain intact throughout the working life of the terminal.
- the wall thickness of the insulation amounting to up to about 33% of the total diameter of the cable, that is to say the diameter of the cable including that of the core and that of the insulation.
- thick insulation there is little difficulty in crimping the insulation barrel about the insulation so that it is tightly confined by the insulation barrel, and without the free edges thereof penetrating and thus damaging, the insulation, to any significant extent the crimped connection being of substantially square cross section.
- Such thick insulation may be for example made of polyethelene or rubber.
- Cable insulation of improved resistivity for example irradiated insulation
- the insulation about the core may be made much thinner than heretofore, being for example of a wall thickness equal to between 13% - 22% of the total diameter of the cable.
- improved insulation is increasingly being used, especially in the automotive industry.
- each terminal will usually be required to accommodate cables of several different guages, for example four different guages.
- This difficulty arises, because even in the case of the larger guages of the range, the cable cannot be made to fill the crimped insulation barrel.
- the crimping tooling can be arranged to curl over the side walls of the insulation barrel so that the insulated cable is engaged between the curled over free edges of the insulation barrel and its base, these free edges tend to bite into, and thus disrupt, the insulation and the cable is supported only between what are, in effect, two diametrically opposed points.
- the crimped connection between the insulation barrel and the cable is therefore susceptible to being loosened under the action of cable strain, or vibration.
- a method of crimping a metal ferrule about an insulated cable comprising a base and a pair of opposed ears upstanding from opposite edges of the base so that the ferrule is substantially U-shaped, comprises the steps of laying the cable upon the base of the ferrule and between said ears, and curling over each ear inwardly of the ferrule so that the ear forms a scroll having a smooth arcuate surface which is convex in the direction of the cable and engages the insulation thereof, whereby the cable is gripped between said arcuate surfaces and the base of the ferrule at three discrete positions spaced from one another circumferentially of the cable.
- the cable is accordingly securely supported by the crimped ferrule, no edges of which bite into the cable insulation.
- the ears can be curled over to a different extent to accommodate respective cable guages.
- the same crimping tooling can be used in respect of four different cable guages.
- the ears are curled over so as to engage the insulation at positions spaced circumferentially thereof by about 90°, the position at which the cable insulation engages the base of the ferrule being spaced from each ear by about 135°, so that a cable is incapable of escaping from the crimped ferrule.
- the scolls act as energy storing means, relaxing slightly following the crimping operation and thereby exerting pressure against the cable insulation securely to support the cable and to prevent the insulation from creeping back.
- the method can be used effectively with all types of insulation even where the wall thickness of the insulation of the cable is as small as between 13% and 22% of the total cable diameter.
- the minimum developed length of the ferrule required that is to say the length of the ferrule when in a flat state, to provide satisfactory scrolling thereof should be 1.6 x the total circumference of the largest guage cable with which the ferrule is to be used.
- a crimping die for crimping a metal ferrule about an insulated cable, the ferrule comprising a base and a pair of opposed ears upstanding from opposite edges of the base so that the ferrule is substantially U-shaped, comprises a flat metal plate having extending inwardly from an edge thereof, a crimping recess for receiving a crimping anvil for externally supporting the base of the ferrule, the recess being defined by a pair of opposed, spaced side edges spanned by an ear -forming base edge defined by a pair of concave scroll forming surfaces arranged in mirror image symmetry on either side of a scroll separating bridge having a flat surface facing outwardly of said recess in parrallel relationship with the axes of curvature of said concave surfaces.
- the anvil with the base of the ferrule supported thereon can be advanced into said recess and towards said ear forming base edge, with the cable resting on the base of the ferrule and between the ears thereof, to cause, the scroll forming surfaces, in cooperation with the scroll separating bridge, to curl over each ear of the ferrule inwardly thereof, so that the ear forms a scroll having a smooth arcuate surface which is convex in the direction of the cable, and engages the insulation thereof so that the cable is gripped between the arcuate surfaces of the ears and the base of the ferrule at three discrete positions spaced from one another circumferentially of the cable.
- the width of the scroll separating bridge, in the plane of the crimping die is preferably 28% of the crimp width, that is to say the overall diameter of the largest guage cable with which the die is to be used plus twice the thickness of the metal stock from which the ferrule was formed.
- each of the scroll forming surfaces has a first portion remote from the bridge, the radius of which portion is 24% of the crimp width and a portion of smaller radius, which is adjacent to the bridge, and the radius of which is 12% of the crimp width.
- the smaller radius portion of each of the scroll forming surfaces preferably adjoins a flat lateral surface of the bridge which extends at right angles to the flat surface thereof and the flat surface of the bridge prefereably lies in a plane midway between the axes of curvature of the scroll forming surfaces.
- the crimping dye according to the invention is preferably finished to an eight microinch finish. This smooth finish ensures that as the ears are curled over, they slide readily along the scroll forming surfaces and said lateral surfaces of the bridge, which ensure that the end surfaces of the ears do not bite into the insulation of the cable.
- a metal ferrule which has been crimped about an insulated cable, comprises a base engaging one side of the cable, a pair of opposed ears up standing from opposite edges of the base and each terminating, at a position remote from the base, in a scroll of the ferrule material, having a smoothly arcuate surface which is convex in the direction of the cable and which engages the opposite side of the cable insulation and urges the cable towards the base, the scrolls being spaced from one another transverely of the longitudinal axis of the cable so that the cable is gripped between said arcuate surfaces and the base, at three discrete positions which are spaced from one another circumferentially of the cable.
- an electrical terminal 2 comprises a plug portion 4, a transition portion 6 a wire barrel 8, a stabilising portion 10 and an insulation barrel 12.
- the wire barrel 8 which is substantially U-shaped, is intended to be crimped about the bared end of the electrically conductive core of an insulated electrical cable.
- the insulation barrel 12 is also U-shaped comprising an arcuate base 14 and a pair of ears 16 upstanding from opposite edges of the base 14, the ears 16 having chamfered free edges 18 remote from the base 14.
- Figure 4 shows the insulation barrel 12 crimped to a cable 20 having an electrically conductive core 22 surrounded by a cover of insulation 24, made for example, of rubber or polyethelene which layer is relatively thick, the wall thickness W of the layer of insulation 24, at least prior to the crimping operation, amounting to as much as 33% of the total cable diameter D.
- the insulation barrel 12 was crimped to substantially square shape, the thick insulation 24 filling the interior of the barrel 12 substantially voidlessly and the edges 18 of the barrel 12 being in contiguous relationship and thus not biting to any significant extent into the insulation 24.
- the cable 20 is accordingly tightly confined between the base 14 and the deformed ears 16 of the barrel 12 so as to provide satisfactory strain relief support for the core 22 to which the wire barrel 8 was crimped during the same crimping operation.
- the integrity of the electrical connection between the barrel 8 and the core 22 cannot, therefore, be impared by vibration to which the crimped terminal may be subjected.
- Figure 5 shows insulation barrel 12 when crimped to a cable 20/ having an electrically conductive core 22/ surrounded by a covering of insulation 24/, for example irradiated insulation which is much thinner than the insulation 24, the wall thickness W of the insulation 24/ being only 13% to 22% of the total diameter D/ of the cable 20/.
- the base 14 of the barrel 12 is supported upon a correspondingly configured working surface 26 of a crimping anvil 28, the cable 20 being layed on the base 14 of the barrel 12 and between the ears 16 thereof.
- a crimping die 30 is advanced towards the anvil 28 in the direction of the arrow A in Figure 5A so that the anvil and thus the barrel 12 are received in a crimping recess 32 of the die 30, which is in the form of a flat metal plate into an edge 34 of which the recess 32 opens.
- the recess 32 has opposed side walls 36 which diverge from one another towards the edge 34 to provide a mouth for receiving the anvil 28.
- the side edges 36 are spanned by a base edge 38 having a pair of concave, ear forming surfaces 40 arranged in mirror image symmetry on either side of a sharp cusp 42 which is defined by the surfaces 40, each of which is of constant radius.
- the ears 16 of the barrel 12 are, at least in theory, curled over smoothly by the surfaces 40 so that the cable 20/ is gripped between the chamfered edges 18 of the barrel 12 and the base 14 thereof. That is to say the cable 20/ is, in effect, supported in the barrel 12 only at two opposite positions.
- the shape of the crimped barrel 12 is, as shown in Figures 6 and 7 somewhat arbitary, at least one of the edges 18 deeply penetrating into the insulation 24/ with the cable 20/ being asymmetrical with respect to the crimped barrel 12 and therebeing substantial voids between the cable 20/ and the barrel 12.
- each ear forms a scroll 50 having a smooth arcuate surface 52 which is convex toward the cable 20/ and engages the insulation 24/ thereof at a position substantially opposite to the base 14 of the barrel 12.
- the cable 12 is thus gripped between the arcuate surfaces 52 at two positions 54 spaced circumferentially of the cable 20/ on one side thereof, and the base 14 on the opposite side thereof at a position 56.
- the cable 20/ cannot, therefore, move under the action of vibration and even if the cable is pulled there are no sharp surfaces engaging in the insulation 24/, that would cause it to tear under the pulling force.
- the positions 54 are spaced from one another by about 90° circumferentially of the cable 20/, the position 56 at which the cable is engaged by the base 14, being spaced from each position 54 by approximately 135°.
- the scrolling forces which produce the scrolls 50 cause the free end portions of the ears 16, each to roll up in the manner of a spring, so that following the crimping operation the scrolls 50 relax slightly, that is to say they uncoil slightly, so as to exert pressure against the insulation 24/ thereby pressing against the insulation 24/ to provide extra insulation support and prevent creep back of the insulation 24/.
- the tooling for crimping the barrel 12 to the cable 20/ in the manner just described with reference to Figure 10, will now be described with reference to Figures 8, 9 and 9A.
- the tooling comprises an anvil 56 similar to the anvil 28 described above and having a concave working surface 57 for supporting the exterior of the base 14 of the barrel 12, and a crimping die 58 only the lower part of which is shown.
- the die 58 which is in the form of a flat metal plate has its upper end secured in the tool holder of a conventional crimping press (not shown), the anvil 56 being arranged upon the press base (not shown) with respect to which the die 58 is moveable by means of the press ram, vertically towards and away from the anvil 56.
- a further crimping die 59 ( Figure 9A) is mounted to the tool holder in juxtaposed relationship with the die 58, the die 59 being, for example, of similar shape to the die 30 described above, but being thicker, as shown in Figure 9A
- a crimping recess 62 for receiving the anvil 56, the recess 62 being defined by a pair of opposed, spaced, side edges 64 spanned by an ear forming base edge 66 defined by a pair of concave, scroll forming surfaces 68 which are of identical form and dimensions but are arranged in mirror image symmetry on either side of a scroll separating bridge 70 having a flat surface 72 facing outwardly of the recess 62, and having flat lateral edges 74 extending at right angles to the surface 72, as best seen in Figure 9, and which adjoin the
- Each surface 68 is curved to two different radii, the part of each recess 68 remote from the bridge 70 having a radius R1 of 24% of the crimp width CW, CW being equal to the total diameter D/ of the largest guage cable 24/ to which a barrel 12 is to be crimped by means of the tooling, plus twice the stock thickness of the barrel 12, it being recalled that the barrel 12 will be of the same size in respect of a range of cable guages. Between that part of each surface 68 having the radius R1 and the adjacent edge 74 of the bridge 70, each surface 68 has a radius R2 which is smaller than the radius R1 being approximately 12% of the crimp width CW.
- the width of the flat surface 72, in the plane of the die 78 is 28% of the crimp width CW, the depth of the bridge 70, that is to say the height of its edges 74 in the plane of the die 58 being 18% of the crimp width CW, so that the surface 72 extends in a plane P midway between the two axes of curvature of each of the surfaces 68.
- edges 64 diverge from one another to provide a mouth opening into the edge 60, for guiding the anvil 56 into the recess 62, but towards the base edge 66, the edges 64 are parrallel to one another and are spaced apart by the crimp width CW.
- the terminal 2 is positioned with its barrels 8 and 12 supported on the surface 57 of the anvil 56 which is common to a die 58 and the die 59, so that the barrel 12 lies beneath the die 58, the barrel 8 lying beneath the wire crimping die 59.
- the crimp height that is to say the shut height of both dies having been adjusted in accordance with the guage of the cable 20/, for example by means disclosed in US-A-3,184,950, the cable 20/ is laid in the barrels 8 and 12, with a stripped end portion of the core 22/ in the barrel 8 and the cable insulation 24/, just back from the said stripped end, resting on the base 14 of the barrel 12 between the ears 16.
- the dies are then advanced towards the anvil 56, by means of the press ram, in the direction of the arrow B in Figure 8.
- the chamfered edges 18 engage the outer radiused parts of the respective surfaces 68, so that the ears 26 are gradually curled over to the radius R1 being then more tightly curled over as the edges 18 follow the smaller radiused parts of the surfaces 68, as the surface 72 of the bridge 70 engages the insulation 24/ of the cable 20/ at a position opposite to the base 14, compressing the insulation slightly to allow the edges 18 to pass over the insulation 24/ without piercing it and to move towards the undeformed portions of the ears 26 as shown in Figure 10, whereby the smooth arcuate surfaces 52 of the scrolls 50 engage the insulation 24/ at the spaced positions 54 so that the cable 20/ is supported by the crimped barrel 12 at three spaced positions as described above with reference to Figure 10.
- the scrolls 50 are, in each case so formed that the insulation of the cable is not damaged during the crimping operation and in each case the cable insulation is engaged by the smooth arcuate surfaces of the scrolls 50 at positions spaced circumferentially of the cable.
- the wire crimping die 59 crimps the barrel 8 to the bared end portion of the core 22/ according to well known practice.
- the crimping dies 58 and 59 are withdrawn by the press ram from the anvil 56, the scrolls relaxing slightly as described above, resiliently to apply substantial pressure to the insulation 24/ of the cable.
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- Manufacturing Of Electrical Connectors (AREA)
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- Cable Accessories (AREA)
Abstract
Description
- This invention relates to a method of, and a die for use in crimping a metal ferrule about the insulation of an insulated cable and also relates to the ferrule when it has been so crimped.
- Electrical terminals to be crimped to stripped end portions of electrical cables having a central metal core surrounded by a layer of insulation, comprise a first ferrule which is usually of U-shaped cross section and which is known as a wire barrel for crimping to the cable core and a second ferrule which is also of U-shaped cross section and which is known as the insulation barrel which is for crimping about the insulation of said stripped end portion. The purpose of the insulation barrel, is to minimise strain and vibration, that could affect the integrity of the crimped connection between the wire barrel and the cable core. Especially where the terminal, when crimped to the cable, is to be used in an environment, for example in an automotive vehicle, where considerable vibration may obtain, it is important that the connection between the insulation barrel and the insulation of the cable should remain intact throughout the working life of the terminal.
- Hitherto, in the automotive industry, it has been customary to use cable having relatively thick insulation, the wall thickness of the insulation amounting to up to about 33% of the total diameter of the cable, that is to say the diameter of the cable including that of the core and that of the insulation. Where such thick insulation is used, there is little difficulty in crimping the insulation barrel about the insulation so that it is tightly confined by the insulation barrel, and without the free edges thereof penetrating and thus damaging, the insulation, to any significant extent the crimped connection being of substantially square cross section. Such thick insulation may be for example made of polyethelene or rubber.
- Cable insulation of improved resistivity, for example irradiated insulation, has now, however, been developed so that without impairing the insulating properties of insulated cables, the insulation about the core may be made much thinner than heretofore, being for example of a wall thickness equal to between 13% - 22% of the total diameter of the cable. In view of its ability to reduce the bulk of cabling, such improved insulation is increasingly being used, especially in the automotive industry.
- With insulation of such reduced thickness, it is difficult to provide a satisfactory crimped connection between the insulation barrel of a terminal and the cable insulation, bearing in mind that each terminal will usually be required to accommodate cables of several different guages, for example four different guages. This difficulty arises, because even in the case of the larger guages of the range, the cable cannot be made to fill the crimped insulation barrel. Although the crimping tooling can be arranged to curl over the side walls of the insulation barrel so that the insulated cable is engaged between the curled over free edges of the insulation barrel and its base, these free edges tend to bite into, and thus disrupt, the insulation and the cable is supported only between what are, in effect, two diametrically opposed points. The crimped connection between the insulation barrel and the cable, is therefore susceptible to being loosened under the action of cable strain, or vibration.
- According to one aspect of the invention, a method of crimping a metal ferrule about an insulated cable, the ferrule comprising a base and a pair of opposed ears upstanding from opposite edges of the base so that the ferrule is substantially U-shaped, comprises the steps of laying the cable upon the base of the ferrule and between said ears, and curling over each ear inwardly of the ferrule so that the ear forms a scroll having a smooth arcuate surface which is convex in the direction of the cable and engages the insulation thereof, whereby the cable is gripped between said arcuate surfaces and the base of the ferrule at three discrete positions spaced from one another circumferentially of the cable.
- The cable is accordingly securely supported by the crimped ferrule, no edges of which bite into the cable insulation.
- By suitable adjustment of the tooling used for crimping the ferrule, the ears can be curled over to a different extent to accommodate respective cable guages. Thus for example the same crimping tooling can be used in respect of four different cable guages.
- Preferably, the ears are curled over so as to engage the insulation at positions spaced circumferentially thereof by about 90°, the position at which the cable insulation engages the base of the ferrule being spaced from each ear by about 135°, so that a cable is incapable of escaping from the crimped ferrule.
- The scolls act as energy storing means, relaxing slightly following the crimping operation and thereby exerting pressure against the cable insulation securely to support the cable and to prevent the insulation from creeping back.
- The method can be used effectively with all types of insulation even where the wall thickness of the insulation of the cable is as small as between 13% and 22% of the total cable diameter.
- The minimum developed length of the ferrule required, that is to say the length of the ferrule when in a flat state, to provide satisfactory scrolling thereof should be 1.6 x the total circumference of the largest guage cable with which the ferrule is to be used.
- According to another aspect of the invention, a crimping die for crimping a metal ferrule about an insulated cable, the ferrule comprising a base and a pair of opposed ears upstanding from opposite edges of the base so that the ferrule is substantially U-shaped, comprises a flat metal plate having extending inwardly from an edge thereof, a crimping recess for receiving a crimping anvil for externally supporting the base of the ferrule, the recess being defined by a pair of opposed, spaced side edges spanned by an ear -forming base edge defined by a pair of concave scroll forming surfaces arranged in mirror image symmetry on either side of a scroll separating bridge having a flat surface facing outwardly of said recess in parrallel relationship with the axes of curvature of said concave surfaces. The anvil with the base of the ferrule supported thereon can be advanced into said recess and towards said ear forming base edge, with the cable resting on the base of the ferrule and between the ears thereof, to cause, the scroll forming surfaces, in cooperation with the scroll separating bridge, to curl over each ear of the ferrule inwardly thereof, so that the ear forms a scroll having a smooth arcuate surface which is convex in the direction of the cable, and engages the insulation thereof so that the cable is gripped between the arcuate surfaces of the ears and the base of the ferrule at three discrete positions spaced from one another circumferentially of the cable.
- The width of the scroll separating bridge, in the plane of the crimping die is preferably 28% of the crimp width, that is to say the overall diameter of the largest guage cable with which the die is to be used plus twice the thickness of the metal stock from which the ferrule was formed.
- Peferably also, each of the scroll forming surfaces has a first portion remote from the bridge, the radius of which portion is 24% of the crimp width and a portion of smaller radius, which is adjacent to the bridge, and the radius of which is 12% of the crimp width. The smaller radius portion of each of the scroll forming surfaces, preferably adjoins a flat lateral surface of the bridge which extends at right angles to the flat surface thereof and the flat surface of the bridge prefereably lies in a plane midway between the axes of curvature of the scroll forming surfaces.
- Although dies for crimping ferrules to the insulation of insulated cables, are usually finished only to a sixteen microinch finish, the crimping dye according to the invention, is preferably finished to an eight microinch finish. This smooth finish ensures that as the ears are curled over, they slide readily along the scroll forming surfaces and said lateral surfaces of the bridge, which ensure that the end surfaces of the ears do not bite into the insulation of the cable.
- According to a further aspect of the invention, a metal ferrule which has been crimped about an insulated cable, comprises a base engaging one side of the cable, a pair of opposed ears up standing from opposite edges of the base and each terminating, at a position remote from the base, in a scroll of the ferrule material, having a smoothly arcuate surface which is convex in the direction of the cable and which engages the opposite side of the cable insulation and urges the cable towards the base, the scrolls being spaced from one another transverely of the longitudinal axis of the cable so that the cable is gripped between said arcuate surfaces and the base, at three discrete positions which are spaced from one another circumferentially of the cable.
- For a better understanding of the invention and to show how it may be carried into effect, reference will now be made by way of example to the accompanying drawings in which;
- Figure 1 is a side view of an electrical terminal;
- Figure 2 is a top plan view of the terminal;
- Figure 3 is a cross sectional view taken on the lines 3-3 of Figure 2;
- Figure 4 is an end view illustrating an insulation barrel of the terminal crimped to a cable having thick insulation, by a prior art method;
- Figure 5 is an enlarged end view showing the insulation barrel crimped to a cable having thin insulation, by a prior art method;
- Figure 5A is a fragmentary view of a crimping die and a crimping anvil for carrying out the prior art method;
- Figures 6 and 7 are enlarged views drawn from section photographs illustrating actual results achieved by the prior art method;
- Figure 8 is a fragmentary view of a crimping die and crimping anvil for carrying out the method of the present invention;
- Figure 9 is an enlarged fragmetary view illustrating details of Figure 8;
- Figure 9A is a reduced view taken on the
lines 9A-9A of Figure 8; - Figure 10 is an enlarged, diagramatic cross sectional view illustrating the insulation barrel when crimped to an insulated cable having thin insulation, by means of the die and anvil illustrated in Figure 8; and
- Figures 11 to 13 are enlarged views drawn from section photographs each illustrating the insulation barrel when crimped to an insulated cable having thin insulation, the cable being of a different gauge in each of these Figures.
- As shown in Figures 1 and 2 an
electrical terminal 2 comprises aplug portion 4, a transition portion 6 awire barrel 8, a stabilisingportion 10 and aninsulation barrel 12.
Thewire barrel 8 which is substantially U-shaped, is intended to be crimped about the bared end of the electrically conductive core of an insulated electrical cable. Theinsulation barrel 12 is also U-shaped comprising anarcuate base 14 and a pair ofears 16 upstanding from opposite edges of thebase 14, theears 16 having chamferedfree edges 18 remote from thebase 14. - Figure 4 shows the
insulation barrel 12 crimped to acable 20 having an electricallyconductive core 22 surrounded by a cover ofinsulation 24, made for example, of rubber or polyethelene which layer is relatively thick, the wall thickness W of the layer ofinsulation 24, at least prior to the crimping operation, amounting to as much as 33% of the total cable diameter D. As will be apparent from Figure 4, theinsulation barrel 12 was crimped to substantially square shape, thethick insulation 24 filling the interior of thebarrel 12 substantially voidlessly and theedges 18 of thebarrel 12 being in contiguous relationship and thus not biting to any significant extent into theinsulation 24. Thecable 20 is accordingly tightly confined between thebase 14 and thedeformed ears 16 of thebarrel 12 so as to provide satisfactory strain relief support for thecore 22 to which thewire barrel 8 was crimped during the same crimping operation. The integrity of the electrical connection between thebarrel 8 and thecore 22 cannot, therefore, be impared by vibration to which the crimped terminal may be subjected. - Figure 5 shows
insulation barrel 12 when crimped to acable 20/ having an electricallyconductive core 22/ surrounded by a covering ofinsulation 24/, for example irradiated insulation which is much thinner than theinsulation 24, the wall thickness W of theinsulation 24/ being only 13% to 22% of the total diameter D/ of thecable 20/. According to this prior art method of crimping thebarrel 12 to thecable 20/ having thin insulation, thebase 14 of thebarrel 12 is supported upon a correspondingly configured workingsurface 26 of a crimping anvil 28, thecable 20 being layed on thebase 14 of thebarrel 12 and between theears 16 thereof. Acrimping die 30 is advanced towards the anvil 28 in the direction of the arrow A in Figure 5A so that the anvil and thus thebarrel 12 are received in acrimping recess 32 of thedie 30, which is in the form of a flat metal plate into anedge 34 of which therecess 32 opens. Therecess 32 hasopposed side walls 36 which diverge from one another towards theedge 34 to provide a mouth for receiving the anvil 28. Theside edges 36 are spanned by abase edge 38 having a pair of concave,ear forming surfaces 40 arranged in mirror image symmetry on either side of asharp cusp 42 which is defined by thesurfaces 40, each of which is of constant radius. As thedie 30 is advanced towards the anvil 28, theears 16 of thebarrel 12 are, at least in theory, curled over smoothly by thesurfaces 40 so that thecable 20/ is gripped between thechamfered edges 18 of thebarrel 12 and thebase 14 thereof. That is to say thecable 20/ is, in effect, supported in thebarrel 12 only at two opposite positions. Even so, theedges 18 bite to a substantial extent into theinsulation 24/ and, since there are substantial voids between thecable 20/ and the remainder of thebarrel 12 thecable 20/ could be dislodged from the position in which it is shown in Figure 5, under the action of vibration causing whipping of the cable and tension upon the cable cover would cause theedges 18/ to tear theinsulation 24/ lengthwise, so that the insulation support provided by the crimpedbarrel 12 must clearly be defective even as envisaged in Figure 5, which as is only a theoretical diagram. Figures 6 and 7 show the practical results of employing the tooling shown in Figure 5 to crimp thebarrel 12 to thecable 20/. In practice, the shape of the crimpedbarrel 12 is, as shown in Figures 6 and 7 somewhat arbitary, at least one of theedges 18 deeply penetrating into theinsulation 24/ with thecable 20/ being asymmetrical with respect to the crimpedbarrel 12 and therebeing substantial voids between thecable 20/ and thebarrel 12. - According to the present invention the disadvantages mentioned above are avoided by crimping the
barrel 12 to the configuration that is diagramatically illustrated in Figure 10. As shown in that Figure, theears 16 are so curled over that each ear forms ascroll 50 having a smootharcuate surface 52 which is convex toward thecable 20/ and engages theinsulation 24/ thereof at a position substantially opposite to thebase 14 of thebarrel 12. Thecable 12 is thus gripped between thearcuate surfaces 52 at twopositions 54 spaced circumferentially of thecable 20/ on one side thereof, and thebase 14 on the opposite side thereof at aposition 56. Thecable 20/ cannot, therefore, move under the action of vibration and even if the cable is pulled there are no sharp surfaces engaging in theinsulation 24/, that would cause it to tear under the pulling force. As shown in Figure 10 thepositions 54 are spaced from one another by about 90° circumferentially of thecable 20/, theposition 56 at which the cable is engaged by thebase 14, being spaced from eachposition 54 by approximately 135°. Following the crimping operation, which is described below, the scrolling forces which produce thescrolls 50 cause the free end portions of theears 16, each to roll up in the manner of a spring, so that following the crimping operation thescrolls 50 relax slightly, that is to say they uncoil slightly, so as to exert pressure against theinsulation 24/ thereby pressing against theinsulation 24/ to provide extra insulation support and prevent creep back of theinsulation 24/. - The tooling for crimping the
barrel 12 to thecable 20/ in the manner just described with reference to Figure 10, will now be described with reference to Figures 8, 9 and 9A. The tooling comprises ananvil 56 similar to the anvil 28 described above and having a concave workingsurface 57 for supporting the exterior of thebase 14 of thebarrel 12, and a crimpingdie 58 only the lower part of which is shown. The die 58 which is in the form of a flat metal plate has its upper end secured in the tool holder of a conventional crimping press (not shown), theanvil 56 being arranged upon the press base (not shown) with respect to which thedie 58 is moveable by means of the press ram, vertically towards and away from theanvil 56. For crimpingwire barrel 8 of theterminal 2 to the bared end of the electricallyconductive core 22/ of thecable 20/, a further crimping die 59 (Figure 9A) is mounted to the tool holder in juxtaposed relationship with the die 58, the die 59 being, for example, of similar shape to the die 30 described above, but being thicker, as shown in Figure 9A There extends inwardly, from anedge 60 of thedye 58, a crimpingrecess 62 for receiving theanvil 56, therecess 62 being defined by a pair of opposed, spaced, side edges 64 spanned by an ear formingbase edge 66 defined by a pair of concave,scroll forming surfaces 68 which are of identical form and dimensions but are arranged in mirror image symmetry on either side of ascroll separating bridge 70 having aflat surface 72 facing outwardly of therecess 62, and having flatlateral edges 74 extending at right angles to thesurface 72, as best seen in Figure 9, and which adjoin thesurfaces 68. Eachsurface 68 is curved to two different radii, the part of eachrecess 68 remote from thebridge 70 having a radius R1 of 24% of the crimp width CW, CW being equal to the total diameter D/ of thelargest guage cable 24/ to which abarrel 12 is to be crimped by means of the tooling, plus twice the stock thickness of thebarrel 12, it being recalled that thebarrel 12 will be of the same size in respect of a range of cable guages. Between that part of eachsurface 68 having the radius R1 and theadjacent edge 74 of thebridge 70, eachsurface 68 has a radius R2 which is smaller than the radius R1 being approximately 12% of the crimp width CW. The width of theflat surface 72, in the plane of the die 78 is 28% of the crimp width CW, the depth of thebridge 70, that is to say the height of itsedges 74 in the plane of the die 58 being 18% of the crimp width CW, so that thesurface 72 extends in a plane P midway between the two axes of curvature of each of thesurfaces 68. - The
edges 64 diverge from one another to provide a mouth opening into theedge 60, for guiding theanvil 56 into therecess 62, but towards thebase edge 66, theedges 64 are parrallel to one another and are spaced apart by the crimp width CW. - In the use of the tooling shown in Figures 8 to 9A, the
terminal 2 is positioned with itsbarrels surface 57 of theanvil 56 which is common to adie 58 and thedie 59, so that thebarrel 12 lies beneath thedie 58, thebarrel 8 lying beneath thewire crimping die 59. The crimp height, that is to say the shut height of both dies having been adjusted in accordance with the guage of thecable 20/, for example by means disclosed in US-A-3,184,950, thecable 20/ is laid in thebarrels barrel 8 and thecable insulation 24/, just back from the said stripped end, resting on thebase 14 of thebarrel 12 between theears 16. The dies are then advanced towards theanvil 56, by means of the press ram, in the direction of the arrow B in Figure 8. As the die 58 advances towards theanvil 56, the chamfered edges 18 engage the outer radiused parts of therespective surfaces 68, so that theears 26 are gradually curled over to the radius R1 being then more tightly curled over as theedges 18 follow the smaller radiused parts of thesurfaces 68, as thesurface 72 of thebridge 70 engages theinsulation 24/ of thecable 20/ at a position opposite to thebase 14, compressing the insulation slightly to allow theedges 18 to pass over theinsulation 24/ without piercing it and to move towards the undeformed portions of theears 26 as shown in Figure 10, whereby the smootharcuate surfaces 52 of thescrolls 50 engage theinsulation 24/ at the spacedpositions 54 so that thecable 20/ is supported by the crimpedbarrel 12 at three spaced positions as described above with reference to Figure 10. As will be apparent from Figures 11 to 13, which show thebarrel 12 crimped tocables 20/A, 20/B and 20/C, which are of substantially different guages, thescrolls 50 are, in each case so formed that the insulation of the cable is not damaged during the crimping operation and in each case the cable insulation is engaged by the smooth arcuate surfaces of thescrolls 50 at positions spaced circumferentially of the cable. During the operations described above, thewire crimping die 59 crimps thebarrel 8 to the bared end portion of the core 22/ according to well known practice. Following the crimping operations, the crimping dies 58 and 59 are withdrawn by the press ram from theanvil 56, the scrolls relaxing slightly as described above, resiliently to apply substantial pressure to theinsulation 24/ of the cable. - Because the scrolling operations take place on either side of the cable, the scrolls naturally centralize the cable within the ferrule so that the cable is symmetrical with the crimped
barrel 12.
Claims (17)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB888819904A GB8819904D0 (en) | 1988-08-22 | 1988-08-22 | Crimping ferrule to insulation of insulated cable |
GB8819904 | 1988-08-22 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0356168A1 true EP0356168A1 (en) | 1990-02-28 |
EP0356168B1 EP0356168B1 (en) | 1994-03-16 |
Family
ID=10642513
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP89308404A Expired - Lifetime EP0356168B1 (en) | 1988-08-22 | 1989-08-18 | Crimping a ferrule to the insulation of an insulated cable |
Country Status (8)
Country | Link |
---|---|
EP (1) | EP0356168B1 (en) |
JP (1) | JPH02181375A (en) |
KR (1) | KR900003917A (en) |
AR (1) | AR244471A1 (en) |
BR (1) | BR8904107A (en) |
DE (1) | DE68913863T2 (en) |
GB (1) | GB8819904D0 (en) |
MX (1) | MX170726B (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5356318A (en) * | 1993-10-14 | 1994-10-18 | Molex Incorporated | Conductor crimping electrical terminal |
US5415015A (en) * | 1993-10-14 | 1995-05-16 | Molex Incorporated | Electrical terminal crimping tool |
EP0657962A2 (en) * | 1993-12-10 | 1995-06-14 | Sumitomo Wiring Systems, Ltd. | Terminal for high-voltage resistant electrical cable |
EP0923159A2 (en) * | 1997-12-09 | 1999-06-16 | Siemens Aktiengesellschaft | Crimping contact for connecting system |
EP1811608A2 (en) | 2006-01-18 | 2007-07-25 | Sumitomo Wiring Systems, Ltd. | A terminal fitting and connector provided therewith |
EP2793326A1 (en) * | 2013-04-16 | 2014-10-22 | Delphi International Operations Luxembourg S.à r.l. | Insulation or sealing crimp die |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2008177034A (en) * | 2007-01-18 | 2008-07-31 | Yazaki Corp | Crimping machine |
CN115446158B (en) * | 2022-08-09 | 2024-06-11 | 沪东中华造船(集团)有限公司 | Marine cable reinforcing ring, preparation device and preparation method |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CH363391A (en) * | 1957-06-20 | 1962-07-31 | Amp Inc | Electrical connection between a terminal and an electrical conductor and method of making that connection |
US3239924A (en) * | 1965-02-09 | 1966-03-15 | Amp Inc | Electrical terminal applicator |
DE1540556A1 (en) * | 1965-09-25 | 1970-01-02 | Siemens Ag | Contact element |
DE3003213A1 (en) * | 1980-01-30 | 1981-08-06 | Fa. Leopold Kostal, 5880 Lüdenscheid | Conductor end connector pin - is formed from flat profiled platen rolled and curled to grip conductor and sheath |
DE8805338U1 (en) * | 1988-04-22 | 1988-06-09 | Wesma Kabelverbindungsmaschinen GmbH, 5470 Andernach | Tool carrier for a cable crimping machine |
-
1988
- 1988-08-22 GB GB888819904A patent/GB8819904D0/en active Pending
-
1989
- 1989-08-15 BR BR898904107A patent/BR8904107A/en not_active IP Right Cessation
- 1989-08-17 MX MX017231A patent/MX170726B/en unknown
- 1989-08-18 DE DE68913863T patent/DE68913863T2/en not_active Expired - Lifetime
- 1989-08-18 EP EP89308404A patent/EP0356168B1/en not_active Expired - Lifetime
- 1989-08-19 KR KR1019890011830A patent/KR900003917A/en not_active Application Discontinuation
- 1989-08-22 AR AR89314711A patent/AR244471A1/en active
- 1989-08-22 JP JP1215881A patent/JPH02181375A/en active Pending
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CH363391A (en) * | 1957-06-20 | 1962-07-31 | Amp Inc | Electrical connection between a terminal and an electrical conductor and method of making that connection |
US3239924A (en) * | 1965-02-09 | 1966-03-15 | Amp Inc | Electrical terminal applicator |
DE1540556A1 (en) * | 1965-09-25 | 1970-01-02 | Siemens Ag | Contact element |
DE3003213A1 (en) * | 1980-01-30 | 1981-08-06 | Fa. Leopold Kostal, 5880 Lüdenscheid | Conductor end connector pin - is formed from flat profiled platen rolled and curled to grip conductor and sheath |
DE8805338U1 (en) * | 1988-04-22 | 1988-06-09 | Wesma Kabelverbindungsmaschinen GmbH, 5470 Andernach | Tool carrier for a cable crimping machine |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5356318A (en) * | 1993-10-14 | 1994-10-18 | Molex Incorporated | Conductor crimping electrical terminal |
US5415015A (en) * | 1993-10-14 | 1995-05-16 | Molex Incorporated | Electrical terminal crimping tool |
EP0657962A2 (en) * | 1993-12-10 | 1995-06-14 | Sumitomo Wiring Systems, Ltd. | Terminal for high-voltage resistant electrical cable |
EP0657962A3 (en) * | 1993-12-10 | 1997-05-07 | Sumitomo Wiring Systems | Terminal for high-voltage resistant electrical cable. |
EP0923159A2 (en) * | 1997-12-09 | 1999-06-16 | Siemens Aktiengesellschaft | Crimping contact for connecting system |
EP0923159A3 (en) * | 1997-12-09 | 2001-04-18 | Tyco Electronics Logistics AG | Crimping contact for connecting system |
EP1811608A2 (en) | 2006-01-18 | 2007-07-25 | Sumitomo Wiring Systems, Ltd. | A terminal fitting and connector provided therewith |
EP1811608A3 (en) * | 2006-01-18 | 2008-11-05 | Sumitomo Wiring Systems, Ltd. | A terminal fitting and connector provided therewith |
EP2793326A1 (en) * | 2013-04-16 | 2014-10-22 | Delphi International Operations Luxembourg S.à r.l. | Insulation or sealing crimp die |
Also Published As
Publication number | Publication date |
---|---|
JPH02181375A (en) | 1990-07-16 |
MX170726B (en) | 1993-09-09 |
KR900003917A (en) | 1990-03-27 |
GB8819904D0 (en) | 1988-09-21 |
EP0356168B1 (en) | 1994-03-16 |
BR8904107A (en) | 1990-04-10 |
DE68913863D1 (en) | 1994-04-21 |
AR244471A1 (en) | 1993-10-29 |
DE68913863T2 (en) | 1994-10-06 |
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