EP0398342A1 - A crimp terminal and its wire crimping structure - Google Patents
A crimp terminal and its wire crimping structure Download PDFInfo
- Publication number
- EP0398342A1 EP0398342A1 EP90109379A EP90109379A EP0398342A1 EP 0398342 A1 EP0398342 A1 EP 0398342A1 EP 90109379 A EP90109379 A EP 90109379A EP 90109379 A EP90109379 A EP 90109379A EP 0398342 A1 EP0398342 A1 EP 0398342A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- crimped
- wire
- copper conductor
- terminal
- 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.)
- Withdrawn
Links
Images
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
Definitions
- the present invention relates to a crimp terminal which provides secure connection, both mechanical and electrical, between it and a conductor.
- Figure 6A and 6B show a conventional crimp or solderless terminal.
- Reference numeral 1 designates a crimp terminal; 2 indicates a tongue, a connecting portion of the terminal that is connected to a mating terminal; 3 a grip portion that holds the wire insulation; and 4 another grip portion that firmly holds the bare portion of a copper conductor.
- Denoted 5 is an insulated wire and 6 is a copper conductor. The end portion of the wire 5 is stripped of insulation to expose the bare copper conductor 6 , and then the wire end is inserted into the grip portions 3 , 4 of the terminal that are crimped against the bare conductor and insulation.
- This invention has been accomplished to overcome the above drawback, and its objective is to provide a crimp terminal whose electrical and mechanical characteristics are improved and also provide a crimping structure for securely connecting the crimp terminal and the copper conductor.
- the crimp terminal and its wire crimping structure comprises: a crimp terminal having at one end thereof a first grip portion for holding a wire insulation and a second grip portion for holding a bare copper conductor, said second grip portion being divided in two sections and crimped against the bare conductor in such a manner that the copper conductor deformation ratio at one of said two sections is different from the other, said copper conductor deformation ratio being obtained by first calculating a difference between copper conductor cross sections before and after crimping and then dividing said difference by said copper conductor cross section before the crimping, said two sections being crimped against the bare conductor in such a manner that at one of said two sections the copper conductor deformation ratio is more than 40% and that at the other section said copper deformation ratio is 10 to 30%.
- Figure 1A and 1B show the crimp terminal according to this invention that is connected with a wire.
- the crimp terminal 1 is formed by punching and bending a metal sheet.
- Denoted 2 is a tongue formed at one end of the terminal that is to be connected with a mating terminal.
- the other end of the terminal is formed with a grip portion 3 that grips the wire insulation and with two other grip portions 4a , 4b that grip a bare copper conductor 6 .
- These gripping portions are formed by first punching from a metal sheet strips that extend from both sides of the terminal 1 and bending these strips in circle from both sides toward the center.
- Designated 5 and 6 are an insulation-covered wire and a copper conductor, respectively.
- the copper conductor deformation factor is defined as follows.
- the residual resistance ratio (R.R.R) is defined as R 293K /R 4.2K , where R 293K is the electrical resistance of the crimped portion at 20°C and R 4.2K is the resistance of the crimped portion when placed in liquid helium.
- R 293K is the electrical resistance of the crimped portion at 20°C
- R 4.2K is the resistance of the crimped portion when placed in liquid helium.
- This invention has been achieved by utilizing the fact that there is a definite relationship between the copper conductor deformation ratio and the residual resistance ratio.
- Figures 2 to 4 show the characteristics of the crimped portion of the terminal connected with copper conductors, which are 3, 0.5 and 1.25 mm2 in cross section and are made up of 41, 7 and 16 core wires, respectively, each wire being 0.32 mm in diameter.
- curves (1) indicate the residual resistance ratio and curves (2) the bonding force.
- the residual resistance ratio increases as the copper conductor deformation ratio increases, as indicated by the curves (1), and the electrical characteristic is improved.
- the residual resistance ratio becomes sufficiently high for the copper conductor deformation ratio of 40% and its rate of increase reduces from that point forward. From this it is seen that when the copper conductor deformation ratio is set higher than 40%, the crimped portion will have a good and stable electrical characteristic.
- Figure 5 is a graph showing the relationship between the wire size and the average bonding force required for the wire.
- the bonding forces in the above range in Figures 2 to 4 satisfy the required value.
- this invention divides the bare conductor grip portion into two parts 4a , 4b , so that when they are crimped their heights or the copper conductor deformation ratios differ from each other. This is illustrated in Figure 1.
- the grip portion 4b is crimped with a less force than that applied to the grip portion 4a so that the copper conductor deformation ratio for the portion 4b will be 10 to 30%.
- the bonding force of the grip portion 4b is maintained at high level, i.e., the mechanical strength of the crimped portion is high.
- the crimp terminal of this invention has its conductor gripping portion divided in two.
- One of the divided grip portions provides a strong mechanical connection and the other portion ensures a good electrical contact.
Landscapes
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
One end of a crimp terminal is formed with a wire insulation grip portion and a bare conductor grip portion. The bare conductor grip portion is divided in two. When the terminal is crimped on the wire, the divided bare conductor grip portions are crimped in such a way that the cross section of the conductor portion held by one of the divided bare conductor grip portions will be deformed more than 40% and the cross section of the adjacent conductor portion held by the other grip portion will be deformed 10 to 30%. The first crimped portion, which is deformed more than 40%, provides a reduced electrical contact resistance and the second crimped portion, which is deformed 10 to 30%, provides a good mechanical strength or connecting force between the terminal and the wire. Thus, the crimped terminal as a whole exhibits a good electrical characteristic while at the same time providing a good mechanical strength.
Description
- The present invention relates to a crimp terminal which provides secure connection, both mechanical and electrical, between it and a conductor.
- Figure 6A and 6B show a conventional crimp or solderless terminal.
Reference numeral 1 designates a crimp terminal; 2 indicates a tongue, a connecting portion of the terminal that is connected to a mating terminal; 3 a grip portion that holds the wire insulation; and 4 another grip portion that firmly holds the bare portion of a copper conductor. Denoted 5 is an insulated wire and 6 is a copper conductor. The end portion of thewire 5 is stripped of insulation to expose thebare copper conductor 6, and then the wire end is inserted into thegrip portions - To improve the electrical characteristic of the connecting portion (in other words, to reduce contact resistance), it is preferred to increase the crimping force and thereby produce plastic deformation in the
grip portion 4 and thecopper conductor 6 to securely hold them together. But, too large a crimping force will result in an excessive deformation in thecopper conductor 6, which can easily break. In other words its mechanical strength is reduced. That is, as the electrical characteristic is improved, the mechanical strength reduces. Conversely, as the mechanical strength is increased, the electrical characteristic deteriorates. Hence it has been impossible to meet the both requirements at the same time. - This invention has been accomplished to overcome the above drawback, and its objective is to provide a crimp terminal whose electrical and mechanical characteristics are improved and also provide a crimping structure for securely connecting the crimp terminal and the copper conductor.
- To achieve the above objective, the crimp terminal and its wire crimping structure according to this invention comprises: a crimp terminal having at one end thereof a first grip portion for holding a wire insulation and a second grip portion for holding a bare copper conductor, said second grip portion being divided in two sections and crimped against the bare conductor in such a manner that the copper conductor deformation ratio at one of said two sections is different from the other, said copper conductor deformation ratio being obtained by first calculating a difference between copper conductor cross sections before and after crimping and then dividing said difference by said copper conductor cross section before the crimping, said two sections being crimped against the bare conductor in such a manner that at one of said two sections the copper conductor deformation ratio is more than 40% and that at the other section said copper deformation ratio is 10 to 30%.
-
- Figure 1 shows a crimp terminal of this invention and a wire crimped together, Figure 1A being a front view and Figure 1B a top view;
- Figures 2 to 4 are graphs showing the relationship between the copper conductor deformation factor, electrical characteristic, and bonding force of the crimp terminal;
- Figure 5 shows the relationship between the cross-sectional area of wires (wire size) and the average bonding force required for the wires; and
- Figure 6 shows a conventional crimp terminal and a wire crimped together, Figure 1A being a front view and Figure 1B a top view.
- Referring to the accompanying drawings one embodiment of this invention will be described. Figure 1A and 1B show the crimp terminal according to this invention that is connected with a wire.
- As shown in these drawings, the
crimp terminal 1 is formed by punching and bending a metal sheet. Denoted 2 is a tongue formed at one end of the terminal that is to be connected with a mating terminal. The other end of the terminal is formed with agrip portion 3 that grips the wire insulation and with twoother grip portions bare copper conductor 6. These gripping portions are formed by first punching from a metal sheet strips that extend from both sides of theterminal 1 and bending these strips in circle from both sides toward the center. Designated 5 and 6 are an insulation-covered wire and a copper conductor, respectively. - Our experiments have found that there is a relationship, as shown in Figures 2 to 4, between the deformation factor of the crimped copper conductor in the crimp terminal and the electrical and mechanical characteristics of the terminal. In the graph, for a certain size of crimp terminal, the abscissa represents a copper conductor deformation factor (%), the ordinate on the left-hand side indicates a residual resistance ratio as an electrical characteristic (no dimension), and the ordinate on the right-hand side designates a bonding force (kgf) between the wire and the terminal as a mechanical characteristic.
- The copper conductor deformation factor is defined as follows.
- Copper conductor deformation factor
= [(A - A′)/A] x 100%
where A = S x N
S : cross sectional area of a single core wire of the conductor before being crimped
N : number of core wires in the conductor
A : cross sectional area of the conductor before being crimped
A′ : true cross sectional area of the conductor after being crimped (measured by using a microscope)
The larger the value of the copper conductor deformation factor, the smaller the height of the crimped terminal will be. - The residual resistance ratio (R.R.R) is defined as R293K/R4.2K, where R293K is the electrical resistance of the crimped portion at 20°C and R4.2K is the resistance of the crimped portion when placed in liquid helium. The greater the residual resistance ratio, the better the condition of the boundary surface of the crimped portion and its electrical characteristic. This invention has been achieved by utilizing the fact that there is a definite relationship between the copper conductor deformation ratio and the residual resistance ratio.
- The greater the bonding force (kgf) represented by the vertical axis on the right, the larger the tensile strength of the crimped portion and the better its mechanical characteristic.
- Figures 2 to 4 show the characteristics of the crimped portion of the terminal connected with copper conductors, which are 3, 0.5 and 1.25 mm² in cross section and are made up of 41, 7 and 16 core wires, respectively, each wire being 0.32 mm in diameter. In these figures, curves (1) indicate the residual resistance ratio and curves (2) the bonding force.
- The residual resistance ratio increases as the copper conductor deformation ratio increases, as indicated by the curves (1), and the electrical characteristic is improved. The residual resistance ratio becomes sufficiently high for the copper conductor deformation ratio of 40% and its rate of increase reduces from that point forward. From this it is seen that when the copper conductor deformation ratio is set higher than 40%, the crimped portion will have a good and stable electrical characteristic.
- As for the bonding force, it remains high for the copper conductor deformation ratio range between 10% and 30%, as indicated by the curves (2). Figure 5 is a graph showing the relationship between the wire size and the average bonding force required for the wire. The bonding forces in the above range in Figures 2 to 4 satisfy the required value. Making use of this fact, this invention divides the bare conductor grip portion into two
parts - Next, we will explain how the invention works. As shown in Figure 1, the end of the
wire 5 is stripped of insulation to expose itsbare conductor 6 and the wire end is inserted into thecrimp terminal 1. Then thegrip portions grip portion 4a is crimped with a force strong enough so that the copper conductor deformation ratio for this portion will be 40% or more. This will increase the residual resistance ratio, as seen from Figures 2 to 4, and thereby improve the electrical characteristic. - Then, the
grip portion 4b is crimped with a less force than that applied to thegrip portion 4a so that the copper conductor deformation ratio for theportion 4b will be 10 to 30%. The bonding force of thegrip portion 4b is maintained at high level, i.e., the mechanical strength of the crimped portion is high. With the above structure, thegrip portion 4a provides an improved electrical characteristic and thegrip portion 4b provides a strong mechanical strength. - As explained above, the crimp terminal of this invention has its conductor gripping portion divided in two. One of the divided grip portions provides a strong mechanical connection and the other portion ensures a good electrical contact.
Claims (1)
- A crimp terminal and its wire crimping structure, comprising: a crimp terminal having at one end thereof a first grip portion for holding a wire insulation and a second grip portion for holding a bare copper conductor, said second grip portion being divided in two sections and crimped against the bare conductor in such a manner that the copper conductor deformation ratio at one of said two sections is different from the other, said copper conductor deformation ratio being obtained by first calculating a difference between copper conductor cross sections before and after crimping and then dividing said difference by said copper conductor cross section before the crimping, said two sections being crimped against the bare conductor in such a manner that at one of said two sections the copper conductor deformation ratio is more than 40% and that at the other section said copper deformation ratio is 10 to 30%.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP57019/89U | 1989-05-19 | ||
JP5701989U JPH02148564U (en) | 1989-05-19 | 1989-05-19 |
Publications (1)
Publication Number | Publication Date |
---|---|
EP0398342A1 true EP0398342A1 (en) | 1990-11-22 |
Family
ID=13043724
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP90109379A Withdrawn EP0398342A1 (en) | 1989-05-19 | 1990-05-17 | A crimp terminal and its wire crimping structure |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP0398342A1 (en) |
JP (1) | JPH02148564U (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0873042A4 (en) * | 1995-05-29 | 1998-10-21 | ||
DE102006045567A1 (en) * | 2006-09-25 | 2008-04-24 | Tyco Electronics Amp Gmbh | Crimp connection for producing electrical contact between crimp case and electrical conductor, has crimp case with two crimp flanks and bent under formation of longitudinal weld, where ends of crimp flanks engage into each other along weld |
EP1993171A1 (en) | 2007-05-16 | 2008-11-19 | Delphi Technologies, Inc. | Cable shoe |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP4809591B2 (en) * | 2003-11-20 | 2011-11-09 | 古河電気工業株式会社 | Terminal crimping structure to aluminum wire, terminal crimping method, and manufacturing method of aluminum wire with terminal |
JP2010097781A (en) * | 2008-10-15 | 2010-04-30 | Autonetworks Technologies Ltd | Manufacturing method of electric wire with terminal fitting, and terminal crimping device |
JP5723087B2 (en) * | 2009-08-10 | 2015-05-27 | 矢崎総業株式会社 | Terminal crimping method and terminal crimping apparatus |
JP6007198B2 (en) * | 2014-01-15 | 2016-10-12 | 古河電気工業株式会社 | Connection structure and connection method between copper wire and aluminum wire |
JP5714749B2 (en) * | 2014-05-15 | 2015-05-07 | 矢崎総業株式会社 | Terminal crimping method and terminal crimping apparatus |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1790118B2 (en) * | 1967-09-13 | 1977-09-22 | AMP Inc., Harrisburg, Pa. (V.St A.) | CONNECTOR ATTACHED TO AN ALUMINUM WIRE LADDER |
DE2554310B2 (en) * | 1974-12-03 | 1979-09-20 | Thomas & Betts Corp., Raritan, N.J. (V.St.A.) | Electrical connection between a connector and a conductor and crimping device for making this connection |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS59165390A (en) * | 1983-03-10 | 1984-09-18 | 東洋端子株式会社 | Method of bonding solderless terminal and terminal thereof |
-
1989
- 1989-05-19 JP JP5701989U patent/JPH02148564U/ja active Pending
-
1990
- 1990-05-17 EP EP90109379A patent/EP0398342A1/en not_active Withdrawn
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1790118B2 (en) * | 1967-09-13 | 1977-09-22 | AMP Inc., Harrisburg, Pa. (V.St A.) | CONNECTOR ATTACHED TO AN ALUMINUM WIRE LADDER |
DE2554310B2 (en) * | 1974-12-03 | 1979-09-20 | Thomas & Betts Corp., Raritan, N.J. (V.St.A.) | Electrical connection between a connector and a conductor and crimping device for making this connection |
Non-Patent Citations (2)
Title |
---|
IBM TECHNICAL DISCLOSURE BULLETIN * |
UND- ODER NOR + STEUERUNGSTECHNIK * |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0873042A4 (en) * | 1995-05-29 | 1998-10-21 | ||
EP0873042A1 (en) * | 1995-05-29 | 1998-10-21 | R-Amtech International, Inc. | Elongated flexible electrical heater and a method of manufacturing it |
DE102006045567A1 (en) * | 2006-09-25 | 2008-04-24 | Tyco Electronics Amp Gmbh | Crimp connection for producing electrical contact between crimp case and electrical conductor, has crimp case with two crimp flanks and bent under formation of longitudinal weld, where ends of crimp flanks engage into each other along weld |
DE102006045567A8 (en) * | 2006-09-25 | 2008-09-11 | Tyco Electronics Amp Gmbh | Crimpstabilisierung |
EP1993171A1 (en) | 2007-05-16 | 2008-11-19 | Delphi Technologies, Inc. | Cable shoe |
Also Published As
Publication number | Publication date |
---|---|
JPH02148564U (en) | 1990-12-18 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP2290747B1 (en) | Metal terminal fitting and electric wire with terminal | |
US8425266B2 (en) | Terminal connector and electric wire with terminal connector | |
JPH0713180Y2 (en) | Electrical connector | |
US4261629A (en) | Slotted plate terminal | |
JP2005050736A (en) | Method of manufacturing terminal crimping structure to aluminum wire and aluminum wire with terminal | |
EP1503453B1 (en) | H-Tap compression connector | |
US4050760A (en) | Solderless electrical contact | |
EP0312550B1 (en) | Insulation displacement terminal | |
US4442316A (en) | Crimp connector for electrical wires | |
EP0782215A1 (en) | Conductor connection terminal and method of connection | |
JPH0744046B2 (en) | Insulated perforated conductive terminal | |
US10498048B2 (en) | Wire with terminal having a core crimping portion with enlarged diameter portion and a recess in the enlarged diameter portion | |
CA1113163A (en) | Solderless termination system | |
EP0398342A1 (en) | A crimp terminal and its wire crimping structure | |
JPS59165390A (en) | Method of bonding solderless terminal and terminal thereof | |
US4264118A (en) | Insulation-pierce and crimp termination and method for effecting same | |
CA1294682C (en) | Electrical connector | |
EP0717461A1 (en) | IDC branch connector for large range of wire sizes | |
EP0210062A2 (en) | Electrical crimp connection | |
EP0195784B1 (en) | Electrical connector for stranded wires | |
US4938713A (en) | Electrical terminal for wave crimp termination of flat power cable | |
US4480385A (en) | Tool and method for terminating electrical conductors in contact members | |
US4414740A (en) | Insulation-pierce and crimp termination tool | |
US4540224A (en) | Grounding clip for use with shielded, jacketed flat cable | |
JP2824497B2 (en) | Crimping method and structure of crimp terminal and wire |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
AK | Designated contracting states |
Kind code of ref document: A1 Designated state(s): DE GB |
|
17P | Request for examination filed |
Effective date: 19910319 |
|
17Q | First examination report despatched |
Effective date: 19931027 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN |
|
18D | Application deemed to be withdrawn |
Effective date: 19940308 |