EP3039747B1 - Terminal/connector having integral oxide breaker element - Google Patents
Terminal/connector having integral oxide breaker element Download PDFInfo
- Publication number
- EP3039747B1 EP3039747B1 EP14759428.7A EP14759428A EP3039747B1 EP 3039747 B1 EP3039747 B1 EP 3039747B1 EP 14759428 A EP14759428 A EP 14759428A EP 3039747 B1 EP3039747 B1 EP 3039747B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- wire
- receiving portion
- wire receiving
- terminal
- seal rings
- 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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- 239000004020 conductor Substances 0.000 claims description 53
- 229910052782 aluminium Inorganic materials 0.000 claims description 34
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 34
- 238000007789 sealing Methods 0.000 claims description 25
- 238000000576 coating method Methods 0.000 claims description 24
- 239000000463 material Substances 0.000 claims description 24
- 239000011248 coating agent Substances 0.000 claims description 21
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 18
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 14
- 239000000314 lubricant Substances 0.000 claims description 12
- 229910052802 copper Inorganic materials 0.000 claims description 9
- 239000010949 copper Substances 0.000 claims description 9
- 229910052759 nickel Inorganic materials 0.000 claims description 9
- 238000009413 insulation Methods 0.000 claims description 8
- 239000011345 viscous material Substances 0.000 claims description 3
- 238000002788 crimping Methods 0.000 description 20
- 239000010410 layer Substances 0.000 description 17
- 238000012360 testing method Methods 0.000 description 15
- 230000007704 transition Effects 0.000 description 15
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- 230000001351 cycling effect Effects 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 229910052718 tin Inorganic materials 0.000 description 4
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 230000005611 electricity Effects 0.000 description 3
- 230000002706 hydrostatic effect Effects 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000001965 increasing effect Effects 0.000 description 2
- 239000012212 insulator Substances 0.000 description 2
- 238000005201 scrubbing Methods 0.000 description 2
- 239000000565 sealant Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
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- 230000002708 enhancing effect Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
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- 238000009434 installation Methods 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- LQBJWKCYZGMFEV-UHFFFAOYSA-N lead tin Chemical compound [Sn].[Pb] LQBJWKCYZGMFEV-UHFFFAOYSA-N 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 229920002631 room-temperature vulcanizate silicone Polymers 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Images
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
- 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
- H01R4/20—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 using a crimping sleeve
- H01R4/203—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 using a crimping sleeve having an uneven wire-receiving surface to improve the contact
- H01R4/206—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 using a crimping sleeve having an uneven wire-receiving surface to improve the contact with transversal grooves or threads
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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
- H01R4/26—Connections in which at least one of the connecting parts has projections which bite into or engage the other connecting part in order to improve the contact
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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
- H01R11/12—End pieces terminating in an eye, hook, or fork
-
- 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
- H01R13/02—Contact members
- H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
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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
- 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
- H01R13/5219—Sealing means between coupling parts, e.g. interfacial seal
-
- 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
- H01R4/188—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 having an uneven wire-receiving surface to improve the contact
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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
- H01R4/58—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 characterised by the form or material of the contacting members
Definitions
- This present invention relates generally to electrical terminals and connectors, and particularly to improving the performance, construction and ease of use of connectors on aluminum wire. It also relates to cables comprising such terminals and connectors and a plurality of wires.
- Electrical wires are most often made with copper or aluminum conductors. These may be of one solid piece, or stranded. For ease of connections, for instance to grounding studs, or to power strips, a lug or terminal is often attached to the end of the wire.
- the terms lug, terminal lug, and terminal will be used interchangeably in this application.
- a wire with a terminal is also referred to as a "cable" herein.
- a cable might also incorporate multiple electrical conductors or wires that are connected or spliced together end-to-end. The cable, including the interface between the terminal and the conductor or between adjacent conductors, must efficiently conduct the electricity that the cable is meant to carry.
- the cable may not perform the function for which it is intended, or it may overheat.
- the terminal mechanically fastens to the aluminum or copper conductor. If there is insulation on the wire, it is first removed or penetrated in an area sufficient to allow proper electrical contact which is usually metal-to-metal contact. Sometimes attachment occurs with a heat process such as welding or soldering, however these tend to be slower methods than mechanical fastening. Also, the heat of these processes could deteriorate the properties of the nearby insulation that is on the conductor.
- Mechanical crimping of a terminal around a wire is commonly used. However, the chemistry of aluminum oxidation makes crimping to an aluminum wire more difficult than to a copper wire, as will be explained.
- aluminum resists corrosion (oxidation) better than steel does.
- lawn furniture made of steel develops flaking rust (oxidation) but aluminum furniture does not.
- Aluminum also oxidizes almost instantaneously when exposed to air, but the oxide does not subsequently flake off. Instead, the oxidized surface layer is very thin and very strong. It protects the nonoxidized aluminum below by separating it from the surrounding air.
- This property of aluminum presents a problem in the manufacture of aluminum cables because the oxide layer is a poor conductor of electricity.
- one consideration in aluminum cable manufacture is how to get good electrical conductivity between a terminal and an aluminum wire or between the transition spanning between two coupled or spliced sections of wire.
- good electrical conductivity is achieved in a cost effective manner that has a low opportunity for problems to arise during the manufacturing process.
- Another consideration in cable manufacture is how to create a cable that resists moisture and air infiltration between the terminal and the conductor or at the transition between two spliced wires. In many cases this means making an airtight connection between the terminal or transition and the exterior of the wire insulation.
- a tin plated copper terminal 10 includes a ring tongue (RT) style connector portion 11, a cylindrical wire barrel 12, a perforated liner 14, and an annular ring 16 with an inclined wall 18.
- Terminal 10 is shown in exploded view with stranded aluminum wire 20 having conductor strands 22, an insulating sheath 24, and an abrasion sheath 26.
- Figures 2 and 3 show the wire 20 installed in the terminal 10, before and after crimping by die set 27.
- the deformation, known as terminal skew, of the terminal 10 is extensive, with the upper mounting surface 28 and lower mounting surface 30 no longer parallel to the axis 32 of the wire 20.
- several conductor strands 22 might be severed as shown at 34 in the area of annular ring 16.
- the pre-crimp geometry of Figure 2 is represented with phantom lines in Figure 3 .
- US-A1-2010/206631 provides a terminal having a mount portion and a wire receiving portion , the wire receiving portion having a contact portion for contacting the wire conductor and a sealing portion.
- US-A1-2002/0050385 provides a terminal having a tubular wire receiving portion and a cylindrical connecting portion. The wire receiving portion is uniformly caulked around the exposed end of an insulated wire and around an adjacent insulated portion. The compressed conductor forms an electrical connection with the terminal while the compressed insulator restricts the entry of air into the inner portion of the tube.
- US Patent 2974400 shows an insulated terminal comprising a wire receiving portion and a connecting portion.
- the wire receiving portion is formed from a copper tube surrounded by an insulating, plastic sleeve. The tube and sleeve are crimped together onto a wire to secure the wire in the terminal.
- US-A1-2008/0217055 provides an electrical connector with a tubular body having a wire receiving portion at each end. The wire receiving portions are tapered and have inward projections for gripping the wires prior to crimping of the tubular body, without providing a permanent electrical connection.
- US-A1-2011/0097948 provides a non-crimped electrical terminal.
- the terminal includes a housing and a spiral unit formed by a conductive coil. Stripped wire is inserted into the coil and the housing is moved relative to the spiral unit to tighten the coil against the wire in order to secure the wire within the terminal.
- an electrical terminal according to claim 1 and, in a second aspect, an electrical connector according to claim 2, both for use with wires, such as aluminum or copper wires.
- the terminal has a mount portion, for connecting to a part of an electric circuit, and a wire receiving portion.
- the connector implements adjacent wire receiving portions to receive the ends of wires that are connected together.
- the wire receiving portions have an interior with a contact portion that has an integral oxide breaker element.
- the wire receiving portion also has a sealing portion that has a plurality of integral seal rings and a plurality of flexible seal rings, each of the flexible seal rings being formed by applying a curable, viscous material continuously around the wire receiving portion at a height that is higher than the height of the respective integral seal rings (318b, 318c) so that_each flexible seal ring is positioned between and adjacent to respective integral seal rings for sealing with the insulator of a wire.
- the integral oxide breaker element has a plurality of protrusions and may have tapered protrusions with a coating.
- the coating is nickel, but may be other suitable materials.
- the wire receiving portion accepts a wire, such as aluminum or copper wire to make a cable, and upon crimping of the receiving portion the oxide breaker element makes electrical contact with conductor(s) of the wire.
- an integral electrical terminal 100 includes a body made from a solid piece of 1100 Aluminum per ASTM B221, and has a wire receiving portion 102 and a mount portion 104, and is shown with a stranded aluminum wire 20 having a conductor with conductor strands 22, an insulating sheath 24.
- aluminum wire might be used in one embodiment of the invention, the conductor of the wire might be made of other suitable electrically conducting material, such as copper.
- the wire connected with the terminal may also include an abrasion sheath 26.
- the receiving portion 102 of the terminal body has a front face 106 surrounding an aperture 108, a back face 110, and an outer wall 112 between the front face 106 and the back face 110.
- the receiving portion 102 is cylindrical, consistent with the usual cylindrical shape of wire, although the receiving portion 102 may be a variety of shapes.
- Between the back face 110 and the mount portion 104 is a transition radius 114.
- the mount portion has a parallel leg 116 and a perpendicular leg 118 coming from the end of the parallel leg 116 opposite the receiving portion 102.
- This terminal 100 is in the shape of what is known in the industry as a CRN terminal, however the mount portion 104 may be a variety of shapes.
- the mount portion 104 had only the parallel leg 116, it would be an RT (Ring Tongue) configuration.
- a top face 120 and a bottom face 122 are approximately parallel to an axis 124 of the receiving portion 102.
- Hole 126 and a second hole 128 pass through the mount portion 104 from the top face 120 to the bottom face 122.
- the receiving portion 102 has a top 130 and a bottom 132, as determined by the orientation of the top face 120 and bottom face 122.
- the wire receiving portion 102 is configured to be crimped, and has continuous annular interior wall 133 comprising a crimp portion 134 ( Figure 8 ) that comprises a seal portion or sealing portion 136 and a contact portion 138.
- the sealing portion 136 is adjacent to, and spaced from, the contact portion 138 toward aperture 108.
- a chamfer or radius 140 at the front face 106 connects with a seal zone surface 142.
- the seal zone surface 142 is broken into four areas 144a, b, c, d by three integral seal rings 146a, b, c protruding radially inward from the seal zone surface 142.
- each seal ring 146 has a face 148 ( Figure 5B ) of a particular width, with a front angled wall 150 and a back angled wall 152 leading to the adjacent one of the four areas 144. In this embodiment, all the angled walls 150, 152 are the same angle, however, in other embodiments the angles may be different, or may be a positive or a negative radius.
- An integral funnel 154 is between the seal or sealing portion 136 and the contact portion 138.
- the integral funnel 154 guides the conductor strands 22 from the larger seal portion 136 into the contact portion 138, while the wire 20 is being inserted into the terminal 100.
- the contact portion 138 has a continuous cylindrical wall 155 with a major diameter 156 and an integral oxide breaker or oxide breaker element 158, the term this application will use for the macro object that breaks through the oxide layer on the conductor or conductor strands 22 when the wire receiving portion is crimped.
- the integral oxide breaker element 158 comprises a plurality of protrusions, such as tapered protrusions 162, extending radially inward from the major diameter 156 of the contact portion 138.
- the protrusions are configured to engage the conductor of a wire positioned in the contact portion, and to protrude into the wire when the wire receiving portion is crimped.
- These tapered protrusions 162 may be separate from each other, but in other embodiments, for ease of manufacture, these tapered protrusions 162 are in the form of a helical thread 164 ( Figure 5A ) that is conveniently manufactured on metal cutting or forming equipment.
- the thread 164 has a sixty degree included angle 166 and a pitch 167 of eighty, and is .008/.010 inch deep. A pitch 167 of sixty has also worked successfully. It is contemplated that other included angles 166 and pitch 167 combinations as well as depths would also work. A minor diameter 168 of the threads equal to .481 +/- .002 inch has been used for wire gauge 2/0.
- the oxide breaker 158 further comprises a coating 170 on the protrusions 162. In various embodiments, the oxide breaker and the structures forming same might be coated with a material layer or left uncoated. In one particular embodiment, the coating 170 is an electroless nickel plate of .0005 +/- .002 per ASTM B733 Type III.
- blind refers to a hole with only one aperture 108
- coating process In addition to nickel, other coatings might be utilized and include electro nickel, gold, silver, tin and tin-lead, and alkaline-bismouth-tin.
- the structure of the oxide breaker element provides not only the ability to break through the oxide layer on the conductor strand, but also improves the electrical and mechanical features of the invention.
- the construction of the oxide breaker element increases the surface area of the crimp, and the contact with the conductor, to improve the overall electrical properties of the connection in the transition from the wire to the terminal.
- the oxide breaker element 158 increases the grip function at the contact portion 138, and increases the pull force necessary to remove the wire 20 from terminal 100.
- FIG. 10 illustrates an alternative embodiment of a contemplated terminal 500 in which the protrusions 162 of the oxide breaker 502 are axial ridges 504. The orientation of the axial ridges 504 are parallel to the direction of pull-out.
- the protrusions 162 improve upon the prior art and provide improved electrical properties for current conductance purposes, they might be slightly less effective in improving pull-out requirements as those illustrated in Figure 5 .
- these protrusions 162 comprise peaks 172, angular faces 174, and bottoms 176, and may have no coating, or may be covered by coating 170 as seen in detail Figure 5A .
- Other embodiments of protrusions 162 are contemplated but not shown, for example, a plurality of spikes rising from the major diameter 156 might also be implemented.
- the wire 20 is inserted in the terminal so that the conductor or conductor strands 22 are guided by the integral funnel 154 into the contact portion 138.
- the three seal rings 146a,b,c surround the insulation sheath 24, and the integral oxide breaker 158 surrounds the conductor of the wire, including the conductor strands 22.
- the assembly 178 is placed in a suitable crimping die, such as a modified hex crimping die 182 ( Figure 11 ), and crimped to make a cable 184 with a crimp 186.
- the crimp 186 comprises 2 opposing concave facets 188 and four straight facets 190. Between the facets are six corners 192.
- On one of the concave facets 188 is an indicator button 194.
- the indicator button 194 will be properly formed if the wire 20 was properly inserted and crimped. If the wire 20 was improperly inserted or crimped the indicator button 194 will be shaped improperly, indicating to a person or a visual inspection system that the particular cable 184 should be rejected.
- the indicator button 194 is formed by a recess (not shown) in crimping die 182. If the conductor strands 22 are not present in the proper position in the terminal 100, the receiving portion 102 will not extrude into the recess, and the indicator button 194 will not be formed.
- the conductor strands 20 are squeezed together tightly at 195 as compared to the visibly individual strands at 196 outside of the terminal 100.
- the sealing rings 146a,b,c are squeezed into the insulating sheath 24 to make a hydrostatic seal 198.
- the integral oxide breaker 158 is squeezed into the aluminum conductor strands 22 to give the assembly 178 a conductive electrical path 202 between the receiving portion 102 and the stranded aluminum wire 20.
- Oxide Breaker testing A smooth bore design was compared with a machined oxide breaker by testing. Results showed that the smooth bore did not meet the low initial 6.0 millivolt requirement whereas the machined oxide breaker barrel met the requirement with very good margin. Further testing after Thermal Shock and Current Cycling proved that the machined oxide breaker feature continued to perform well.
- Thermal Shock testing After the initial millivolt drop testing, a modified 100 cycle Thermal Shock test was run on the same set of 2/0 AWG Single -Hole Tensolite Aluminum Terminal samples. The temperature was cycled between -65°C and +175°C but no current flow was included in the testing. Millivolt drop results were tested at the end of the 100 cycles. The millivolt results after 100 cycles show that the terminals met the millivolt requirement of BPS-T-217 and the more stringent millivolt requirement of BPS-T-233.
- Hydrostatic seal testing The hydrostatic test used aluminum terminals crimped to wire and installed into a water filled chamber. The chamber was cycled 25 times from 0 to 80 PSI and held at pressure for 15 minutes each cycle. All samples passed.
- Figures 12-16 illustrate further alternative embodiments of the invention in the form of a connector that might be implemented to connect together or splice together two conductors or wires.
- the connector may act as a splice connector to splice together two wires of the same size, or could be in the form of a transition connector to splice together two different size wires.
- Figures 12 and 13 illustrate a connector device or element wherein the two wires that are connected together or spliced together are generally of the same size or gauge, such as 1/0 to 1/0 size wires.
- Figures 14 and 15 illustrate the transition connector for connecting together wires having different gauges, such as a 1/0 to 2/0 size wire transition.
- the connectors of Figures 12-16 may be used to connect wires of the same material, such as two aluminum or two copper wires, or may be used to connect together two different wires, such as an aluminum wire and a copper wire.
- the connector 300 of Figures 12 and 13 has a body formed of a suitable electrically conductive material, such as aluminum or copper.
- Connector 300 has two adjacent wire receiving portions 302 that are positioned at opposing ends of the body, and configured to receive the exposed end of a wire, such as an aluminum wire or a copper wire.
- Each receiving portion 302 forms a corresponding aperture 304 in the end of the connector like with the terminal embodiment.
- the receiving portion 302 might also be cylindrical, consistent with other embodiments, and the usual cylindrical shape of a wire, but the receiving portion might also be a variety of other shapes.
- each receiving portion 302 includes an interior wall 306 that forms a suitable portion to be crimped that includes a sealing portion 308 and a contact portion 310.
- a chamfer 312 transitions to surface 314 that forms the sealing portion 308.
- the seal zone of the sealing portion might be considered to be broken into a number of different areas 316a-316d by integral seal rings 318a-318c that protrude radially inwardly from surface 314.
- a greater or lesser number of areas 316 or seal rings 318 might be implemented in the embodiment of the invention than the three rings 318 and four areas 316 illustrated in the figures.
- Each seal ring 318a-318c will be constructed or configured as illustrated in Figure 5b having suitable faces and angled walls, as noted herein.
- An integral transition area or funnel 320 feeds between the sealing portion 308 and the contact portion 310 to guide the conductor of a wire, as illustrated in Figure 16 , from a larger diameter sealed portion 308 to the smaller diameter contact portion.
- the contact portion also has a continuous inner surface 322, which has an oxide breaker element 324 formed thereon for breaking up the oxide layer on a conductor of a wire inserted into the connector 300.
- the integral oxide breaker element 324 may have a plurality of protrusions, such as tapered protrusions, such as those illustrated and discussed with respect to Figure 5 .
- the protrusions extend radially inwardly from the surface 322 in the contact position, and they include individually tapered protrusions or a helical thread, as illustrated in Figures 5-5A , or might take the form as illustrated in Figure 10 .
- the oxide breaker element 324 is suitably configured to engage a wire positioned in the contact portion, and the protrusion protrude into or penetrate into a conductor 22 of a wire when the receiving portion 302 is crimped.
- the oxide breaker element breaks up any oxide on the conductor, and also electrically engages the conductor for the purposes of conducting electrical current through the connector 300. While embodiments of the invention in the form of a terminal might conduct electricity to a particular point of a circuit, the embodiment of connector 300 is directed to form a suitable electrical connection, splice, or transition between the ends of two wires that are connected end-to-end, as illustrated in Figure 16 .
- the oxide breaker element might be a bare structure essentially presenting the metal of the connector 300 to the wire conductor.
- the oxide breaker element, and particularly the protrusions and structures of the oxide breaker element 324 might be coated with a suitable coating, similar to the coatings discussed herein above with respect to the terminal embodiment.
- Both of the oxide breaker elements of the connectors 300, 301 might be coated with a coating, or only one might be coated with the other one left uncoated.
- Figures 12 and 13 illustrate a connector 300 for use with wires that are essentially the same size, diameter, or gauge, such as 1/0.
- Figures 14 and 15 illustrate an embodiment wherein the wires have a different gauge, such as a 1/0 to 2/0 transition.
- connector 301 has one receiving portion 303 that is smaller than another receiving portion 305.
- the connector 301 provides a suitable splice and transition between differently-sized wires.
- the inner surface 322a of the contact portion 310 has a smaller inner diameter than the corresponding surface 322b in the adjacent wire receiving portion 305.
- All of the other elements of connector 301 are similar to those of connector 300, and thus, are set forth with similar reference numerals.
- an angled outer surface 307 indicates the transition between the different sizes.
- a structure having a uniform outside diameter such as that shown by connector 300, might also be implemented with only the inner surface 322a being accordingly sized to its smaller size.
- suitable wire stop structures 309, 311 are formed.
- an appropriate connector 300, 301 might be utilized to connect together or splice together the ends of two wires similar to the way that the terminal 100 is connected to the end of a wire.
- the ends of the wire 20 are inserted into the terminal, and the conductor 22 is guided into the appropriate contact portion 310.
- the seal rings surround the insulation sheath 24 of the wire, while the oxide breaker 324 surrounds the conductor 22.
- the entire assembly can then be placed in a suitable crimping die and crimped so that the seal rings seal around the insulation sheath 24, and the oxide breaker element 324 presses into and engages the conductor 22.
- the connectors 300, 301 are otherwise similar in operation and performance to the terminal 100 discussed herein.
- the wires connected may be of the same material or of different materials.
- both of the oxide breaker elements of a connector might be coated with a coating such as Nickel, or only one might be coated.
- a coating such as Nickel
- only one might be coated if an aluminum wire is spliced to a copper wire, only the receiving portion and oxide breaker element that engages the aluminum wire might be coated.
- both oxide breaker elements might be coated, for example.
- Figure 17 illustrates another alternative embodiment of the invention incorporating a lubricant layer for the purposes of improved crimping of a connector or terminal of the invention. While a terminal embodiment is illustrated in Figure 17 , the features of the lubricant layer are equally applicable to the connector embodiments disclosed herein, such as those shown in Figures 12-16 . Like reference numerals are used where applicable.
- the terminal 350 includes a mount portion 352, which may be mounted to an appropriate surface, such as a grounding surface, when a wire or cable implementing terminal 350 is implemented.
- Terminal 350 also includes a wire receiving portion 354 constructed as discussed herein.
- the wire receiving portion will have an appropriate sealing portion 308 and contact portion 310.
- Each wire receiving portion 354 will include an aperture 304 with other appropriate structures positioned on an interior surface, including integral seal rings 318a-318c.
- the terminal 350 of Figure 17 is similar to other terminals or connectors discussed herein in most of its construction, but also has a lubricant layer.
- the crimping process can be affected, sometimes detrimentally.
- the interior surfaces such as the oxide breaker element
- the exterior surfaces of the device are also coated.
- a majority percentage of the wire receiving portion 354 will be crimped as shown herein for capturing a wire conductor, and breaking up any oxide on the outer surface of the wire conductor. While certain coating materials flow over the outer surface of wire receiving portion 354 during the crimping process, other coating materials are harder and more brittle.
- the coating material may extrude or flow into various crimp points of the die, such as the seams 183, as illustrated in Figure 11 .
- a coating of tin will sufficiently flow around the outside surface of the wire receiving portion 354 when it is crimped, a coating material layer of nickel, will not.
- a hard material like nickel extrudes into the crimp seams 183 of the die during the crimping process, it will create flashing in the form of fins or wings at certain areas of the crimp. Such flashing may then pull away from the crimped terminal or connector, thus exposing the aluminum of the terminal or connector to corrosion.
- such a situation with flashing formed may be considered a failed crimp process.
- the outside surface of the wire receiving portion is coated with a lubricant layer 360.
- the lubricant layer 360 is made of a suitable lubricant material, such as PTFE, such as FluoroPlate®-XK3-654-LT, available from Orion Industries of Chicago, Illinois.
- the lubricant layer 360 is applied generally to the wire receiving portion 354, but only on the outside surface thereof.
- Other areas, such as the internal surfaces of the wire receiving portion 354, as well as the mount portion 352 are appropriately masked to prevent any overspray.
- the wire receiving portion 354 outside or external surface may be appropriately degreased while certain of the conductive areas are masked to be kept free from overspray.
- the lubricant material is applied on the outside surface of at least part of the wire receiving portion, such as in a thickness in the range of 0.0003 - 0.001 inches.
- the thickness of the applied lubricant layer 360 may be 0.0006 +/- 0.0002 inches.
- the applied lubricant layer 360 may also be cured at around 160° +/- 5° Fahrenheit, for around twenty minutes.
- the lubricant layer 360 provides lubrication to a harder coating material, such as nickel, so that, during the crimp, the coating materials flow more easily in the die, and prevents undesirable flashing. In that way, the overall terminal or connector is improved, and failed crimps are minimized.
- Figure 18 illustrates another alternative embodiment, which has features which may be implemented in either a terminal or connector, as disclosed herein.
- Figure 18 illustrates a terminal embodiment, but the features are equally applicable to a connector embodiment as well.
- the terminal 362 has an appropriate wire receiving portion 364, which is constructed as disclosed herein, including a sealing portion 308 and contact portion 310, with appropriate structures as shown.
- flexible seal rings may be implemented along with the seal rings 318a - 318c.
- one or more flexible seal rings 370a, 370b might be implemented in one or more of the areas 316a - 316d that are provided between the seal rings 318 of the sealing portion 208.
- flexible seal ring 370a is positioned between and adjacent to rings 318a and 318b, while flexible seal ring 370b is positioned between and adjacent to rings 318b and 318c.
- the flexible seal rings 370 are formed of a suitably flexible material, such as an RTV Silicone.
- One suitable material is Heat Resistant Sealant 736, available from Dow Corning.
- the flexible seal rings 370 are deposited in the appropriate spaces 316, and would generally take up less than the space or volume between the seal rings 318.
- Each of the flexible seal rings 370 is formed continuously for 360° around the inner surface of the sealing portion 308. An exact shape for the flexible seal rings 370 is not critical.
- the flexible seal rings 370a are flexed when the wire receiving portion 364 is crimped, as noted herein for forming a complete wire assembly or cable using an appropriate wire.
- the flexible seal rings 370 provide additional sealing to the overall seal that is provided by the crimping of the rings 318. In that way, an overall sealed environment within contact portion 310 is created and maintained.
- a solvent wash might be utilized to wash the interior surfaces of the wire receiving portion 364.
- a high pressure dispenser with volumetric control one or more 360° rings of sealant are applied.
- the flexible seal rings 370 in one embodiment, may be 50% higher than the height of the adjacent rigid seal rings 318.
- the flexible seal rings 370 might be applied by hand, with a suitable tool to deposit material in the various areas 316, such as up to a level with the rings 318. The material applied is appropriately viscous, and can flow, but then hardens. Material may then be allowed to cure at room temperature, such as for a minimum of twenty-four hours, to provide the seal features of embodiments of the invention.
Landscapes
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Description
- This present invention relates generally to electrical terminals and connectors, and particularly to improving the performance, construction and ease of use of connectors on aluminum wire. It also relates to cables comprising such terminals and connectors and a plurality of wires.
- Electrical wires are most often made with copper or aluminum conductors. These may be of one solid piece, or stranded. For ease of connections, for instance to grounding studs, or to power strips, a lug or terminal is often attached to the end of the wire. The terms lug, terminal lug, and terminal will be used interchangeably in this application. A wire with a terminal is also referred to as a "cable" herein. A cable might also incorporate multiple electrical conductors or wires that are connected or spliced together end-to-end. The cable, including the interface between the terminal and the conductor or between adjacent conductors, must efficiently conduct the electricity that the cable is meant to carry. If the conductance at the interface is not efficient (if resistance is high), the cable may not perform the function for which it is intended, or it may overheat. Usually, the terminal mechanically fastens to the aluminum or copper conductor. If there is insulation on the wire, it is first removed or penetrated in an area sufficient to allow proper electrical contact which is usually metal-to-metal contact. Sometimes attachment occurs with a heat process such as welding or soldering, however these tend to be slower methods than mechanical fastening. Also, the heat of these processes could deteriorate the properties of the nearby insulation that is on the conductor. Mechanical crimping of a terminal around a wire is commonly used. However, the chemistry of aluminum oxidation makes crimping to an aluminum wire more difficult than to a copper wire, as will be explained.
- It is known that aluminum resists corrosion (oxidation) better than steel does. For example, lawn furniture made of steel develops flaking rust (oxidation) but aluminum furniture does not. Aluminum also oxidizes almost instantaneously when exposed to air, but the oxide does not subsequently flake off. Instead, the oxidized surface layer is very thin and very strong. It protects the nonoxidized aluminum below by separating it from the surrounding air. This property of aluminum presents a problem in the manufacture of aluminum cables because the oxide layer is a poor conductor of electricity. Thus, one consideration in aluminum cable manufacture is how to get good electrical conductivity between a terminal and an aluminum wire or between the transition spanning between two coupled or spliced sections of wire. Preferably, good electrical conductivity is achieved in a cost effective manner that has a low opportunity for problems to arise during the manufacturing process.
- Another consideration in cable manufacture is how to create a cable that resists moisture and air infiltration between the terminal and the conductor or at the transition between two spliced wires. In many cases this means making an airtight connection between the terminal or transition and the exterior of the wire insulation.
- Still another consideration in cable manufacture is how to provide a terminal/cable combination that has a consistent and strong geometry. Preferably the terminal and cable are straight and smooth to avoid stress concentrations. With stranded wire, severing one or more strands during the terminal attachment process should also be avoided. There have been many attempts at making a terminal for use with Aluminum wire. For example,
United States Patent 3955044 to Hoffman et al., issued May 4, 1976 shows one such prior art.Figures 1-3 in the present application are representative of a prior art configuration showing some drawbacks to the prior art. A tin platedcopper terminal 10 includes a ring tongue (RT)style connector portion 11, acylindrical wire barrel 12, aperforated liner 14, and anannular ring 16 with aninclined wall 18.Terminal 10 is shown in exploded view with strandedaluminum wire 20 havingconductor strands 22, aninsulating sheath 24, and anabrasion sheath 26.Figures 2 and 3 show thewire 20 installed in theterminal 10, before and after crimping by dieset 27. InFigure 3 , the deformation, known as terminal skew, of theterminal 10 is extensive, with theupper mounting surface 28 andlower mounting surface 30 no longer parallel to theaxis 32 of thewire 20. Also, with such a designseveral conductor strands 22 might be severed as shown at 34 in the area ofannular ring 16. The pre-crimp geometry ofFigure 2 is represented with phantom lines inFigure 3 . The extensive extrusion and crimping of theconductor strands 22 andbarrel 12 changes thelength 36 and theangle 38 an amount that is significant and not precisely predictable. Further examples will now be discussed.US-A1-2010/206631 provides a terminal having a mount portion and a wire receiving portion , the wire receiving portion having a contact portion for contacting the wire conductor and a sealing portion.US-A1-2002/0050385 provides a terminal having a tubular wire receiving portion and a cylindrical connecting portion. The wire receiving portion is uniformly caulked around the exposed end of an insulated wire and around an adjacent insulated portion. The compressed conductor forms an electrical connection with the terminal while the compressed insulator restricts the entry of air into the inner portion of the tube.US Patent 2974400 shows an insulated terminal comprising a wire receiving portion and a connecting portion. The wire receiving portion is formed from a copper tube surrounded by an insulating, plastic sleeve. The tube and sleeve are crimped together onto a wire to secure the wire in the terminal.US-A1-2008/0217055 provides an electrical connector with a tubular body having a wire receiving portion at each end. The wire receiving portions are tapered and have inward projections for gripping the wires prior to crimping of the tubular body, without providing a permanent electrical connection.US-A1-2011/0097948 provides a non-crimped electrical terminal. The terminal includes a housing and a spiral unit formed by a conductive coil. Stripped wire is inserted into the coil and the housing is moved relative to the spiral unit to tighten the coil against the wire in order to secure the wire within the terminal. - There are many drawbacks to the prior art, including, but not limited to the multiple pieces that are required and that lead to increased cost and opportunity for assembly errors, severing of one or more strands, and the non-linear alignment between the connector portion and the wire barrel after crimping. The present invention addresses these drawbacks and other drawbacks in the prior art.
- The invention is defined by the claims. In the present disclosure, there is provided, in a first aspect, an electrical terminal according to claim 1 and, in a second aspect, an electrical connector according to claim 2, both for use with wires, such as aluminum or copper wires. The terminal has a mount portion, for connecting to a part of an electric circuit, and a wire receiving portion. The connector implements adjacent wire receiving portions to receive the ends of wires that are connected together. The wire receiving portions have an interior with a contact portion that has an integral oxide breaker element. The wire receiving portion also has a sealing portion that has a plurality of integral seal rings and a plurality of flexible seal rings, each of the flexible seal rings being formed by applying a curable, viscous material continuously around the wire receiving portion at a height that is higher than the height of the respective integral seal rings (318b, 318c) so that_each flexible seal ring is positioned between and adjacent to respective integral seal rings for sealing with the insulator of a wire.
- The integral oxide breaker element has a plurality of protrusions and may have tapered protrusions with a coating. In one embodiment the coating is nickel, but may be other suitable materials. The wire receiving portion accepts a wire, such as aluminum or copper wire to make a cable, and upon crimping of the receiving portion the oxide breaker element makes electrical contact with conductor(s) of the wire.
- The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given below, serve to explain the principles of the invention.
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Figure 1 is an exploded view of a terminal of the prior art, with a wire. -
Figure 2 is an assembled view ofFigure 1 prior to crimping, and is also prior art. -
Figure 3 is an assembled view ofFigure 1 after crimping, and is also prior art. -
Figure 4 illustrates one embodiment of the current invention with a stranded wire prior to installation. -
Figure 5 is a partial cross-section of the embodiment, as indicated inFigure 4 . -
Figure 5A is a detail view of the embodiment, as indicated inFigure 5 . -
Figure 5B is a detail view of the embodiment, as indicated inFigure 5 . -
Figure 6 illustrates a not cross-sectioned wire slid into a cross-sectioned embodiment ofFigure 4 for illustrative purposes. -
Figure 7 illustrates an assembled and crimped embodiment ofFigure 4 . -
Figure 8 is a cross-section of the embodiment, as indicated inFigure 7 . -
Figure 9 is another cross-section of the embodiment, as indicated inFigure 7 . -
Figure 10 is a partial cross-section illustrating an alternative embodiment of the current invention. -
Figure 11 is a perspective view of a die set used for crimping. -
Figure 12 is a perspective view of another alternative embodiment of the invention. -
Figure 13 is a cross-sectional view of the embodiment ofFigure 12 . -
Figure 14 is a perspective view of another alternative embodiment of the invention. -
Figure 15 is a cross-sectional view of the embodiment ofFigure 14 . -
Figure 16 illustrates a cross-sectional view of an embodiment of the connector ofFigure 12 showing two wires connected together. -
Figure 17 is a perspective view of another alternative embodiment of the invention. -
Figure 18 is a perspective view of the main embodiment of the electrical terminal according to claim 1. - With reference to
Figure 4 , in one embodiment of the invention, an integralelectrical terminal 100, includes a body made from a solid piece of 1100 Aluminum per ASTM B221, and has awire receiving portion 102 and amount portion 104, and is shown with a strandedaluminum wire 20 having a conductor withconductor strands 22, an insulatingsheath 24. Although aluminum wire might be used in one embodiment of the invention, the conductor of the wire might be made of other suitable electrically conducting material, such as copper. In one embodiment, the wire connected with the terminal may also include anabrasion sheath 26. The receivingportion 102 of the terminal body has afront face 106 surrounding anaperture 108, aback face 110, and anouter wall 112 between thefront face 106 and theback face 110. The receivingportion 102 is cylindrical, consistent with the usual cylindrical shape of wire, although the receivingportion 102 may be a variety of shapes. Between theback face 110 and themount portion 104 is atransition radius 114. The mount portion has aparallel leg 116 and aperpendicular leg 118 coming from the end of theparallel leg 116 opposite the receivingportion 102. This terminal 100 is in the shape of what is known in the industry as a CRN terminal, however themount portion 104 may be a variety of shapes. If themount portion 104 had only theparallel leg 116, it would be an RT (Ring Tongue) configuration. Atop face 120 and abottom face 122 are approximately parallel to anaxis 124 of the receivingportion 102.Hole 126 and asecond hole 128 pass through themount portion 104 from thetop face 120 to thebottom face 122. The receivingportion 102 has a top 130 and a bottom 132, as determined by the orientation of thetop face 120 andbottom face 122. - With reference to
Figures 4, 5 , and8 , thewire receiving portion 102 is configured to be crimped, and has continuous annularinterior wall 133 comprising a crimp portion 134 (Figure 8 ) that comprises a seal portion or sealingportion 136 and acontact portion 138. The sealingportion 136 is adjacent to, and spaced from, thecontact portion 138 towardaperture 108. A chamfer orradius 140 at thefront face 106 connects with aseal zone surface 142. In one embodiment, theseal zone surface 142 is broken into fourareas 144a, b, c, d by three integral seal rings 146a, b, c protruding radially inward from theseal zone surface 142. In this embodiment the fourareas 144a, b, c, d all measure substantially the same diameter, however in other embodiments the diameters may be different. Similarly, the seal rings 146a, b, c, having a smaller diameter than the diameter of the fourareas 144a, b, c, d, all measure substantially the same diameter, however in other embodiments the diameters may be different. It is also contemplated that there may be more than or fewer than the three illustrated seal rings. Eachseal ring 146 has a face 148 (Figure 5B ) of a particular width, with a frontangled wall 150 and a backangled wall 152 leading to the adjacent one of the four areas 144. In this embodiment, all theangled walls - An
integral funnel 154 is between the seal or sealingportion 136 and thecontact portion 138. Theintegral funnel 154 guides theconductor strands 22 from thelarger seal portion 136 into thecontact portion 138, while thewire 20 is being inserted into the terminal 100. - The
contact portion 138 has a continuous cylindrical wall 155 with amajor diameter 156 and an integral oxide breaker oroxide breaker element 158, the term this application will use for the macro object that breaks through the oxide layer on the conductor orconductor strands 22 when the wire receiving portion is crimped. - The integral
oxide breaker element 158 comprises a plurality of protrusions, such as taperedprotrusions 162, extending radially inward from themajor diameter 156 of thecontact portion 138. The protrusions are configured to engage the conductor of a wire positioned in the contact portion, and to protrude into the wire when the wire receiving portion is crimped. These taperedprotrusions 162 may be separate from each other, but in other embodiments, for ease of manufacture, these taperedprotrusions 162 are in the form of a helical thread 164 (Figure 5A ) that is conveniently manufactured on metal cutting or forming equipment. In one embodiment thethread 164 has a sixty degree includedangle 166 and apitch 167 of eighty, and is .008/.010 inch deep. Apitch 167 of sixty has also worked successfully. It is contemplated that other includedangles 166 and pitch 167 combinations as well as depths would also work. Aminor diameter 168 of the threads equal to .481 +/- .002 inch has been used for wire gauge 2/0. Theoxide breaker 158 further comprises acoating 170 on theprotrusions 162. In various embodiments, the oxide breaker and the structures forming same might be coated with a material layer or left uncoated. In one particular embodiment, thecoating 170 is an electroless nickel plate of .0005 +/- .002 per ASTM B733 Type III. This may be successfully put in the blind hole (blind refers to a hole with only one aperture 108) by using an appropriate coating process. In addition to nickel, other coatings might be utilized and include electro nickel, gold, silver, tin and tin-lead, and alkaline-bismouth-tin. - The structure of the oxide breaker element provides not only the ability to break through the oxide layer on the conductor strand, but also improves the electrical and mechanical features of the invention. For example, electrically, the construction of the oxide breaker element increases the surface area of the crimp, and the contact with the conductor, to improve the overall electrical properties of the connection in the transition from the wire to the terminal. Furthermore, the
oxide breaker element 158 increases the grip function at thecontact portion 138, and increases the pull force necessary to remove thewire 20 fromterminal 100. - It is also contemplated that other forms of structures or elements might be used for the
oxide breaker element 158, for example discrete annular protrusions might also be used. The making of one or more spiral threads is a widely perfected and efficient process.Figure 10 illustrates an alternative embodiment of a contemplated terminal 500 in which theprotrusions 162 of theoxide breaker 502 areaxial ridges 504. The orientation of theaxial ridges 504 are parallel to the direction of pull-out. Thus, while theprotrusions 162 improve upon the prior art and provide improved electrical properties for current conductance purposes, they might be slightly less effective in improving pull-out requirements as those illustrated inFigure 5 . In bothembodiments protrusions 162 comprisepeaks 172, angular faces 174, andbottoms 176, and may have no coating, or may be covered by coating 170 as seen in detailFigure 5A . Other embodiments ofprotrusions 162 are contemplated but not shown, for example, a plurality of spikes rising from themajor diameter 156 might also be implemented. - In use to make an assembly 178 (
Figure 6 ), thewire 20 is inserted in the terminal so that the conductor orconductor strands 22 are guided by theintegral funnel 154 into thecontact portion 138. The three seal rings 146a,b,c surround theinsulation sheath 24, and theintegral oxide breaker 158 surrounds the conductor of the wire, including theconductor strands 22. There is aclearance space 180 between the terminal 100 and thewire 20. Assembly only requires the electrical terminal and the wire, thus it is far easier than stocking, handling, and properly orienting multiple pieces as shown inFig. 1 . There is not a concern that an internal piece may be left out, installed backwards, or installed incorrectly. Costs are reduced for at least component manufacturing and stocking, and for assembly. - The
assembly 178 is placed in a suitable crimping die, such as a modified hex crimping die 182 (Figure 11 ), and crimped to make acable 184 with acrimp 186. (Figure 7 ). Thecrimp 186 comprises 2 opposingconcave facets 188 and fourstraight facets 190. Between the facets are sixcorners 192. On one of theconcave facets 188 is anindicator button 194. Theindicator button 194 will be properly formed if thewire 20 was properly inserted and crimped. If thewire 20 was improperly inserted or crimped theindicator button 194 will be shaped improperly, indicating to a person or a visual inspection system that theparticular cable 184 should be rejected. Theindicator button 194 is formed by a recess (not shown) in crimpingdie 182. If theconductor strands 22 are not present in the proper position in the terminal 100, the receivingportion 102 will not extrude into the recess, and theindicator button 194 will not be formed. - Internally, as illustrated in
Figure 8 , theconductor strands 20 are squeezed together tightly at 195 as compared to the visibly individual strands at 196 outside of the terminal 100. The sealing rings 146a,b,c are squeezed into the insulatingsheath 24 to make ahydrostatic seal 198. Theintegral oxide breaker 158 is squeezed into thealuminum conductor strands 22 to give the assembly 178 a conductiveelectrical path 202 between the receivingportion 102 and the strandedaluminum wire 20. - Magnified examinations of sectioned
cables 184 showed scrubbing action as theoxide breaker 158 penetrated theoutside conductor strands 22 about 40% of their individual diameters. Theprotrusions 162 were seen to be buckled by compression, further increasing the scrubbing action that breaks the oxide. - Testing was conducted to verify the performance of the terminal with the
integral oxide breaker 158 as follows: - Oxide Breaker testing: A smooth bore design was compared with a machined oxide breaker by testing. Results showed that the smooth bore did not meet the low initial 6.0 millivolt requirement whereas the machined oxide breaker barrel met the requirement with very good margin. Further testing after Thermal Shock and Current Cycling proved that the machined oxide breaker feature continued to perform well.
- Thermal Shock testing: After the initial millivolt drop testing, a modified 100 cycle Thermal Shock test was run on the same set of 2/0 AWG Single -Hole Tensolite Aluminum Terminal samples. The temperature was cycled between -65°C and +175°C but no current flow was included in the testing. Millivolt drop results were tested at the end of the 100 cycles. The millivolt results after 100 cycles show that the terminals met the millivolt requirement of BPS-T-217 and the more stringent millivolt requirement of BPS-T-233.
- Current Cycling testing: After Thermal Shock, a Current Cycling test was run on the same 2/0 AWG samples. A BPS-T-233 test method was used to evaluate the performance of the Tensolite 2/0 AWG single-hole terminals. Two assemblies were mounted in series with each of the four terminals attached to 7054-T4751 aluminum plates. Temperature verses current results showed all samples passed the 160 F degrees maximum and MV maximum drop.
- Hydrostatic seal testing: The hydrostatic test used aluminum terminals crimped to wire and installed into a water filled chamber. The chamber was cycled 25 times from 0 to 80 PSI and held at pressure for 15 minutes each cycle. All samples passed.
- Mechanical Strength of Crimp testing: All samples exceeded the 825-850 lb-Force target. The samples failed at the conductor and not in the crimp zone. Samples had previously gone through Thermal Shock and Current Cycling testing.
- Consistent and Repeatable Length testing: Crimping of the 2/0 samples resulted in a consistent .10 inch length growth verses .25 to .38 inches for the bath tub crimp of the prior art.
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Figures 12-16 illustrate further alternative embodiments of the invention in the form of a connector that might be implemented to connect together or splice together two conductors or wires. The connector may act as a splice connector to splice together two wires of the same size, or could be in the form of a transition connector to splice together two different size wires.Figures 12 and13 illustrate a connector device or element wherein the two wires that are connected together or spliced together are generally of the same size or gauge, such as 1/0 to 1/0 size wires. Alternatively,Figures 14 and15 illustrate the transition connector for connecting together wires having different gauges, such as a 1/0 to 2/0 size wire transition. - The connectors of
Figures 12-16 may be used to connect wires of the same material, such as two aluminum or two copper wires, or may be used to connect together two different wires, such as an aluminum wire and a copper wire. - The connector embodiments share various features with the terminal embodiments discussed hereinabove. Specifically, the
connector 300 ofFigures 12 and13 has a body formed of a suitable electrically conductive material, such as aluminum or copper.Connector 300 has two adjacentwire receiving portions 302 that are positioned at opposing ends of the body, and configured to receive the exposed end of a wire, such as an aluminum wire or a copper wire. Each receivingportion 302 forms acorresponding aperture 304 in the end of the connector like with the terminal embodiment. The receivingportion 302 might also be cylindrical, consistent with other embodiments, and the usual cylindrical shape of a wire, but the receiving portion might also be a variety of other shapes. - Turning now to
Figure 13 , each receivingportion 302 includes aninterior wall 306 that forms a suitable portion to be crimped that includes a sealingportion 308 and acontact portion 310. Achamfer 312 transitions to surface 314 that forms the sealingportion 308. As in previously discussed embodiments, the seal zone of the sealing portion might be considered to be broken into a number ofdifferent areas 316a-316d byintegral seal rings 318a-318c that protrude radially inwardly fromsurface 314. As noted, a greater or lesser number of areas 316 or seal rings 318 might be implemented in the embodiment of the invention than the three rings 318 and four areas 316 illustrated in the figures. Eachseal ring 318a-318c will be constructed or configured as illustrated inFigure 5b having suitable faces and angled walls, as noted herein. An integral transition area or funnel 320 feeds between the sealingportion 308 and thecontact portion 310 to guide the conductor of a wire, as illustrated inFigure 16 , from a larger diameter sealedportion 308 to the smaller diameter contact portion. - As illustrated in
Figure 13 , the contact portion also has a continuousinner surface 322, which has anoxide breaker element 324 formed thereon for breaking up the oxide layer on a conductor of a wire inserted into theconnector 300. The integraloxide breaker element 324 may have a plurality of protrusions, such as tapered protrusions, such as those illustrated and discussed with respect toFigure 5 . The protrusions extend radially inwardly from thesurface 322 in the contact position, and they include individually tapered protrusions or a helical thread, as illustrated inFigures 5-5A , or might take the form as illustrated inFigure 10 . In any case, theoxide breaker element 324 is suitably configured to engage a wire positioned in the contact portion, and the protrusion protrude into or penetrate into aconductor 22 of a wire when the receivingportion 302 is crimped. The oxide breaker element breaks up any oxide on the conductor, and also electrically engages the conductor for the purposes of conducting electrical current through theconnector 300. While embodiments of the invention in the form of a terminal might conduct electricity to a particular point of a circuit, the embodiment ofconnector 300 is directed to form a suitable electrical connection, splice, or transition between the ends of two wires that are connected end-to-end, as illustrated inFigure 16 . - As discussed herein, the oxide breaker element might be a bare structure essentially presenting the metal of the
connector 300 to the wire conductor. Alternatively, the oxide breaker element, and particularly the protrusions and structures of theoxide breaker element 324, might be coated with a suitable coating, similar to the coatings discussed herein above with respect to the terminal embodiment. Both of the oxide breaker elements of theconnectors
As noted,Figures 12 and13 illustrate aconnector 300 for use with wires that are essentially the same size, diameter, or gauge, such as 1/0.Figures 14 and15 illustrate an embodiment wherein the wires have a different gauge, such as a 1/0 to 2/0 transition. That is,connector 301, as illustrated inFigures 14 and15 , has one receivingportion 303 that is smaller than another receivingportion 305. To that end, theconnector 301 provides a suitable splice and transition between differently-sized wires. Theinner surface 322a of thecontact portion 310 has a smaller inner diameter than thecorresponding surface 322b in the adjacentwire receiving portion 305. All of the other elements ofconnector 301 are similar to those ofconnector 300, and thus, are set forth with similar reference numerals. Fortransition connector 301, an angledouter surface 307 indicates the transition between the different sizes. Of course, a structure having a uniform outside diameter, such as that shown byconnector 300, might also be implemented with only theinner surface 322a being accordingly sized to its smaller size. Internally, between each of the receiving portions of theconnectors wire stop structures 309, 311 are formed. - Turning now to
Figure 16 , anappropriate connector wire 20 are inserted into the terminal, and theconductor 22 is guided into theappropriate contact portion 310. The seal rings surround theinsulation sheath 24 of the wire, while theoxide breaker 324 surrounds theconductor 22. The entire assembly can then be placed in a suitable crimping die and crimped so that the seal rings seal around theinsulation sheath 24, and theoxide breaker element 324 presses into and engages theconductor 22. Not only will theoxide breaker 324 break any oxide layer on the conductor, but it will also protrude or dig into the metal or other material of the conductor to form a suitable electrical connection for the conductance of electrical current between the wires that are spliced together. Theconnectors - The wires connected may be of the same material or of different materials. Also, as noted, both of the oxide breaker elements of a connector might be coated with a coating such as Nickel, or only one might be coated. For example, if an aluminum wire is spliced to a copper wire, only the receiving portion and oxide breaker element that engages the aluminum wire might be coated. Of course, if two aluminum wires are spliced, both oxide breaker elements might be coated, for example.
-
Figure 17 illustrates another alternative embodiment of the invention incorporating a lubricant layer for the purposes of improved crimping of a connector or terminal of the invention. While a terminal embodiment is illustrated inFigure 17 , the features of the lubricant layer are equally applicable to the connector embodiments disclosed herein, such as those shown inFigures 12-16 . Like reference numerals are used where applicable. - In accordance with one aspect of the invention, the terminal 350 includes a
mount portion 352, which may be mounted to an appropriate surface, such as a grounding surface, when a wire orcable implementing terminal 350 is implemented.Terminal 350 also includes awire receiving portion 354 constructed as discussed herein. For example, as illustrated inFigure 18 , the wire receiving portion will have anappropriate sealing portion 308 andcontact portion 310. Eachwire receiving portion 354 will include anaperture 304 with other appropriate structures positioned on an interior surface, includingintegral seal rings 318a-318c. To that end, theterminal 350 ofFigure 17 is similar to other terminals or connectors discussed herein in most of its construction, but also has a lubricant layer. - Generally, when a plating or coating of a material layer is provided, such as within the interior space of the
wire receiving portion 354, the crimping process can be affected, sometimes detrimentally. In coating the interior surfaces, such as the oxide breaker element, the exterior surfaces of the device are also coated. Generally, when crimped, a majority percentage of thewire receiving portion 354 will be crimped as shown herein for capturing a wire conductor, and breaking up any oxide on the outer surface of the wire conductor. While certain coating materials flow over the outer surface ofwire receiving portion 354 during the crimping process, other coating materials are harder and more brittle. In such cases, the coating material may extrude or flow into various crimp points of the die, such as theseams 183, as illustrated inFigure 11 . For example, while a coating of tin will sufficiently flow around the outside surface of thewire receiving portion 354 when it is crimped, a coating material layer of nickel, will not. When a hard material like nickel extrudes into the crimp seams 183 of the die during the crimping process, it will create flashing in the form of fins or wings at certain areas of the crimp. Such flashing may then pull away from the crimped terminal or connector, thus exposing the aluminum of the terminal or connector to corrosion. Generally, such a situation with flashing formed may be considered a failed crimp process. - In accordance with one aspect of the invention, the outside surface of the wire receiving portion is coated with a
lubricant layer 360. Thelubricant layer 360 is made of a suitable lubricant material, such as PTFE, such as FluoroPlate®-XK3-654-LT, available from Orion Industries of Chicago, Illinois. Thelubricant layer 360 is applied generally to thewire receiving portion 354, but only on the outside surface thereof. Other areas, such as the internal surfaces of thewire receiving portion 354, as well as themount portion 352, are appropriately masked to prevent any overspray. Thewire receiving portion 354 outside or external surface may be appropriately degreased while certain of the conductive areas are masked to be kept free from overspray. The lubricant material is applied on the outside surface of at least part of the wire receiving portion, such as in a thickness in the range of 0.0003 - 0.001 inches. In one particular embodiment, the thickness of the appliedlubricant layer 360 may be 0.0006 +/- 0.0002 inches. The appliedlubricant layer 360 may also be cured at around 160° +/- 5° Fahrenheit, for around twenty minutes. - The
lubricant layer 360 provides lubrication to a harder coating material, such as nickel, so that, during the crimp, the coating materials flow more easily in the die, and prevents undesirable flashing. In that way, the overall terminal or connector is improved, and failed crimps are minimized. -
Figure 18 illustrates another alternative embodiment, which has features which may be implemented in either a terminal or connector, as disclosed herein.Figure 18 illustrates a terminal embodiment, but the features are equally applicable to a connector embodiment as well. - As illustrated in
Figure 18 , the terminal 362 has an appropriatewire receiving portion 364, which is constructed as disclosed herein, including a sealingportion 308 andcontact portion 310, with appropriate structures as shown. In accordance with another aspect of the invention, for enhancing the seal of a wire provided by sealingportion 308, flexible seal rings may be implemented along with theseal rings 318a - 318c. Specifically, as illustrated inFigure 18 , one or moreflexible seal rings areas 316a - 316d that are provided between the seal rings 318 of the sealing portion 208. - For example, as illustrated in
Figure 18 ,flexible seal ring 370a is positioned between and adjacent torings flexible seal ring 370b is positioned between and adjacent torings 318b and 318c. The flexible seal rings 370 are formed of a suitably flexible material, such as an RTV Silicone. One suitable material is Heat Resistant Sealant 736, available from Dow Corning. The flexible seal rings 370 are deposited in the appropriate spaces 316, and would generally take up less than the space or volume between the seal rings 318. Each of the flexible seal rings 370 is formed continuously for 360° around the inner surface of the sealingportion 308. An exact shape for the flexible seal rings 370 is not critical. Theflexible seal rings 370a are flexed when thewire receiving portion 364 is crimped, as noted herein for forming a complete wire assembly or cable using an appropriate wire. The flexible seal rings 370 provide additional sealing to the overall seal that is provided by the crimping of the rings 318. In that way, an overall sealed environment withincontact portion 310 is created and maintained. - In applying the flexible seal rings 370, a solvent wash might be utilized to wash the interior surfaces of the
wire receiving portion 364. Using a high pressure dispenser with volumetric control, one or more 360° rings of sealant are applied. The flexible seal rings 370, in one embodiment, may be 50% higher than the height of the adjacent rigid seal rings 318. In another embodiment of the invention, the flexible seal rings 370 might be applied by hand, with a suitable tool to deposit material in the various areas 316, such as up to a level with the rings 318. The material applied is appropriately viscous, and can flow, but then hardens. Material may then be allowed to cure at room temperature, such as for a minimum of twenty-four hours, to provide the seal features of embodiments of the invention. - While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the scope of the claims.
Claims (12)
- An electrical terminal (362) comprising:a mount portion (352) coupled with a wire receiving portion (364);the wire receiving portion (364) formed of an electrically conductive material;the wire receiving portion (364) configured to be crimped and having an aperture (304) to receive a wire (20), the wire receiving portion (364) including a contact portion (310) having an integral oxide breaker element (324) and a sealing portion (308) that is adjacent to and spaced from the contact portion (310) toward the aperture (304);the integral oxide breaker element (324) including a plurality of protrusions (162) that extend radially inwardly in the contact portion (310), the protrusions (162) configured to engage a wire (20) positioned in the contact portion (310) and to protrude into the wire (20) when the wire receiving portion (364) is crimped;the sealing portion (308) including a plurality of integral seal rings (318a, 318b, 318c), characterized in that the sealing portion (308) further includes a plurality of flexible seal rings (370a, 370b), each of the flexible seal rings being formed by applying a curable, viscous material continuously around the wire receiving portion (364) at a height that is higher than the height of the respective integral seal rings (318b, 318c) so that each flexible seal ring (370a, 370b) is positioned between and adjacent to respective integral seal rings (318a, 318b, 318c) for sealing the wire (20) when the wire receiving portion (364) is crimped.
- An electrical connector (300, 301) for connecting electrical wires comprising:a body formed of an electrically conductive material and including wire receiving portions (364) positioned at opposing ends of the body;each wire receiving portion (364) configured to be crimped and having a respective aperture (304) to receive a wire (20) and including a contact portion (310) having an oxide breaker element (324) and a sealing portion (308) that is adjacent to and spaced from the contact portion (310) toward the respective aperture;at least one of the integral oxide breaker elements (324) of a wire receiving portion including a plurality of protrusions (162) that extend radially inwardly in the contact portion (310), the protrusions configured to engage a wire (20) positioned in the contact portion (310) and to protrude into the wire (20) when the wire receiving portion (364) is crimped;the sealing portion (308) of at least one wire receiving portion including a plurality of integral seal rings (318a, 318b, 318c);characterized in that the sealing portion (308) of the at least one wire receiving portion (364) further includes a plurality of flexible seal rings (370a, 370b), each of the flexible seal rings being formed by applying a curable, viscous material continuously around the at least one wire receiving portion (364) at a height that is higher than the height of the respective integral seal rings (318a, 318b, 318c) so that each flexible seal ring (370a, 370b) is positioned between and adjacent to respective integral seal rings (318a, 318b, 318c) for sealing the wire (20) when the wire receiving portion (364) is crimped.
- The electrical terminal (362) of claim 1 or the electrical connector (300, 301) of claim 2 wherein the plurality of protrusions (162) are tapered and extend from an interior wall (322a) of the contact portion (308) with small ends of the tapered protrusions (162) pointing toward a center axis of the wire receiving portion (364).
- The electrical terminal (362) of claim 1 or the electrical connector (300, 301) of claim 2 wherein the plurality of protrusions (162) are axial ridges having a longitudinal axis parallel to the center axis of the wire receiving portion (364).
- The electrical terminal (362) of claim 1 or the electrical connector (300, 301) of claim 2 further comprising a coating on at least a portion of the oxide breaker element (324) and made of a material different from the material of the integral oxide breaker element (324).
- The electrical terminal (362) of claim 5 or the electrical connector (300, 301) of claim 5 wherein the coating is a nickel material coating.
- The electrical terminal (362) of claim 1 or the electrical connector (300, 301) of claim 2 wherein the oxide breaker element (324) includes a helical thread (164).
- The electrical terminal (362) of claim 1 or the electrical connector (300, 301) of claim 2 wherein the electrically conductive material includes at least one of aluminum or copper.
- The electrical terminal (362) of claim 1 or the electrical connector (300, 301) of claim 2 further comprising a lubricant layer (360) applied on an outside surface of at least part of the wire receiving portion (364).
- The electrical connector (300, 301) of claim 2 wherein one of the wire receiving portions (364) has an inner diameter that is smaller than an inner diameter of another of the wire receiving portions (364) for connecting electrical wires (20) having different sizes.
- A cable comprising:an electrical wire (20) having a conductor (22) and insulation (24); andan electrical terminal (362) according to any of claims 1 and 3 to 9.
- A cable comprising:a plurality of electrical wires (20), each wire (20) having a conductor (22) and insulation (24); andan electrical connector (300, 301) according to any of claims 2 to 10.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/010,073 US9385449B2 (en) | 2009-02-16 | 2013-08-26 | Terminal/connector having integral oxide breaker element |
PCT/US2014/052482 WO2015031236A1 (en) | 2013-08-26 | 2014-08-25 | Terminal/connector having integral oxide breaker element |
Publications (2)
Publication Number | Publication Date |
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EP3039747A1 EP3039747A1 (en) | 2016-07-06 |
EP3039747B1 true EP3039747B1 (en) | 2021-09-15 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP14759428.7A Active EP3039747B1 (en) | 2013-08-26 | 2014-08-25 | Terminal/connector having integral oxide breaker element |
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EP (1) | EP3039747B1 (en) |
WO (1) | WO2015031236A1 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
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JP7228087B2 (en) * | 2018-08-13 | 2023-02-24 | 株式会社プロテリアル | Wire with terminal |
DE102020103866A1 (en) * | 2020-02-14 | 2021-08-19 | Phoenix Contact E-Mobility Gmbh | Contact element assembly for a connector part |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2974400A (en) * | 1952-03-11 | 1961-03-14 | Frank J Sowa | Method of making an insulated electrical connector |
US3955044A (en) | 1970-12-03 | 1976-05-04 | Amp Incorporated | Corrosion proof terminal for aluminum wire |
US5422438A (en) * | 1991-02-07 | 1995-06-06 | Raychem Sa | Electrical crimp connector |
JP2002124310A (en) * | 2000-10-13 | 2002-04-26 | Yazaki Corp | Terminal-mounting structure and terminal-mounting method for coated wire |
GB2387280B (en) * | 2001-01-19 | 2004-10-13 | Yazaki Corp | Method of waterproofing terminal-wire connecting portion |
JP2002216862A (en) * | 2001-01-19 | 2002-08-02 | Yazaki Corp | Waterproof structure of connection part of electric wire and terminal, and waterproofing method |
US7786383B2 (en) * | 2006-07-27 | 2010-08-31 | Markus Gumley | Electrical wire connector with temporary grip |
US8066525B2 (en) * | 2008-02-21 | 2011-11-29 | Melni Mark L | Electrical connectors and methods of manufacturing and using same |
US8519267B2 (en) * | 2009-02-16 | 2013-08-27 | Carlisle Interconnect Technologies, Inc. | Terminal having integral oxide breaker |
CN201797061U (en) * | 2010-04-14 | 2011-04-13 | 方军 | 10-35kV high-voltage pothead KFD connection device |
-
2014
- 2014-08-25 WO PCT/US2014/052482 patent/WO2015031236A1/en active Application Filing
- 2014-08-25 EP EP14759428.7A patent/EP3039747B1/en active Active
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EP3039747A1 (en) | 2016-07-06 |
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