GB2429853A - Sealed crimpled electrical terminal assembly - Google Patents

Sealed crimpled electrical terminal assembly Download PDF

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Publication number
GB2429853A
GB2429853A GB0617522A GB0617522A GB2429853A GB 2429853 A GB2429853 A GB 2429853A GB 0617522 A GB0617522 A GB 0617522A GB 0617522 A GB0617522 A GB 0617522A GB 2429853 A GB2429853 A GB 2429853A
Authority
GB
United Kingdom
Prior art keywords
electrical terminal
wire assembly
assembly
wire
cavity
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Withdrawn
Application number
GB0617522A
Other versions
GB0617522D0 (en
Inventor
Josep Roset
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lear Corp
Original Assignee
Lear Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Lear Corp filed Critical Lear Corp
Priority to GB0617522A priority Critical patent/GB2429853A/en
Publication of GB0617522D0 publication Critical patent/GB0617522D0/en
Publication of GB2429853A publication Critical patent/GB2429853A/en
Withdrawn legal-status Critical Current

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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
    • 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
    • H01R13/5205—Sealing means between cable and housing, e.g. grommet
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

An electrical terminal assembly 24 comprising an electrical terminal 7 made of an electrically conductive material and having a cavity to receive a wire assembly 1, and a wire assembly 1 comprising an electrically conductive wire and insulation surrounding the wire such that a portion 3 of the wire assembly 1 is insulated and a portion 5 of the wire assembly 1 is uninsulated (stripped bare). The wire assembly 1 extends into the cavity of the electrical terminal 24 such that the uninsulated portion 5 of the wire assembly 1 comes into contact with the electrical terminal 7. The electrical terminal 7 is crimped at a first location 15 around the insulated portion 3 of the wire assembly 1 which seals the assembly and inhibits fluid from entering the portion of the cavity housing the uninsulated portion 5 of the wire assembly 1. The electrical terminal 7 is preferably crimped at a second location 17 around the uninsulated portion 5 of the wire assembly 1. An independent claim is included to the method of manufacturing the electrical terminal assembly which includes forming a contact portion 11 from a hollow tube, for example by pressing (see figures 5a-5c).

Description

ELECTRICAL TERMINAL ASSEMBLY
The invention relates to an electrical terminal assembly.
An electrical terminal assembly is disclosed herein. Examples of electrical terminal assemblies are disclosed in U S. Patent Nos. 6,613, 263 and 6,783,377 and in U.S. Patent Application Publication Nos. US 2001/0003688 Al, US 2002/0127915 Al and US 2004/0253871 Al.
It is however desirable to provide an improved electrical terminal assembly which addresses problems and/or more generally offers improvements or an alternative to the prior arrangements.
According to the present invention there is therefore provided an electrical terminal assembly, and method of making such an assembly, as described in the accompanying claims.
In an embodiment of the invention there is provided a new electrical terminal assembly comprising an electrical terminal made of an electrically conductive material and having a cavity and a wire assembly, comprising an electrically conductive wire and insulation surrounding the wire such that a portion of the wire assembly is insulated and a portion of the wire assembly is uninsulated. The wire assembly extends into the cavity of the electrical terminal such that the uninsulated portion of the wire assembly comes into contact with the electrical terminal. The electrical terminal is crimped at a first location around the insulated portion of the wire assembly which inhibits fluid from entering the portion of the cavity housing the uninsulated portion of the wire assembly.
In another aspect of an embodiment of the invention there is also provided a method of making the electrical terminal assembly which includes the steps of providing a wire assembly comprising an electrically conductive wire and insulation surrounding the wire such that a portion of the wire assembly is insulated and a portion of the wire assembly is uninsulated; providing a electrical terminal made of an * 2 electrically conductive material and having a cavity to receive the wire assembly; positioning the wire assembly in the cavity so that a portion of the uninsulated portion of the wire assembly and a portion of the insulated portion of the wire assembly are contained within the cavity; and crimping the electrical terminal around the insulated portion of the wire assembly at a first location to inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
While exemplary embodiments in accordance with the invention are illustrated and disclosed, such disclosure should not be construed to limit the claims. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention.
The present invention will now be described by way of example only with reference to the following figures in which: FIGURE 1 is a perspective view of an electrical terminal assembly of an embodiment of the present invention showing a electrical terminal and a wire assembly extending into the electrical terminal; FIGURE 2 is a perspective view of the wire assembly showing an electrically conductive wire surrounded by insulation, wherein a portion of the wire assembly is insulated and a portion of the wire assembly is uninsulated; FIGURE 3 is a perspective view of the electrical terminal showing a cavity for receiving the wire assembly, a contact zone and an adaptation for being mounted to a mounting member; FIGURE 4 is a side elevational view of the wire assembly received within the electrical terminal and crimped at two locations; FIGURE 5 is a perspective view of a hollow metal tube for use in making the electrical terminal; FiGURE Sb is a perspective view of a forming device engaging the hollow metal tube to form the electrical terminal; FIGURE Sc depicts the electrical terminal formed by the process of engaging the hollow metal tube with the forming device; FIGURE Sd is a perspective view depicting the insertion of a portion of the wire assembly into the electrical terminal; and FIGURE Se is a perspective view depicting the wire assembly received within the electrical terminal.
FIGURE 5f is a perspective view of the electrical terminal assembly showing the crimping of the electrical terminal around the wire assembly at two locations and also showing the electrical terminal mounted to a mounting member.
The following descriptions are merely exemplary in nature and are in no way intended to limit the invention or its application or uses.
Figure 1 shows an electrical terminal assembly 24 according to the present invention mounted on a mounting member 14, such as a mounting stud of a vehicle battery, starter, alternator, vehicle body or any other suitable component. The electrical terminal assembly 24 includes a wire assembly 1, and an electrical terminal 7 for electrically connecting the wire assembly to the mounting member 14.
The wire assembly 1 comprises an electrically conductive wire surrounded by insulation having an insulated portion 3 and an uninsulated portion 5, as shown in figures 1 and 2. The wire may be made from any suitable material.
The electrical terminal 7 has an opening 10 into a cavity 9, an electrical contact zone ii and an adaptation 13, such as an opening, for mounting the electrical terminal to a mounting member 14, as shown in figures 1 and 3. The cavity 9 is depicted in phantom lines. The electrical terminal may be made of any suitable electrically conductive material including, but not limited to, copper zinc alloys.
The wire assembly I extends into the cavity 9 of the electrical terminal through the opening 10 as shown in figures 1 and 4.
The electrical terminal 7 has been crimped at a first location 15 as shown in figures 1 and 4. At the first crimped location 15, the electrical terminal7 is crimped around the insulated portion 3 of the wire assembly 1 such that it engages the insulation, thereby forming a seal (as shown in figures 1 and 4) which inhibits fluid from entering a portion of the cavity 9 housing the uninsulated portion 5 of the wire assembly 1.
Crimping the electrical terminal 7 at the first location 15 may also cause a deformation 16 of the insulated portion 3 of the wire assembly I as shown in figure 4.
The electrical terminal 7 is crimped at a second location 17, preferably around an uninsulated portion 5 of the wire assembly 1, as shown in figures 1 and 4. Crimping at the second location 17 serves to strengthen the grip that the electrical terminal 7 has on the wire assembly 1. Crimping the electrical terminal 7 at the second location 17 may also cause a deformation 18 in the wire assembly 1 as shown in figure 4. If the portion of the wire assembly 1 that is engaged by the electrical terminal 7 at the second crimping location 17 is the uninsulated portion 5 of the wire assembly 1, then the electrical terminal 7, which is made of an electrically conductive material, comes into contact with the uninsulated portion 5 of the wire assembly and forms an electrical connection. An electrical connection may also be formed by inserting the wire assembly I into the cavity of the electrical terminal 7 such that the uninsulated portion 5 comes into contact with walls of the cavity.
iS Figure 4 is a side elevational view of the wire assembly I received within the electrical terminal 7 after the electrical terminal 7 has been crimped at the first location and the second location 17. The electrical terminal 7 is depicted in phantom lines.
Deformation of the insulated portion 3 of the wire assembly I may occur in the vicinity of the first crimped location 15. Such deformation is depicted at reference numeral 16.
Additional deformation of the wire assembly I may occur in the vicinity of the second crimped location 17. This is depicted at reference numeral 18 as deformation of the uninsulated portion 5 of the wire assembly I. The deformation 18 of the uninsulated portion 5 of the wire assembly 1 is one way of establishing electrical contact between the uninsulated portion 5 of the wire assembly 1 and the electrical terminal 7. An alternate or additional contact 2 between the uninsulated portion 5 of the wire assembly I and the electrical terminal 7 is also depicted at reference numeral 2.
Referring to Figures 5a-Sf, an exemplary method of making the electrical tenninal assembly will now be described.
In Figure 5a, a hollow tube 4, made of an electrically conductive material such as a copper zinc alloy, and having an opening at both ends 8, 10 is provided. The hollow portion is depicted at reference numeral 6 with phantom lines.
In Figure Sb, the hollow tube 4 is engaged by a forming device 19, such as a press, which compresses the hollow tube 4, at least partially closing the opening (either 8 or 10) at one end of the hollow tube 4.
Figure 5c depicts the electrical terminal 7 having a cavity 9, an electrical contact zone 11, and an adaptation 13 for mounting the electrical terminal to a mounting member. The electrical terminal 7 was formed by the process depicted in Figures 5a and Sb.
In Figure Sd, the wire assembly 1, comprising the electrically conductive wire surrounded by insulation such that a portion of the wire assembly is insulated 3 and a portion of the assembly is uninsulated 5, is provided. A portion of the wire assembly I, including a portion of the insulated portion 3 and a portion of the uninsulated portion 5 is inserted into the cavity 9 of the electrical terminal 7 through the opening 10.
in Figure 5e is a perspective view of the electrical terminal assembly depicting an insulated portion 3 and an uninsulated portion 5 of the wire assembly I resting within the cavity of the electrical terminal 7.
Figure 5f is a perspective view of the electrical terminal assembly depicting the steps of crimping the electrical terminal 7 at a first location 15 around an insulated portion 3 of the wire assembly I. The step of crimping the electrical terminal at a second location 17 is also depicted. The electrical terminal assembly is shown mounted to a mounting member 14 at its adaptation for mounting 13 such that the electrical contact zone 11 comes into contact with the mounting member.
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the scope of the invention.

Claims (22)

1. An electrical terminal assembly comprising: a wire assembly comprising an electrically conductive wire and insulation surrounding the wire such that a portion of the wire assembly is insulated and a portion of the wire assembly is uninsulated; and an electrical terminal made of an electrically conductive material and having a cavity that receives the wire assembly; wherein the wire assembly extends into the cavity so that a portion of the uninsulated portion and a portion of the insulated portion are contained within the cavity, and the uninsulated portion is in contact with the electrical terminal, and wherein the electrical terminal is crimped at a first location around the insulated portion of the wire assembly to inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
2. The electrical terminal assembly of claim I wherein the electrical terminal has an electrical contact zone and is adapted to be fixed to a mounting member.
3. The electrical terminal assembly of claim I or 2 wherein the electrical terminal has only one opening to the cavity, and the wire assembly sufficiently fills the opening to thereby inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
4. The electrical terminal assembly of claim I wherein the electrical terminal is crimped around the wire assembly at a second location.
5. The electrical terminal assembly of claim 4 wherein the electrical terminal has an electrical contact zone and is adapted to be fixed to a mounting member.
6. The electrical terminal assembly of claim 4 or 5 wherein the electrical terminal has only one opening to the cavity, and the wire assembly sufficiently fills the opening to thereby inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
7. A method of making an electrical terminal assembly comprising: providing a wire assembly comprising an electrically conductive wire and insulation surrounding the electrically conductive wire such that a portion of the wire assembly is insulated and a portion of the wire assembly is uninsulated; providing an electrical terminal, made of an electrically conductive material, having a cavity to receive the wire assembly; positioning the wire assembly in the cavity so that a portion of the uninsulated portion and a portion of the insulated portion are contained within the cavity; and crimping the electrical terminal around the insulated portion of the wire assembly at a first location to inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
8. The method of claim 7 wherein the electrical terminal has an electrical contact zone and is adapted to be fixed to a mounting member.
9. The method of claim 7 or 8 wherein the electrical terminal has only one opening to the cavity, and the wire assembly sufficiently fills the opening to thereby inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
10. The method of any one of claims 7 to 9 comprising the further step of crimping the electrical terminal around the wire assembly at a second location.
11. The method of claim 10 wherein the electrical terminal has an electrical contact zone and is adapted to be fixed to a mounting member.
12. The method of claim 10 or 11 wherein the electrical terminal has only one opening to the cavity, and the wire assembly sufficiently fills the opening to thereby inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
13. The method of any one of claims 10 to 12 wherein crimping the electrical terminal around the wire assembly at a second location causes a portion of the uninsulated portion of the wire assembly to contact the electrical terminal.
14. A method of making an electrical terminal assembly comprising: engaging a hollow metal tube having an opening at each end with a forming device to at least partially compress a portion of the tube to form a electrical terminal having a cavity; positioning a portion of a wire assembly in the cavity, wherein the wire assembly comprises an electrically conductive wire and insulation surrounding the wire such that a portion of the wire assembly is insulated and a portion of the wire assembly is uninsulated; and crimping the electrical terminal at a first location around the insulated portion of the wire assembly to inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
15. The method of claim 14 wherein the forming device engages the hollow metal tube to form an electrical contact zone, and wherein the electrical terminal is adapted to be fixed to a mounting member.
16. The method of claim 14 or 15 wherein the electrical terminal has only one opening to the cavity, and the wire assembly sufficiently fills the opening to thereby inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
17. The method of any one of claims 14 to 16 comprising the further step of crimping the electrical terminal around the wire assembly at a second location.
18. The method of any one of claims 14 to 17 wherein crimping the electrical terminal around the wire assembly at a second location causes a portion of the uninsulated portion of the wire assembly to contact the electrical terminal.
19. The method of any one of claims 14 to 18 wherein the forming device engages the hollow metal tube to form an electrical contact zone and wherein the electrical terminal is adapted to be fixed to a mounting member.
20. The method of any one of claims 14 to 19 wherein the electrical terminal has only one opening to the cavity, and the wire assembly sufficiently fills the opening to thereby inhibit fluid from entering a portion of the cavity housing the uninsulated portion of the wire assembly.
21. An electrical terminal assembly substantially as hereinbefore described with reference to, and/or as shown in any one or more of figures 1 to 5f.
22. A method of making an electrical terminal assembly substantially as hereinbefore described with reference to, and/or as shown in any one or more of figures I to Sf.
GB0617522A 2006-09-05 2006-09-05 Sealed crimpled electrical terminal assembly Withdrawn GB2429853A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0617522A GB2429853A (en) 2006-09-05 2006-09-05 Sealed crimpled electrical terminal assembly

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0617522A GB2429853A (en) 2006-09-05 2006-09-05 Sealed crimpled electrical terminal assembly

Publications (2)

Publication Number Publication Date
GB0617522D0 GB0617522D0 (en) 2006-10-18
GB2429853A true GB2429853A (en) 2007-03-07

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Family Applications (1)

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GB0617522A Withdrawn GB2429853A (en) 2006-09-05 2006-09-05 Sealed crimpled electrical terminal assembly

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3471212A1 (en) * 2017-10-12 2019-04-17 Aptiv Technologies Limited Electrical connecting cable
WO2024022815A1 (en) * 2022-07-28 2024-02-01 Huber+Suhner Ag Crimp contact

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1227726A (en) * 1916-08-03 1917-05-29 Central Electric Company Cable-terminal.
US2467012A (en) * 1945-01-27 1949-04-12 Buchanan Electrical Prod Corp Tool for making electrical connectors
US2480280A (en) * 1945-09-24 1949-08-30 Thomas & Betts Corp Electric connector
DE19843886A1 (en) * 1998-09-24 2000-03-30 Grote & Hartmann Cable shoe for electrical conductor wire or cable, has termination sleeve receiving stripped end of conductor wire or cable enclosed coaxially by reinforcing sleeve

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1227726A (en) * 1916-08-03 1917-05-29 Central Electric Company Cable-terminal.
US2467012A (en) * 1945-01-27 1949-04-12 Buchanan Electrical Prod Corp Tool for making electrical connectors
US2480280A (en) * 1945-09-24 1949-08-30 Thomas & Betts Corp Electric connector
DE19843886A1 (en) * 1998-09-24 2000-03-30 Grote & Hartmann Cable shoe for electrical conductor wire or cable, has termination sleeve receiving stripped end of conductor wire or cable enclosed coaxially by reinforcing sleeve

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3471212A1 (en) * 2017-10-12 2019-04-17 Aptiv Technologies Limited Electrical connecting cable
WO2024022815A1 (en) * 2022-07-28 2024-02-01 Huber+Suhner Ag Crimp contact

Also Published As

Publication number Publication date
GB0617522D0 (en) 2006-10-18

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)