JPH0265079A - Electric terminal for flat power cable - Google Patents

Abstract

PURPOSE: To provide a reliable and durable electromechanical coupling which crimps the leading edge of a cable with its pair of plate parts to be screwed on each other and thus firmly holds the cable with its plurality of needles stuck into an insulator on the cable. CONSTITUTION: A central adapter 40 is fitted to one end 12 of a cable to form a terminal which is to be fixed inside an insulating body assembly 22 comprising a first and a second cover 24 and 26. The covers 24 and 26 adapted to be easily swung onto or away from each other are screwed on each other to latch and seal off the end of the terminate cable. The contact parts 42 of the adapter 40 are placed along passages 28 extending inward from a fitting face 30 so as to be coupled to mating contact parts. The body assembly 22 is designed according to the type of the contact parts 42 formed in the adapter 40 and the application of the connector. The connector is thus easily applicable to cables which are free of processing in advance and establishes reliable electromechanical connection with cables.

Description

DETAILED DESCRIPTION OF THE INVENTION This invention relates to electrical terminals, and more particularly to terminal termination for flat electrical cables.

One type of flat electrical cable terminal component is an intermediate adapter that is crimped onto the flat electrical cable and engages one or more contact portions of the adapter with mating contacts on the electrical connector, thereby transferring current from the cable to the connector. Communicate. The cable may be - for example, a commercially available power transmission cable with a nominal 75 amps and a width of lin.
, a single flat conductor approximately 0.020 inches thick with an extruded insulating coating approximately 0.004 to 61 nm thick on each surface, giving the cable an average total thickness of approximately 0.0
It is 34 inches. The material of the flat conductor is copper alloy 1, for example.
10 and the insulation is - for example E, 1. Dup
ontdc Ncmours and Company
pOI＞'61hylt3nO-eO-tetraf
luoro-ethylene copolyn+cr
(TEPZEL thermoplastic resin).

The terminal has a pair of plate sections that are hinged together at the front end of the adapter, and the front end of the cable is crimped between the plate sections. bending at least one plate portion at an angle away from the other plate portion at a location spaced a predetermined distance forward from the cable crimp stop location;
The plate portions face each other at an angle, and a distance is provided between the plate portions to receive the cable end (edge) between the plate portions. A plurality of bodies protrude from one plate part toward a mating opening provided in the other plate part, and when the drawing board parts are pressed together, the bodies can penetrate the cable, or the bodies can be inserted into the opening and the bodies can be inserted into the opening. The ends are bent with a tool or with integral circular guides in each opening against the outside surface of the other plate section. A plurality of electrical connections are formed between the adapter and the shear conductor edge of the cable by penetrating the cable. The cable is cut out of sheet metal of a suitable alloy and preferably formed with a shear lip, preferably by engagement with a specimen receptacle opening having at least one shear lip against which the cable is pressed when the fuselage is inserted. Penetrates insulation materials and conductors. A plurality of conductors penetrate the cable insulation and bite into the cable conductors to form additional electrical connections.

Dual-conductor flat power cables are also commercially available that have an extruded insulating coating around the periphery and a pair of spaced coplanar conductor strips that provide the power path for transmission and the return path. U.S. Patent No. 4,241.498
In the method disclosed in that patent, a member is engaged with one or two conductors whose upper and lower parts are joined by tabs. Move the upper and lower parts from the side of the cable along the top and bottom surfaces of the conductor, and place the tab on the side of the cable. There is a semi-cylindrical conductor made of metal on the upper and lower parts, and grooves and lands are provided alternately on the conductor, and when the upper and lower parts are pressed against the conductor, the groove on one conductor will be connected to the groove on the opposite side. The conductor land will fit. A punch/die method is used to shear strips of conductor at lands and force the sheared strips into opposing grooves. When terminated, the sheared edges of the conductor abut the sides of the groove of the semi-cylindrical conductor and form an electrical connection to the groove. The tab projects laterally from the cable and is exposed for electrical engagement with another appliance. The other conductor can be similarly terminated at a nearby location.

To develop an adapter having a means for shearing a flat electrical cable at multiple locations to form multiple electrical connections between the adapter and the conductors of the cable and maintaining the electrical connections airtight with stored energy. is desirable.

It is also desirable to ensure that each hermetic connection has a large engagement area between the adapter and the cable conductor.

It is also desirable to form elongated hermetic connections to increase the interconnect metal surface area.

It would also be desirable to develop terminals for terminating multi-conductor flat power cables.

It is also desirable to form a mechanical/electrical joint between the adapter and the flat cable that is strong, reliable, and does not weaken over long periods of use.

It would also be desirable to develop an adapter that is made of an alloy suitable for power transmission applications, maintains a stamped shape, has a shear edge that penetrates the cable, and has a surface area that will engage the cable conductor once it is terminated into the cable. It would be desirable to develop an adapter that is shaped to be as large as possible and whose stored energy maintains the connection airtight for long periods of use.

The present invention is an adapter that crimps onto a flat electrical cable by penetrating the insulation covering the cable conductor and shearing the conductor at multiple locations. The adapter is stamped from sheet metal and in one embodiment includes at least one plate section for positioning along the major surface of the cable during termination, and at least one transverse termination area, one or more preferably forms a termination region with a plurality of regularly spaced shear corrugations. When the plate section is pressed against an insulated flat cable supported by a suitable die, the cable section with the engaged corrugated head begins to be pushed (flexed) into the recess in the gouge surface; at the same time, the corrugated head The shear edges of the head penetrate into the insulation sheath, tear the insulation sheath, and begin shearing the cable section adjacent to the head-flex cable section, which is further The head flexure conductor part stretches. The shear conductor edge of the head flex cable section is thus pushed out of the face of the cable and electrically coupled by soldering to the adapter or alternatively by staking and deforming the mild steel adapter section to fit tightly against the exposed conductor edge. should have a fairly large length (e.g. 0.2
51n). The plate section maintains a mechanical attachment to the cable by the ends shearing the corrugated edges and the ends of the intermediate flexible conductor section tightly engaging the shearing edges of the cable conductor; Additional retention means can also be used, such as conventional specimens that bend against the sides or bend tabs against the side edges of the cable.

In a second embodiment, the body of the adapter includes a pair of plate portions, each plate portion having at least one transverse termination region, and the termination regions of both plate portions facing and engaging. Each termination region is comprised of alternating shear corrugations/recesses, with multiple corrugations on one plate section protruding toward the other plate section, separated from each other by recesses, and corrugations on one plate section. corresponds to the recess in the other plate portion. The radiused transverse head of each shear corrugation is spanned between coaxial parallel shear edges that are perpendicular to the head.

Basically, if the drawing board parts are pressed together, the corrugations on one board part will mesh with the corrugations on the other board part, but it is preferable to mesh them with almost no gaps.

Preferably, the hinged plate sections are pressed together with the cable therebetween and the intermediate adapter terminates the cable between the plate sections. Each corrugation is pressed against an adjacent surface portion of the cable, and its head pushes the adjacent surface portion of the cable out of the face of the cable and stretches this portion. At the same time, the shear edges of the corrugations engage the shear edges of the adjacent corrugations on the opposite side plate section: the shear edges are coaxially aligned without gaps and are paired, and the corrugations are pressed against the opposing faces of the cable. A mating shearing edge penetrates the insulation layer and tears the insulation layer, shearing the conductor perpendicular to the corrugation head. Preferably, each recess pointing away from the other plate section has an arched shape, each corrugation is placed in its opposite mating recess, and the head flex cable section is connected to the corrugated head and the opposite arcuate recess. Place it between the inner surface and the inner surface. A portion of each shear edge of one plate portion of the adapter engages a newly formed edge of the cable conductor sheared by an adjacent corrugation of the other plate portion. - Shearing the cable conductor at multiple locations over an axial shear length of, for example, 0.25 In, with little or no significant bulk deformation of the material during shearing. Since the shear is axial to the cable when terminating the adapter to one end of the cable, the cable is not substantially weakened. Basically, multiple interlocking wave joints are formed by interlocking the adapter corrugations, the cable conductor forms a strong termination across the cable, and both plate parts are then used as a zero-gap tool/die that does not open. do the work.

One aspect of the invention is to attach a pair of inserts to the outward facing surface of each plate portion of the stamped adapter body of the second embodiment, preferably transversely along the termination (wave) region.

Each insert is shaped to match the corrugation of the mating plate portion by providing an opening with an arched recess and a similar corrugation. The material of each insert is a copper-rich alloy, which is malleable, and after shearing the cable, each corrugation of the insert is deformed by, for example, staking.

Each corrugation of the insert is staked from the outwardly facing surface of the insert and spread out against the shear edges of the cable conductor now adjacent the corrugations on either side and against the adjacent shear edges of adjacent corrugations on the adapter body.

The insert establishes the main electrical connection to the cable conductor and the intermediate adapter body acts as a means of strong attachment to the cable.

In an additional embodiment, applicable not only to multi-conductor flat electrical cables but also to single-conductor cables, a pair of intermediate adapter terminals are terminated adjacent to each other at the ends of the cable. Disconnect the terminals in advance and connect them with a flexible link.
Easier handling and assembly to cables. Although pair terminals can be applied to single-conductor flat cables, they are particularly suitable for terminating multi-conductor flat cables, and when used for terminating multi-conductor flat cables, the links can be separated and connected after termination. After disconnecting the terminal, insert the terminal into the housing. Each terminal has a pair of plate sections with a series of alternating shear waves and recesses across each plate section, the shear waves engaging when the paired plate section is pressed against the intervening cable ends. to shear the conductor of the flat cable into a plurality of strips that remain integrated into the cable, and the newly sheared conductor strips are forced into the opposite recess. A pair of plate portions of each terminal protrude forward from the rear end of the cable receiving terminal, and are laterally spaced apart from each other by a fixed distance, forming a cable receiving elongated hole of a known transverse width therebetween. protrudes forward at a slight angle from the curved part of the The tab-shaped portion formed at the end of the cable is inserted into the cable-receiving elongated hole and placed between the upper and lower plate portions of each terminal. Accurately cut an axial long hole along the center line of the cable, and cut the sheared conductor edges axially along both sides of the long hole, regardless of whether the cable is a single conductor cable or a multi-conductor cable. The width of the elongated hole exposed to form the tab-shaped portion is at least equal to the width of each cable receiving elongated hole of the terminal to be closely received. The upper and lower plate parts of each pair are rotated and pressed together around the curved part that acts as an integral hinge, and the shear waveform shears the strips of the cable conductor (or two). , push in to terminate the terminal to the cable.

The terminals are placed in an integrated housing or multiple separate housings. A separate elongated bifurcated strain relief body is then placed over the cable and latched to the rear end of the housing to both secure the cable and provide a rear stop for the terminal within the housing.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a flat electrical cable termination adapter that can be easily applied without cable preparation and that can ensure a reliable electrical/mechanical connection to the cable.

The invention also aims to provide a hermetic joint between the adapter and the cable conductor that stores energy over long periods of time and is not susceptible to loosening due to heat or vibration over time.

The present invention also selectively deforms a cable in conjunction with shearing at multiple locations over a large length without substantially weakening the cable conductor, exposing the sheared conductor edges to create multiple locations with a large surface area. The object is to provide an adapter for forming an electrical connection.

The present invention also has a metal portion that is stiff enough to include an edge that shears through a large length (0,0261n) metal conductor at multiple locations; Another object of the present invention is to provide an adapter having a metal portion that can be deformed by stored energy after the cable has penetrated and can be brought into close contact with substantially the entire surface area of the shear conductor edge.

It is also an object of the invention to provide an adapter which ensures equal distribution of the current carried by the conductors to specific contact portions after cable termination.

The invention also aims to provide terminals for terminating multi-conductor flat power cables as well as single-conductor cables.

Hereinafter, some embodiments of the present invention will be introduced with reference to the accompanying drawings.

Referring to FIG. 1, an intermediate adapter 40 of a connector assembly 10 terminates an end 12 of a flat power cable 14 in a power transmission system within an electronic device such as a computer, copier, card cage system, or the like.

The flat conductor 16 of the cable is 0.020 in. thick, made of copper or aluminum, and has extruded insulating coatings (E, I) 4-8 mil thick on both sides.

DuPont de Nell1ours and C
Company TEPZEL thermoplastic resin) 18 is applied. When the intermediate adapter 40 is attached to the cable end 12, the termination terminals are connected to the first and second cover bodies 24, for example.
2B is fixed inside an insulating housing assembly 22. The lids 24,25 can be hinged to easily rotate relative to each other and latched to close off the terminated cable end. A passageway 28 extending inwardly from the mating surface 30
Insert the contact part of the adapter into the mating contact (
(not shown). The housing assembly is adapter 4
0 according to the type of contact portion 42 to be formed and the application of the connector. Various contact portions for the intermediate adapter can be used.

Referring to Figure 2.3, the intermediate adapter 40 of the present invention includes at least a body 44 with one or more contact portions 42 integrated into the body 44 at the mating end 4B. The end of the main body 44 opposite the fitting end 46 is a cable receiving end 48 . A pair of plate portions 50.5 are preferably hinged to the body 44 at hinges 54.
2, and when terminated, the plate portions are placed parallel to each other along opposite major sides of the cable end 12 and fastened to the cable 14. Preferably, as shown, the hinge 54 is located at the cable receiving end 48, but the hinge can also be located near the mating end 4B, as shown in FIG. 11.12.

Plate portions 50.52 each include transverse opposing termination regions 50.58.
is a series of shear waveforms [io
(See FIG. 6A) and recesses formed by arches 62 are arranged alternately in a row. Each corrugation of each plate section is located opposite the arch of the mating plate section. The corrugations of each plate section project outwardly from the cable proximal side 64 and towards the radiused head 66 of the other plate section (Figure 6a); the arched section 62 extends from the cable distal side 68. Projecting outwardly and away from the other plate portion. Each plate part 50.
The waveforms 60 of 52 have an engagement pattern with the waveforms 60 of the other board portion that are misaligned, and when the drawing board portions are pressed together around the hinge 54, both waveforms engage.

Preferably, the insert 100°1 in the intermediate adapter 40
02, by means of which a secure electrical connection to the cable conductor 1G is established. insert too
, 102 are attached to the cable distal side 68 of each plate portion 50.52 of the body 44 across the termination region 50.58 of the body 44. Each insert 100, 102 is provided with a series of alternating corrugations 104 and apertures 106 which, when properly installed in the body 44, engage the corrugations and apertures of both inserts. The head 108 of the corrugation 104 is similar in shape to the adjacent surface of the mating corrugation 6° of the plate portion to which the insert is to be attached. Preferably each insert 100
, 102 is provided with a protrusion 110 at one end 112, and the other end 11
[I provide a protrusion receiving opening +14 so that when terminated, the protrusion of one insert fits into the protrusion receiving opening of the other insert.

2 and 6A, the cable end 12 is inserted into the cable receiving end 48 of the intermediate adapter 40: preferably the plate portion 50.5 of the body 44 of the intermediate adapter 40.
A long hole 70 is formed between a pair of hinge parts 72 connecting two parts.
(Fig. 4) is provided. Preferably, the plate portions 50 , 52 are bent substantially fully toward each other about the hinge portion 72 prior to cable insertion, so that the heads 86 of the corrugations 60 are sufficiently close together and their spacing is less than the thickness of the cable 14 . so that the cable end 12 deflects the plate portion 50.52 slightly outwardly against the pressing force generated by the hinge portion 72, and the intermediate adapter 44 is automatically retained on the cable end 12 and the subsequent To facilitate handling prior to crimping. The radius of the hinge portion 72 is approximately 1/2 the thickness of the cable. The outward protruding flanges 74 provided on both sides of the long elongated hole 70 ensure strength after termination, and there is a risk that the stress acting on the cable, which is large in width and stiffness, may act on the intermediate adapter. The force couple prevents the plate portions 50.52 from flexing and being pulled apart.

The raw metal of body 44 is shown in FIG. 4 before attachment of insert 102 and prior to bending at hinge portion 72. The blade-shaped contact portion 42a is connected to the mating end 4
6A; plate portions 5 on both sides of the elongated hole 70 and the flange 74;
0.52; the width across the body 44 of the termination region 56.58 is approximately equal to that of the cable and the hinge portion 72
The recesses 70 on both sides of the inserts 100, 102 (FIG. 3) provide clearances for the protrusions 110 of each insert 100, 102 (FIG. 3), which are located next to the body 44 during termination and fit into the protrusion receiving openings 114 of the opposite inserts. . Termination area 58.58
In this step, the slots are cut at exactly opposite locations and evenly spaced so as not to create side gaps between the shear edges of the slots 61 that were previously joined during the formation of the corrugations 60 and the arched portions 62. An integral part 78 of the plate portion 50.52 extends forwardly and rearwardly from the end of the slot 61. The flange 74 is formed by making a long hole 70 and is bent at 90 degrees with a small radius.

The main body 44 is, for example, a 61 inch corporate
on to A11oy No, 7025 halrha
rd copper alloy (semi-hard copper alloy) or A11oy N (L 151 temperature
hardally, Tea+per No, H
It can be a copper alloy with a thickness of 0.025In sold under the trade name O5 (which is annealed to ensure ideal stress relaxation properties). The inserts 100 and 102 are -
For example, the thickness is approximately 0.06610, the height of the wave head 108 is approximately 0.1321n, and the axial length is approximately 0.3261n.
dead soft copper CD^110
(very mild steel). If necessary, both the insert and the main body are silver plated to ensure the robustness of electrical connections during long-term use.

Referring to Figure 5.5A, each insert 100°102
are attached to each plate section 50° 52 by a light staking action, and the insert is tapped by blade 148 centered on the outward facing surface of each raised corrugation so that each raised corrugation laterally crosses the insert corrugation. Apply a slight deformation to the adjacent arcuate portion of each adapter plate portion to which the insert is secured.

Referring to FIG. 6A, the cable end 12 is inserted into the cable receiving end 48 of the assembled intermediate adapter 40.
are arranged, and the upper/lower head part 88a/8 of the waveform 60
6b is about to be combined. Connect the end of the cable to long hole 7.
66) and move the cable end forward to move the leading edge 12 forward from the termination area 58.58 and away from the contact contact area (FIG. 66). It is placed at a position a short distance rearward from 42a. Due to the pressing force of the hinge portion 72, the head 68a/G6b grasps the lower portion 32/34 of the insulation 45 surface of the cable 14. Referring to FIG. 6C, the intermediate adapter 40 is pressed together using a tool 150 (FIG. 7A) such as an arbor brace. The shear edges created by the slots 61 along both sides of the corrugations 60 of each plate section engage the shear edges of the misaligned corrugations of the opposite plate section, resulting in a tenacious and ductile cable 14. The insulating coating 18 is first perforated and torn, and the cable conductor 16 is sheared longitudinally by approximately 0°25 In. The heads 8Ba, 86b deflect and stretch the sheared portions of the cable conductors I6 outwardly to form alternating upwardly arched and downwardly arched conductor rings in the opposed arched portions of the opposite plate portions. . A wave joint 80 is formed in each waveform 60. In this embodiment, there are six wave joints 80 across the entire length of the cable 14, and the intermediate adapter of the present invention has four wave joints with simple modifications and integral adapter straps along the lateral edges of the termination region. can be left behind.

Corrugated Cable Deflects the cable outwardly in opposite directions at a single point in the axial direction (by the head), then progressively deflects axially forward and backward, and with zero clearance It is considered that the waveform supports shearing of the cable by first starting shearing at the point [11-] at the same time as the deflection from both sides. The deflected conductor strip remains integrally coupled to the cable and the cable is substantially less weakened. Termination is controlled and precise, and is accomplished by the shear edge of the adapter itself without any cable preparation. Another advantage of the present invention is that the intermediate adapter grips the cable after insertion, making it easier to place the cable end in a tool to use the rigid cable itself for handling.

With reference to FIGS. 7A-70, the first pair of dies 1 of the tool 150
Following shearing of the cable due to the compressive force of the flat surface of 52,
Preferably, die 152 continues to press the upper/lower portion of intermediate adapter 40 against upper/lower cable surface 32/34. Preferably, the die 152 is provided with an opening 154 within certain limits at each location of the wave joint 80 and the insert corrugation 104, as well as at both insert ends 112° 116, for subsequent staking, so that the protrusion 110, the wave joint and Expose the insert waveform. Subsequently, a second step is performed using the second pair of dies 156 (FIG. 7B). The pointed chisel blade 158 has an axial tip (FIG. 8A) that first impinges on the intermediate adapter 40 from above and below each wave joint 80 along the outer surface 82 of the arcuate portion 62. 7B, 1
0, a blade 158 penetrates each wave joint 80 to a predetermined depth, splitting the arched portion 62 into two,
The divided portion 84 is bent downward along the inside of the V-shape of the staked wave joint 86 at the axial center of the wave. The bifurcated portion 84 acts as a pair of springs, the free end 88 of which is permanently deformed by the blade 158 into the cable 14. The wave head 6G of the opposite wave 60 acts as a die and the free end 88 acts on the softer conductor 61 and pushes the conductor portion 90 laterally outward, but the conductor portion 9
The 0's generally remain connected to each other. The spring 84 then inserts the conductor portion 90 into the side surface 1 of the insert opening 106.
20 and acts as a rigid compliant structure.

At the same time, the additional set of blades 160 (FIG. 8B) stakes the protrusion 110 into the protrusion receiving opening 114 of the inserts 100, 102, deforms and expands the protrusion within the undercut opening, Secure electrical/mechanical coupling 12
At 2, the inserts are firmly interconnected.

Then, as shown in FIG. 7C, the blade 158. tea
is pulled back, but the die 152 remains closed and a third step is performed by the third pair of dies 162 of the tool 150. The pointed chisel blade 164 has an axial tip (eighth
A), which impinge simultaneously on the intermediate adapter 40 from above and from below along the outside 124 of each insert 100° 102 between each corrugation 104 and the just staked corrugation joint 86. Thus, the blade 164 is inserted too
, 102, the softer copper material is laterally deformed and a new portion of the cable conductor portion 90 is forced into the corrugations 104 of the inserts along each staked wave joint 8B and the arched opening sides 120 of the insert. The contact interface between the sheared edges is loaded. Free end 88 of spring 84
also serves to prevent the deflected conductor strips from bulging outward at the center during staking of the insert corrugations 104. Blade 158.100.1G4 may also be a separate member that is pushed into blade receiving aperture 154 by a separate comb (not shown).

FIG. 9 is an enlarged cross-sectional view of the actual termination 92;
70 illustrates the type of termination formed by the intermediate adapter described above with reference to FIGS. Four of the six staked wave joints 8b are visible. Referring to FIG. 1O, which shows an enlarged view of one of the staked wave joints 86 of FIG. It can be clearly seen that a main electrical connection 96 is formed between the conductors. Near the axial center of each staked wave joint 86, the conductor 16 consists of two sections that are pushed laterally outward, with the shear conductor edge 94
20; curve 96 indicates the presence of column strength creating stored energy that engages staked adjacent insert portions to form a secure electrical connection. The black layered portion 98 within the staked wave joint 86 is the insulated cable sheathing m1g portion that falls within the available space and does not affect the mechanical/electrical connections. Measurements of the resistance level of the terminations thus formed show that the voltage drop is acceptably small and that high temperature aging ensures a good electrical connection.

Conventional thermal shock testing shows excellent mechanical stability of the termination.

An alternative embodiment of intermediate adapter 200, shown in FIG. 1112, has plate portions 202, 204 integrally joined at a forward-most curved portion 206 of body 208.

The contact portion 210 is bottle-shaped and is made of a double-thick sheet metal punched from the main body 208, and extends rearward from a curved portion 206 at the front end of the contact portion 210. Upper/lower plate part 202 /2
04 is the bending part 212 just behind the contact part 210
It is bent upward and widens towards the rear. Connect the cable end 214 to the cable receiving end 58), (2
18 and placed between the termination areas 218, 220 between the upper/lower plate portions 202/204. Board part 2
02.204 is crimped onto the cable end 214 so that the corrugations 222 shear the cable end 214 at a plurality of transverse locations spaced a distance rearwardly from the forward-most end of the cable end 214, causing shearing. The axial strips are deformed and pressed against the inner surface of the opposing arcuate portions 224 (as in the embodiment of FIGS. 2-70). Four corrugations 222 are illustrated, with integral plate part strap 2
26 is passed laterally to the side of the termination area to assist in maintaining therein an insert 228 attached to the outer surface of the plate portions 202, 204 of the body 208; There is no body reception area. The wave joint can then be staked, and the insert waveform 230 can also be staked (as in Figures 7A-70).
. Strain relief of the cable can be provided by a connector assembly in which the terminated cable end is to be secured.

The intermediate adapter shown in FIGS. 13A and 13B has only one plate section 302 and one termination area that is connected to the plate section 304.
It may be desirable to provide multiple termination regions that extend across the area, but are spaced apart by regular intervals.

Die face 806 of die 368 supports cable 310;
Another die 312 causes the plate portion 302 to connect to the cable 310.
is pressed with sufficient pressure. The head 31 of the wave 316 as the edge of the wave 316 cuts through the cable conductor.
4 deflects the adjacent cable section into the recess 318. Additional cable securing means (tab 32 of adapter 300)
0 can be bent against the lateral edge of the cable 310 by the recess 322 of the die 30G. Conventional cable punch specimens can also be used as additional cable fixing means. Shearing the cable conductor across termination region 304 at a plurality of locations and then deflecting sheared conductor strips 328 out of the plane of the cable to expose edges of conductor strips 328 for electrical connection. let An insert 330 with an aperture 332 can then be placed across the corrugation, and the sheared and deflected conductor strip 328 can be placed into the mating aperture 332, with the cable distal side of the insert 330 having a flat surface. It is. The insert 330 is then bent upward and the tab 3 of the adapter 300 is placed over the end of the insert.
24 to the termination portion, and the tab flange portion 32B
can be secured around the upright insert flange portion 334 (see Figure 13c). The insert 330 can then be stuck next to its opening 332 as shown in FIG. 7C, leaving a recess;
Similar to the wave joint shown in Figure B, conductor strips 328 can also be stuck to leave recesses 338 to form a secure electrical connection.

Opening 352 of insert 350 in Figures 14A and 14B
has a tapered side 354. As in FIG. 13B, pressing against plate portion 360 forms an electrical connection to the cable conductor. The termination area of the adapter 364 is provided with a complex transverse corrugation; the wide (-11) conductor of the cable 362 is covered with a thin insulation sheath 368; the sheared and deflected conductor strip 336 conductor edge 3
70 is exposed and the adapter corrugation has a shear edge 372. When insert 350 is pressed against the termination area, conductor edge 370 and corrugated edge 372 rub against the sidewall near the distal end of opening 352 in FIG. 14B to form electrical connection 380.

The sides of the opening in the insert are provided with vertical serrations that scrape the exposed shear conductor edges by 5 clves to increase the surface area of the electrical connection between the conductor and the insert.

Referring to FIG. 15, as shown in FIG. 13A, the adapter 400 is pressed against the cable 410, and the waveform 414 (phantom) shears and bends the conductor strip 424 (phantom) to bring it out of the plane of the cable. Create a termination area across the cable. A tab 420 may be provided on the adapter 400 to attach to the cable 410.

The edges of conductor strip 424 are exposed and electrically connected to adapter 400 by solder 430. The termination portion 432 thus formed can be placed within an insulating housing.

The intermediate adapter 500 shown in FIGS. 18A and 18B includes:
There are a pair of plate portions 502 and 504 made from the same blank as the blank in FIG. 6A-60, the cable portion is deflected and sheared by interlocking the waves 508, and the deflected cable portion is pressed against the inner surface of the arched portion 512 to connect the intermediate adapter 500 without an insert to the cable end. It can be terminated at the section 50G. When attached to the cable, the adapter is mechanically coupled to the cable and there is some electrical connection between the shear edge portion of the wave and the shear cable conductor portion. shear cable conductor edge 5
The exposed portions of 10 can be electrically connected by solder or the like (see FIG. 15). Termination section 514 can then be placed into a connector housing (not shown).

Although the intermediate adapter using the wave crimp of the present invention is preferably provided with an insert made of soft metal to optimize the termination for long-term use, it is possible to omit the insert and use the intermediate adapter here. The corrugated gapless opposing shear edges ensure significant benefits from the shearing performed;
Wave joints can also be formed that are mechanically strong and have a large surface area of the exposed cable conductors of the cable in establishing electrical connections to the cable. If desired, the lateral edges of the corrugation may be serrated and the shear conductor edges may be provided with corresponding serrations to increase the surface area of the conductor exposed for electrical connection, such as by soldering. Additionally, each insert can have a different shape. If desired, the plate sections may have two termination areas instead of one, each plate section being a separate member. Furthermore, it will be readily appreciated that the intermediate adapter could be terminated at the lateral edge of the flat cable rather than at the end.

Components of the connector 610 in FIG. 17 include a housing 612 that houses a pair of terminals 616 terminated to a flat power cable 618 and a cable strain relief body 614.

Connector 620 and connector 610 are combined to accommodate a pair of matched terminals 622; terminal 622 boss portion 62
4 protrudes rearward from the housing 626, and the post portion 624 is inserted into a mating plated through hole in a printed circuit board (not shown). When connectors 610 and 620 are mated, spring arm contact portion 628 on the front end of terminal 622 mates with spline 630 on the front end of terminal 616. A plurality of front passages 632 provided in the housing 612 communicate with a fitting surface 634, and when the terminal 61G is inserted into the housing 612 from the rear end 636, the spline G
30 enters each passageway 032.

A spring arm 628 is located within a large cavity 638 of the housing 626 of the connector 620, and when assembled, the connector 610
The front portion 640 of the housing 612 enters the large cavity 638 and the spring arm 628 enters the passageway 632 to electrically engage each spline 630. A pair of latch arms 642 provided on both sides of the housing 612
riding on the pair of mating latching protrusions 644 of 26;
The connectors are latched into engagement with the latching protrusion, thereby interconnecting the connectors. Delatching from the protrusion 644 when disconnecting the connector is caused by the action of the rear gripping portion 646 on which the latch arm G42 is provided.
lateing (dissociation) is facilitated. Strain relief body 614 is inserted across flat cable 618 from side edge 648 and moved forward to securely latch housing 612 along rear end 636 . The strain relief body 614 has a pair of upper/lower struts 050/652 projecting laterally from an integral portion 654 separated from each other by a small gap to accommodate the cables therebetween. Lateral end 6 with integral part 654
A first latching arm 658 projects forwardly from 56 toward an inwardly directed latching projection 660 . A pair of second latch arms 66 provided at the lateral ends 662
4 projects forwardly from the upper/lower strut 650/852 toward an inwardly directed latching projection 666, which latching projection 666 is connected to the connector housing 6.
When latching to 12, it engages as a 11t-latch arm. A pair of latching recesses 670 are provided along the outer surface 668 near the rear end 63B of the housing 612, and when the strain relief body 614 is attached to the housing 612, the latching protrusion 660.866.8GB or the latching recesses 670 are provided. Go inside.

When assembled into the housing 612, the cable strain relief body 614 can be attached to the opposing surface 6 of the upper/lower strut l-650/652.
A cable exit is formed between 74 and 67G. When the strain relief body 614 is latched to the housing G12, the upper side/
The dimensions and shape are set so that it comes into close contact with the cable G1g along the lower cable surface and also into close contact with the lateral edge of the cable.

The punched adapter 678 of the terminal 1316 is attached to the cable surface 68.
4.888, and a high copper content insert 680 is secured along the cable distal side of the adapter 678 to provide an airtight electrical connection between the shear edge of the cable conductor when terminated. It is formed. The cable 618 has two flat conductors spaced apart by a fixed distance, and an axial elongated hole 082 is cut along the centerline of the cable so that the narrow inner edge of the conductor and the insulating material between the conductors The central strip is removed to form a tab-shaped cable portion to be inserted into the cable receiving slot of the paired terminal 61G formed between the inner curved portions of the paired curved portions of the terminal adapter 678; The width of the axial elongated hole 682 is set so that the width of the tab-shaped portion is large, and the width of the axial elongated hole 682 is set so that it fits tightly between the opposite curved portion of each adapter 678. Preferably, when inserted into the cable receiving elongated hole, the tab-shaped portion The sections are tightly fitted, and when the plate sections of the adapter are pressed together for termination, the outer curved sections of each pair gradually expand inwardly against and into the lateral edge cable insulation, and the inner curved section deforms slightly and gradually expands inward until it hits and bites into the larger edge of the adjacent metal, forming a stop mechanism that prevents the terminal from moving axially along the cable after termination. Do it like this.

Referring to Figure 18.19, terminal 1316 is connected to cable 6.
18 and are positioned within each cavity 688 of housing 612, and terminals 622 are positioned within housing 626. A cable strain relief 614 is latched to form a cable exit and the upper/lower strut 65
The cable 61g is fastened between the opposing surfaces 674/87B of 0/852, and the adapter part 6 of the terminal 616
A curved portion 690 of 78 is located within the recess 692. Front side 6 of upper/lower struts 650 /652
A stop mechanism 94 holds the terminal 616 within the cavity 688 and prevents the terminal 61[i from moving in the axial direction within the cavity 688. Connector 610,6
20 are combined, and a downwardly angled spline 630a and an upwardly deflecting spring contact arm 628a electrically engage with each other.

In another embodiment shown in FIG. 20.21, terminal 7
50,752 are terminated at the ends of each cable section 754,756 containing a plurality of individual conductors of a multi-conductor cable 758. Individual housing 7 for terminals 750.752
60 and a separate strain relief body 762 is positioned and latched to the rear end of the housing 760. The illustrated embodiment applies when the conductors 764, 788 are spaced apart from each other by a fixed distance for the power and return paths established by the individual conductors of the cable. It goes without saying that the present invention is not limited to the embodiments introduced above, and that various other embodiments are possible within the scope of the claims.

[Brief explanation of the drawing]

FIG. 1 is an illustration of an electrical connector for flat power cables using the intermediate adapter of the present invention. FIG. 2 is a perspective view of the intermediate adapter of FIG. 1 ready to receive and terminate a cable end; FIG. 3 is a perspective view of the adapter with the insert removed from the main body. FIG. 4 is a plan view of the main body before the plate portion is folded back. Figures 5 and 5A are an elevational view of the insert attached to the main body and an enlarged partially sectional perspective view showing staking. Figures 6A-60 are longitudinal cross-sectional views of the adapter ready to receive a cable end, after receiving a cable end, and after being terminated, respectively. Figures 7A-7C are cross-sectional views across the wave termination region showing a shearing step and two staking steps. Figures 8A and 8B show two types of staking blade tips for use in the staking process of Figures 7B and 7C. Figures 9 and 10 are a micrograph of a cross section of a cable terminated with an intermediate adapter as shown in Figures 7A-C, and an enlarged view of a staked wave joint of the same adapter. FIG. 11.1.2 is an elevational and perspective view of an alternative embodiment of an intermediate adapter with an insert. Figures 13A-13c are illustrations of an intermediate adapter in which one plate section is joined to a cable using opposed dies and a trailing insert is secured and staked to the terminated cable section. Figures 14A and 14B are close-up views of the opening of an alternative embodiment insert with tapered sidewalls secured to a wave joint; FIG. 15 shows soldering of a single plate adapter without inserts. Figures 18A and 18B are illustrations of an intermediate adapter mechanically coupled to the cable, with a pair of plate portions as in Figure 4, but without an insert. FIG. 17 shows a pair of terminals of the present invention attached to the tab portion of a double conductor cable, a housing/strain relief body of the terminals, and
The paired terminals and their housings are shown. Figures 18 and 19 are longitudinal sectional views of the housing terminal of Figure 17 before and after combination. Figure 20.21 is an illustration of separate housing terminals for a multi-conductor cable. 10; Connector assembly 40: Intermediate adapter I4: Flat power cable 12: Flat power cable end 18: Insulating coating 22: Insulating housing assembly 24. 26: First and second lid bodies 28: Passage 30: Merging surface 42 : Contact portion 44: Main body 48 Two combined ends 48 Two cable receiving ends 50, 52: Opposite plate portion 54
: Hinge 58. 58 : Termination area 60 : Shear waveform 62 : Arched part 64 : Cable proximal end side of plate part 66 Head with round 68 : Cable distal end side of plate part 100.102 : Insert 106 Two openings b1
04: Waveform 108 Two heads 110: Projection 112: One end 116 of insert 100/102: Other end 114 of insert 100/102: Projection receiving opening A0: Long hole 72: Hinge part 66:
Head 44: Intermediate adapter 74: Outward projecting flange 70: Long elongated hole 42a: Bood-shaped contact portion 76: Recess 61: Slot 78: Integral part of plate portion 50/52 86a/88b: Upper/lower head Sections 32/34: Upper/lower surfaces 150 of cable 14: Tool 16 Two-cable conductor 80: Wave joint 152: Twin die 154 of tool 150: Opening 158 of die 152: Pointed chisel blade 82: Arched portion 62 Outer surface 84; bifurcated portion 88: free end of pair spring 90: conductor portion 84: spring 106: insert opening 120: side surface of insert opening 106 160: additional blade 162: third pair die 16
4: Pointed chisel blade 154 nib blade receiving opening 92: Projected end 94: Shear conductor edge 120: Adjacent side of adjacent insert corrugation 96: Main electrical connection 200: Intermediate adapter 202.204:
Plate portion 206: Curved portion 208 Two main bodies 210: Contact portion 212: Bent portion 214:
Cable end 216 Two cable receiving ends 218, 220: Opposing termination area 222: Corrugated 224: Arched portion 2
2B=integrated plate part strap 228: insert 230
: Insert waveform 300: Intermediate adapter 302:
Plate portion 304: Termination area 368: Die 306: Die surface 310 of die 368: Cable 316: Wave 314: Wave 3
16 head 318: recessed part 320: tab
322: Concave portion 328: Shear conductor strip
330: Insert 332: Opening 326: Tab flange portion 334: Insert flange portion 33G = recessed portion 350: Insert 35
2: Opening 354: Tapered side surface 360: Wave portion 364:
Adapter 362: Cable 368: Insulating cover 366 = Conductor strip 370: Exposed conductor edge
372: Shear edge 370: Conductor edge 372: Corrugated edge 354: Side wall 380:
Electrical connection body 400: Adapter 410: Cable 414: Waveform 424: Conductor strip
420: Tab 430 Nihanda 4
32: Termination part 500: Intermediate adapter 502.5
04: Sealing plate portion 506: Cable end portion 508
: Wave 512: Arched portion 51O: Shear cable conductor edge 514: Termination portion 610: Connector 612
: Housing 614: Strain relief body 616 Two-pair terminal 618 Two flat electric cable pull 610.620 : Connector 622: Pair terminal 624: Boss part 62B: Housing 628 Spring arm contact part 630 Nispline 682: Front Sectional passage B34: mating surface
838: Rear end 638: Large cavity 640: Front part of housing 612 642: Latch arm 644: Latching protrusion 646: Rear grasping portion of latch arm 642 614: Strain relief body 618: Flat cable 648: Lateral edge 636: Rear end 850/652: Upper/lower strut 654 integral part 656: Lateral end 858: First latch arm 660: Latching protrusion 662: Lateral end 664:
Second latch arm 668: Latching protrusion 612: Connector housing 6
36: Rear end of connector housing 612 668: Outer surface of connector housing 612 670: Pair latching recess 674.876: Upper/lower strut 650/6
Opposing surface 616 of 52: terminal 678; adapter 684
．． 686: Cable surface 680: Insert 68
2: Axial long hole 688: Hollow part of housing [1112 622: Terminal 6
26: Housing 690: Curved portion 892:
Recess 694: Front side of upper/lower strut 850/852 610.620: Connector 630a Nispline 828a Nispring contact arm 750
．． 752: Terminal 754.756: Cable portion 758: Double conductor cable 762: Strain relief body 760: Housing 764.786: Connector-4, ○ Full IiE; 4 Homare (, 7T type) 1.
Appalling display 2069 Patent Application No. 2, Title of Invention No. 121.309 Relationship with the case of a person amending electrical terminals for flat electrical cables Patent applicant 6, in the specification subject to amendment, ``simple drawings'' Column 7 of "Explanation", Contents of the correction ■) Insert "indicates metallographic structure" next to "cross section" on page 52, line 19 of the specification. 2) ``Enlarged view'' on page 52, line 20 to page 53, line 1, is corrected to ``micrograph showing an enlarged view of the metal structure of the end surface.'' Name: Amp Incoholated 4, Agent address: 7th floor, Hauraiya Building, 5-2-1 Roppongi, Minato-ku, Tokyo, August 2019 (starting gate)

Claims (1)

[Claims] 1) A flat power cable (
14), (214), (310), (382), (41
0), (506), (618), (758), which terminates in the conductor and merges into the contacts (42), (210), (302), (630) of the adapter. (628) Another electrical product (
620) for electrically connecting to and transmitting current, - as a component of the intermediate adapter, at least one element having spring properties and made of a metal suitable for transmitting current; One body (44), (208), (300), (3
64), (400), (500), (678), (75
0), (752), and contacts (42), (210), (302), (630) at the combined end of the body, and further at least one first plate portion as a component of the intermediate adapter. (52), (202), (302),
(504), the first plate portion has a cable proximal side surface and at least one termination region (56), (58), (21).
8), (220), (360), each said termination region being provided with a plurality of shear edges (61), (372);
The first plate portions (52), (202), (302), (5
04) surrounding each said shearing edge (61), (372) and being integrated into each said shearing edge (61), (372); - said first plate portion (52), (202), ( 302), (
at least one corrugation (60), (222), (31) projecting outwardly from the proximal side of the cable (504);
6), (414), and (508) are each of the termination regions (56).
, (58), and each waveform (60), (2
22), (316), (414), (508) has a head (66), (314) passing between two parallel shear edges (61), (372), said first Board part (52
), (202), (302), (504) for each waveform (
60), (222), (316), (414), (50
Recesses (62), (224), (
Dies (50) and (204) with 318) and (512)
, (306), (502), the cables (14), (214), (3
10), (362), (410), (506), (61
8), (758), a plurality of shearing edges (18), (36) shearing the insulation sheathing (18), (368) and the conductor (16);
8) each of the termination regions (56), (58), (222),
(316), (414), (508) are shear edges (18)
, (368) sheared cable (14), (
214), (310), (362), (410), (5
06), (618), (758), each strip (90), (
328) and (366) to bend the dies (50) and (204
), (306), (502), respectively, the recesses (62), (22
4), (318), (512) and take it out from the die, it will have a considerably large length (90), (328), (36).
6) the shear cable conductor (16) is brought out of the plane of the cable, its shear edges (94), (370) exposed for electrical connection to the intermediate adapter, and the intermediate adapter is terminated to the cable; An intermediate adapter featuring: 2) Furthermore, the cable (
14), (214), (310), (362), (41
0), (506), (618), (758) are received between the integral first and second plate portions (50), (52).
, (202), (204), (502), (504) are the main bodies (44), (208), (300), (364)
, (400), (500), (678), (750),
(752), at least one of the first and second plate portions being integrated into the main body; - the plate portions (50), (52), (202), (204);
), (502), (504) have cable proximal end sides facing each other and cable distal end sides facing in opposite directions, and the first plate portions (52), (202), (302), (
504) at least one first termination region (56), (
58), (218), (220), the second plate portions (50), (204), (502) having at least one first termination region (56), (58), (218), (22
0), cables (14), (214), (310
), (362), (410), (506), (618)
, (758), the first and second termination regions (5
8), (58), (218), and (220) are located facing each other at regular intervals, and engage with each other during termination, and the termination areas (56), (58), and (218) ), (22
0) is provided with a plurality of shear edges (61), (372), each of said plate portions (50), (52), (202), (
204), (502), and (504) are the termination area (56).
), (58), (218), (220) and are integrated into said termination region (56), (58), (218), (220); - each said plate portion (50); , (52), (
202), (204), (502), and (504) protruding outward from the proximal end side of the cable.
1st and 2nd waveforms (60), (222), (316)
, (414), and (508) are the first and second termination regions (5
6), (58), (218), and (220), and at least one first and second recessed portions (6) are provided nearby.
2), (224), and (512), and at least one of the first and second recesses (62), (224), and (512).
are the first and second waveforms (60), (222), and (31), respectively.
6), (414), (508); - each of the first and second waveforms (60), (222), (316);
), (414), (508), two parallel shear edges (6
1), the at least one first waveform (60), (314) passing between said at least one first waveform (60), (
222), (316), (414), and (508) of the at least one second waveform (60), (222), and (31
6), (414), (508), with each shear edge (61) of one corrugation being located opposite each shear edge (61) of the other corrugation, with a regular spacing between them. The cables (14), (214), (31
0), (362), (410), (506), (618
), (758), the first and second corrugated shear edges (61) engage to shear the cable from both sides at the same location, and the shear edges (61) The plate portions (50), (52), (202), (204), (
The shear edge (61) and the edge (61) are located opposite to each other at a constant distance from at least one edge (61) provided on the edges (502) and (504).
) are engaged with each other; - the first and second termination regions (56), (58), (218
), (220) are provided with a plurality of opposing shear edges (61), the first and second plate portions (50), (52), (2
02), (204), (502), and (504) against the cable portion inserted between them, the opposing shear edges (6
1) engage with each other and the cable insulator (18) and conductor (
16) at a plurality of positions and a plurality of corrugations (60), (222), (316) in the first and second termination regions (56), (58), (218), (220). , (414)
, (508) are provided, and the waveforms (60), (2
22), (316), (414), (508) are sheared by the shearing edge (61) of the integral strip of the cable (
90) is bent to form a plurality of recesses (62), (224), (
512), after which at least a portion of the sheared edge (61) engages the sheared edge (94) of the strip (90) of the cable conductor (16), and the sheared edge ( 94)
2. Intermediate adapter according to claim 1, characterized in that the other parts of the intermediate adapter are electrically connected to the cable conductor (16) while remaining exposed, and the intermediate adapter is terminated to the cable. 3) Furthermore, the first and second plate portions (50), (52),
(202), (204), (502), (504) are the main bodies (44), (208), (300)O(364),
(400), (500), (678), (750), (
3. An intermediate adapter as claimed in claim 2, characterized in that it is an integral part of 752). 4) Furthermore, the first and second plate portions (50), (52), (
202), (204), (502), and (504) are integrally connected via hinges (54) and (690),
The first and second plate portions (50), (52), (202),
The cables (14), (214), (310), (362) inserted between (204), (502), (504)
, (410), (506), (618), (758), the first and second plate portions (50), (52),
(202), (204), (502), (504) rotate around the hinges (54), (690) and are pressed together, and the first and second termination regions (56), ( 5
The shear edges (61) of 8), (218), and (220) are
4. An intermediate adapter as claimed in claim 3, characterized in that it is perpendicular to said hinges (54), (690) and that upon termination shears said cable perpendicularly to said hinges. 5) Furthermore, the hinges (54) and (690) are connected to the main body (
44), (208), (300), (364), (40
0), (500), (678), (750), (752
), the hinges (54), (690) being located at the cable receiving end (48) of the pair of hinge portions (72);
(690), the hinge portion (72), (
690) are spaced apart at regular intervals in the transverse direction, and between them are cable receiving elongated holes (690) having a height approximately equal to the thickness of the cable.
70) are formed, and one end of the flat cable is inserted into the cable receiving elongated hole to remove the plate portions (50) and (52).
), (202), (502), and (504), the plate portion is rotated around the hinges (54) and (690) to be mechanically/electrically coupled to the cable. to set the termination, and after terminating the hinge part (72), (690
5. An intermediate adapter as claimed in claim 4, characterized in that the mechanical/electrical connections at the termination are protected against force couples acting on the adapter. 6) Furthermore, the first and second plate portions (50), (52),
(202), (502), (504), the first and second inserts ( 100)
, (102), (228), (680) are attached, and each termination region (56), (58), (218),
A surface of each insert (100) adjacent to the distal side of the cable and similar in shape to the distal side of the cable (220)
), (102), (228), (680), and the insert waveforms (104), (230) and each (6
0), (222), (316), (414), (508
) and the connecting plate portions (50), (52), (202), (
The termination region (56) of (204), (502), (504)
), (58), (218), (220) recesses (62)
, (224), (512) and are aligned with each insert (104), (230).
00), (102), (228), (680),
Each of the insert corrugations (104), (230) corresponds to the bonding plate portions (50), (52), (202), (204), (
The termination regions (56) and (58) of 502) and (504)
, (218), (220), which are aligned with the edges (61) of the cable conductors (16), and when terminated, each side faces the portion (90) of the cable conductor (16). 6. Intermediate adapter according to any one of claims 2 to 5, characterized in that it is an electrical connection surface that connects to the shear edge (94) of the intermediate adapter. 7) Furthermore, integral means (110), (114) provided on said inserts (102), (104) allow said inserts (102), (104) to
104) are locked together so that the plate portions (50), (5
2) and the cable portion are connected to the insert (102), (1
7. An intermediate adapter as claimed in claim 6, characterized in that it is clamped between 04), thereby locking the termination and forming a secure mechanical connection to the cable. 8) The cables (618) and (758) further include a pair of conductors separated by a fixed distance by an axial elongated hole (682) cut along the centerline from one end of the cable. tab-shaped parts (754), (756
), and each tab-shaped portion is inserted into the cable receiving elongated hole of each main body (678) formed between the counter hinge portions (690) and the opposite plate portion is inserted. 7. The intermediate adapter according to claim 5, wherein each conductor is terminated to each main body by pressing the facing plate portion against the tab-shaped cable portion placed between the intermediate adapters. 9) A flat electrical cable (14), (214), (310), (362), (
410), (506), (618), (758), comprising the following steps: - at least one first and second termination region (56), (5
8), (216), (220) first and second plate portions (50), (52), (202), (204), (5
02), (504) (the first and second termination areas (504)
6), (58), (218), (220) are provided with a plurality of shear edges (61), and the shear edges (61) are connected to the first and second plate portions (50), (52). , (202), (2
04), (502), (504) and at least one of the first and second waveforms (
60), (222), (316), (414), (50
8) respectively the first and second termination regions (56), (58), (2
18) and (220), and each waveform (60
), (222), (316), (414), (508)
a head (66) passing between said pair of shear edges (61);
) and at least one first and second recesses (62), (224), (5
12) respectively the first and second termination regions (56), (58),
(218), (220), and the first and second plate portions (50), (52), (202), (204)
, (502), (504), (42), (210), (302),
(630) to the other contact (6) of the electrical product (620).
22); - the first and second plate portions (50), (52), (202);
, (204), (502), and (504) are placed facing each other at a constant interval, and the first waveforms (60), (2
22), (316), (414), and (508) in the second
The second waveforms (60), (222), (316), (414) are made to face the recesses (62), (224), and (512).
), (508) into the first recesses (62), (224), (
512), and each termination region (56), (58),
(218), (220) facing and aligning the shear edges (61) with at least one edge (51) of the mating termination region (the recesses (62), (224), (512) The waveforms (60), located opposite at the end, (
222), (316), (414), (508)); - the cables (14), (214), (310), (3
62), (410), (506), (618), (75
8) the first and second plate portions (50) having aligned edges;
(52), (202), (204), (502), (5
04); - applying sufficient force to the first and second plate portions (50), (5
2), (202), (204), (502), (504
) on the cable portion to form the waveforms (60) and (2
22), (316), (414), (508) to engage the cable portion, and the cable is pulled by the shear edge (61) into the first, second end regions (56), (58), ( 21
8), (220) at a plurality of locations to tear the insulation sheathing (18) to form a sheared edge (94) of the cable conductor (16), and the corrugations (60), (222) )
, (316), (414), and (508) to deflect the sheared portion (90) of the cable into the opposite recess (6).
2), (224), (512); -Waveform (60), (222), (316), (414)
, (508) to the shear conductor edge (94).
The first and second plate portions (50), (52), (202), (204), (
502), (504) are electrically connected to the cable conductor (16). 10) - Apply sufficient force to the first and second plate portions (50)
, (52), (202), (204), (502), (
504) to the cable portion to create the waveform (60).
, (222), (316), (414), (508) to engage the cable portion, and the shear edge (61) directs the cable to the first and second end regions (58), (58). ,
(218), shearing at multiple positions along (220),
The cable conductor (1) is removed by tearing off the insulation sheath (18).
6), forming a shear edge (94) of the waveforms (80), (2
22), (316), (414), (508) to deflect the sheared portion (90) of the cable into the opposite recess (62), (224), (512). , After the same process, plate parts (50), (52
), (202), (204) are provided with openings (106) for receiving shear conductor strips (90) along adjacent arcuate portions (62) and opposing shear corrugations (60), (222). Inserts (100), (102), (2
28), (680) to plate parts (50), (52), (2
02), (204) on the side of the cable distal end; - a wave joint (80) at the termination in the insert opening (106);
) and stake the board parts (50), (52), (2
02), (204) is divided into two to form a recess (62), and the free end (88) of the divided arched portion (84) is turned inward. Outward facing surface (32) of deflected, sheared and deflected conductor strip (90)
, (34) and bite into the surfaces (32), (34), thereby causing the rigid compliant structure (s
tiffly compliant structure
- each insert (
100), (102), (228), (680) between the openings (106) and (106) of the cables. staking and laterally deforming a portion of it to apply it to the sheared and deflected conductor edge (94) in the opening (106), so that the sheared conductor edge (94) and the sides of the insert opening (106) 10. The method of claim 9, further comprising forming a hermetic electrical connection between (120) and (120).