US20160294072A1 - Wire and methods for preparing a wire to receive a contact element - Google Patents
Wire and methods for preparing a wire to receive a contact element Download PDFInfo
- Publication number
- US20160294072A1 US20160294072A1 US15/185,272 US201615185272A US2016294072A1 US 20160294072 A1 US20160294072 A1 US 20160294072A1 US 201615185272 A US201615185272 A US 201615185272A US 2016294072 A1 US2016294072 A1 US 2016294072A1
- Authority
- US
- United States
- Prior art keywords
- conductor
- foil layer
- wire
- conductive foil
- terminal
- 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.)
- Abandoned
Links
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
- H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/023—Alloys based on aluminium
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/026—Alloys based on copper
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0036—Details
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/0009—Details relating to the conductive cores
- H01B7/0036—Alkali metal conductors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
- H01B7/2806—Protection against damage caused by corrosion
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
- H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
- H01R11/28—End pieces consisting of a ferrule or sleeve
- H01R11/281—End pieces consisting of a ferrule or sleeve for connections to batteries
-
- 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
- H01R4/187—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 combined with soldering or welding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
- H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
- H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
- H01R4/625—Soldered or welded connections
-
- 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
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
-
- 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
- H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
Definitions
- the articles and methods described below generally relate to the field of preparing a wire to receive a contact element.
- Automotive cables such as a battery cable, can include an aluminum conductor which can be lighter and less expensive than conventional copper conductors.
- a contact element such as a ring terminal, is crimped or otherwise secured to a bare end of the aluminum conductor to form a terminated end.
- the contact element is typically made from copper based alloys such as brass, for example, or another material that is different than aluminum.
- the bare end of aluminum conductor can be susceptible to oxidation (e.g., sapphire oxidation) which can inhibit conductivity between the bare end and the contact element and thus can prevent proper termination with a contact element.
- the aluminum conductor can also be susceptible to galvanic corrosion when it is terminated to a material that is more basic than aluminum, such as brass, and when moisture is present at the interface between the conductor and the contact element. The galvanic corrosion can cause aluminum dissolution which can adversely affect the conductivity between the aluminum conductor and the contact element.
- the aluminum conductor can be more susceptible to mechanical creep at its terminated end at low temperatures (e.g., 80 degrees C.) than conventional copper conductors which can result in undesirable impedances.
- the aluminum conductor is also weaker than a copper conductor which can result in the aluminum conductor being easier to pull out of the contact element after termination.
- a method for preparing a wire to accept a contact element comprises a conductor and an insulating layer surrounding the conductor.
- the conductor is formed of a first material.
- the method comprises removing the insulating layer from the conductor to expose a portion of the conductor.
- the method further comprises joining a conductive foil layer and at least a portion of the exposed portion of the conductor together.
- the conductive foil layer is formed of a second material.
- a method for installing a contact element on a wire comprises a conductor.
- the conductor comprises an exposed portion and is formed of a first material.
- the method comprises joining a conductive foil layer and the exposed portion of the conductor together.
- the method further comprises securing the contact element to the exposed portion of the conductor and the conductive foil layer.
- the conductive foil layer is formed of a second material.
- the terminal is formed of a third material.
- a terminated wire comprises a conductor.
- the conductor comprises an exposed portion and is formed of a first material.
- the terminated wire is prepared by the process of joining a conductive foil layer and an exposed portion of the conductor together and securing a contact element to the exposed portion of the conductor and the conductive foil layer.
- the conductive foil layer is formed of a second material.
- the contact element is formed of a third material.
- a terminated wire comprises a wire, a conductive foil layer, and a contact element.
- the wire comprises a conductor.
- the conductor comprises an exposed portion and is formed of a first material.
- the conductive foil layer is formed of a second material.
- the contact element is formed of a third material.
- the conductive foil layer is joined to the exposed portion of the conductor.
- the terminal is secured to the exposed portion of the conductor and the conductive foil layer.
- FIG. 1 is a perspective view depicting a wire, a conductive foil layer, and a terminal prior to the conductive foil layer being installed on a conductor of the wire, in accordance with one embodiment
- FIG. 2 is a perspective view depicting the conductive foil layer installed on the wire of FIG. 1 ;
- FIG. 3 is a perspective view of the terminal installed on the wire of FIG. 1 ;
- FIG. 4 is a cross-sectional view taken along the line 4 - 4 in FIG. 3 ;
- FIG. 5 is a perspective view depicting a wire, a conductive foil layer, and a terminal prior to the conductive foil layer being installed on a conductor of the wire, in accordance with another embodiment
- FIG. 6 is a perspective view of the terminal installed on the wire of FIG. 5 ;
- FIG. 7 is a cross-sectional view taken along the line 7 - 7 in FIG. 6 ;
- FIG. 8 a perspective view depicting a wire, a conductive foil layer, and a terminal prior to the conductive foil layer being installed on a conductor of the wire, in accordance with another embodiment
- FIG. 9 is a perspective view depicting a wire and ferrule prior to the ferrule being installed on a conductor of the wire, in accordance with another embodiment.
- FIG. 10 is a perspective view of the wire of FIG. 9 , but with the ferrule installed on the conductor.
- FIG. 1 illustrates a wire 10 having a conductor 12 and an insulating layer 14 surrounding the conductor 12 .
- a portion of the insulating layer 14 is shown to be removed from the conductor 12 to expose a bare of the conductor 12 .
- the insulating layer 14 can be removed with any of a variety of suitable methods, such as through interaction with a set of wire strippers.
- any of a variety of suitable alternative conductors can be used having different quantities/sizes of strands, including a conductor having an individual strand (e.g., a solid conductor) and/or being devoid of insulation (e.g., a grounding conductor.
- a conductive foil layer 18 can be attached to a portion of the bare portion 16 of the conductor 12 .
- the conductive foil layer 18 can be wrapped around the bare portion 16 of the conductor 12 , as illustrated in FIG. 2 , and pressure can be applied to the conductive foil layer 18 (in the direction of the arrows P).
- the application of pressure to the conductive foil layer 18 can be the result of simply overlying the conductive foil layer 18 onto the bare portion 16 of the conductor 12 (e.g., by grasping the ends of the conductive foil layer 18 and wrapping it around the bare portion 16 ).
- the desired pressure can be applied by hand, with a tool (e.g., pliers), or any of a variety of other suitable methods.
- the terminal 20 can be nickel plated, or plated with another conductive material, prior to attachment of the terminal 20 to the conductor 12 .
- the nickel plating can protect the terminal from galvanic corrosion to enhance the conductivity between the conductor 12 and the material that forms the terminal 20 (e.g., brass).
- the terminated end can additionally or alternatively be dipped in molten solder to enhance durability of the terminated wire 21 .
- the terminal 20 is shown to be a ring terminal, it is to be appreciated that any of a variety of suitable alternative contact elements, such as a slotted terminal, a bus bar, or a termination block, for example, can be attached to the wire 10 .
- the terminated wire 21 is contemplated for use in a variety of suitable applications, such as, for example, as a vehicular battery cable.
- the conductor 12 and the conductive foil layer 18 can be formed of different conductive materials with the conductive foil layer 18 having about the same or higher conductivity than the conductor 12 .
- the conductive foil layer 18 can enhance the overall conductivity between the conductor 12 and the terminal 20 as compared to the conductive foil layer 18 not being present (i.e., the conductor 12 and the terminal 20 being entirely in contact with each other).
- the conductor 12 can be formed of aluminum or an aluminum alloy
- the conductive foil layer 18 can be formed of copper
- the terminal 20 can be formed of brass.
- the copper of the conductive foil layer 18 can allow the interaction between the aluminum conductor 12 and the brass terminal 20 to be more conductive than crimping the brass terminal 20 directly to the aluminum conductor 12 (which in some instances can be non-conductive).
- the conductive foil layer 18 can be formed of a material that is as conductive as or more conductive than the conductor 12 .
- the conductor 12 can be formed of a conductive material having a conductivity of about 3.5*10 7 S/m (at 20 degrees C.) or less, and the conductive foil layer 18 can be formed of conductive material having a conductivity of about 4.1*10 7 S/m (at 20 degrees C.) or more.
- the conductor 12 can be formed of a conductive material that is substantially susceptible to oxidation, such as an aluminum alloy, a chromium alloy, and/or a magnesium alloy
- the conductive foil layer 18 can be formed of conductive material that is not substantially susceptible to oxidization such as a copper alloy, silver, nickel, and/or gold.
- the different metals described above for the conductor 12 , the conductive foil layer 18 , and the terminal 20 can be any of a variety of different metals or metal alloys, such as, for example copper or copper alloys, such as brass.
- the conductive foil layer 18 is shown to have a length L 1 , a width W, and a thickness T and the bare portion 16 of the conductor 12 is shown to have a length L 2 , a diameter D, and a circumference C.
- the length L 1 and width W of the conductive foil layer 18 can be less than the circumference C and the length L 2 of the bare portion 16 of the conductor 12 , respectively, such that when the conductive foil layer 18 is attached to the conductor 12 , the conductive foil layer 18 neither reaches the end of the conductor 12 nor completely surrounds it.
- the length L 1 of the conductive foil layer 18 can be more than the circumference C of the bare portion 16 of the conductor 12 , respectively, such that when the conductive foil layer 18 is attached to the conductor 12 , the conductive foil layer 18 overlaps at its ends such that it entirely surrounds the bare portion 16 .
- the diameter D of the conductor can be significantly more than the thickness T of the conductive foil layer 18 , and can in certain embodiments have a ratio of between about 100:1 and about 500:1 and in certain embodiments can have a ratio of about 200:1.
- the length L 1 can be about 40 mm
- the width W can be about 18 mm
- the thickness T can be about 0.035 mm
- the length L 2 can be about 20 mm
- the diameter D can be about 8 mm
- the circumference C can be about 25 mm.
- a layer described herein as being a foil, such as conductive foil layer 18 should be understood to mean that the layer is a sheet-like substrate having a length and width that are substantially greater than the thickness of the substrate.
- ratio of the combined length and width of the layer to the thickness of the layer can be between about 500:1 to about 100,000:1. In certain embodiments, the ratio can be about 10,000:1 to about 25,000:1 and preferably about 14,000:1
- the bare portion 16 of the conductor 12 can be cleaned before or after application of the conductive foil layer 18 to remove any oxides on the conductor 12 and/or between the conductor 12 and the conductive foil layer thus enhancing the effectiveness of the conductivity between the conductor 12 , the conductive foil layer 18 , and the terminal 20 .
- the conductor 12 and/or conductive foil layer 18 can be cleaned via a plasma treatment performed by a blown-ion air system (not shown). The blown-ion air system can force pressurized air towards an electrode, through a narrow nozzle, and onto the bare portion 16 .
- the bare portion 16 of the conductor 12 and the conductive foil layer 18 can be joined by soldering such as by dipping the bare portion 16 and the conductive foil layer 18 together in a molten material (e.g., such as molten tin) or resistance soldering the bare portion 16 and the conductive foil layer 18 together, for example, both of which can enhance the conductivity between the bare portion 16 , the conductive foil layer 18 , and the terminal 20 .
- a molten material e.g., such as molten tin
- resistance soldering the bare portion 16 and the conductive foil layer 18 together for example, both of which can enhance the conductivity between the bare portion 16 , the conductive foil layer 18 , and the terminal 20 .
- cleaning the bare portion 16 and/or the conductive foil layer 18 can encourage the application of solder.
- the soldering can be performed in addition to the welding or in addition to or in lieu of the cleaning described above.
- FIGS. 5-7 illustrate a wire 110 , a conductive foil layer 118 and a terminal 120 that are similar to, or the same in many respects as, the wire 10 , the conductive foil layer 18 and the terminal 120 , respectively, illustrated in FIGS. 1-4 .
- the wire 110 can include a conductor 112 , an insulating layer 114 , a bare portion 116 , and a conductive foil layer 118 .
- the conductive foil layer 118 can be joined to the bare portion 116 of the conductor 112 by applying pressure to the conductive foil layer 118 (in the direction of the arrows P) and without any welding (ultrasonic or otherwise).
- the terminal 20 can be slid over the bundle of strands (e.g., 123 ) at the bare portion 16 and secured to the bundle of strands (e.g., 123 ), such as with a crimping tool, for example.
- An exterior surface 122 of a crimping portion 124 of the terminal 120 can be reinforced, such as by applying solder 126 at a separation point 128 of the crimping portion 124 .
- FIG. 8 illustrates a wire 210 , a conductive foil layer 218 and a terminal 220 that are similar to, or the same, in many respects as the wire 10 , the conductive foil layer 18 and the terminal 20 , respectively, illustrated in FIGS. 1-4 .
- the wire 210 can include a conductor 212 , an insulating layer 214 , and a bare portion 216 .
- the conductive foil layer 218 can be a corrugated screen having a plurality of elevated portions (e.g., points) distributed along upper and lower surfaces (upper surface 230 shown).
- the points can abrade the bare portion 216 of the conductor 212 (e.g., remove any oxidation) to facilitate effective electrical contact between the bare portion and the conductive foil layer 218 . If the bare portion 216 and the conductive foil layer 218 are joined by soldering, as described above, the solder can collect in pockets defined between the points to facilitate effective bonding between the bare portion 216 and the conductive foil layer 218 .
- the conductive foil layer 218 can be formed of nickel and the conductor 212 can be formed of aluminum 212 .
- FIGS. 9-10 illustrate a wire 310 that is similar to, or the same, in many respects as the wire 10 illustrated in FIGS. 1-4 .
- the wire 310 can include a conductor 312 , an insulating layer 314 , and a bare portion 316 .
- a ferrule 331 can be provided in lieu of, or in addition to, a conductive foil layer (e.g., 18 ).
- the ferrule 331 can be joined to the bare portion similarly as described above and a terminal (not shown) can then be secured thereto.
- a terminated wire e.g., an alternative terminated wire
- the alternative terminated wire can be similar in many respects to the terminated wire 21 described above except that the alternative terminated wire does not include a conductive foil layer (e.g., 18 ).
- a portion of an insulating layer e.g., 14
- a conductor e.g., 12
- a bare portion e.g., 16
- the bare portion can then be cleaned (e.g., with a plasma treatment) and welded (e.g., through ultrasonic welding) to bind individual strands of the conductor together.
- the steps of cleaning and welding can be performed in any order. Once welded, the bare portion can be soldered (e.g., through tin dipping or resistive soldering). A terminal (e.g., 20 ) can then be attached to the bare portion insulating layer to create the alternative terminated wire.
- the conductor 112 can be formed of aluminum and the conductive foil layer can be formed of nickel.
- the terminated wire that was tested was a 0 AWG (I/O) aluminum wire having a bare portion (e.g., 14 ) measuring about 20 mm, a copper conductive foil layer (e.g., 18 ) having a length (e.g., L 1 ) of about 40 mm, a width (e.g., W) of about 18 mm, and a thickness (e.g., T) of about 0.035 mm, and a brass terminal.
- the copper conductive foil layer was manually wrapped onto the bare portion and then was ultrasonically welded to form a nugget. A terminal was then crimped onto the nugget.
- Comparative testing was also conducted to compare the results for different terminations of a 0 AWG (I/O) aluminum wire having a bare portion (e.g., 14 ) measuring about 20 mm, a copper conductive foil layer (e.g., 18 ) having a length (e.g., L 1 ) of about 40 mm, a width (e.g., W) of about 20 mm, and a thickness (e.g., T) of about 0.035 mm, and a brass terminal.
- a variety of different terminated wires were assembled using certain of the methodologies described above and resistance tests were performed on the terminated wires. The results of the resistance tests are as follows:
- Example Termination Method Resistance (Ohms)
- Example #2 Terminated Conductor Prepared 0.345 milliohms and Terminated Without Conductive Foil Layer as followss: 1.
- Ultrasonically Weld Bare Conductor 2.
- Plasma Clean Welded Bare Conductor 3.
- Dip Bare Conductor in Molten Solder 4.
- Crimp Terminal to Soldered End of Bare Conductor. 5.
- Resistance Solder Outer Surface of Terminal Example #3 Terminated Conductor Prepared 0.179 milliohms and Terminated Without Conductive Foil Layer as followss: 1.
- Plasma Clean Bare Conductor 2.
- Ultrasonically Weld Bare Conductor 3.
- Plasma Clean Bare Conductor 4. Dip Bare Conductor in Molten Solder 5.
- Terminated Conductor Prepared 0.046 milliohms and Terminated With Solid Copper Conductive Foil Layer as follows: 1. Ultrasonically Weld Bare Conductor and Conductive Foil Layer Together 2. Dip Welded End in Molten Solder 3. Crimp Terminal to Soldered End of Bare Conductor. 4. Resistance Solder Outer Surface of Terminal
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Connections By Means Of Piercing Elements, Nuts, Or Screws (AREA)
- Manufacturing Of Electrical Connectors (AREA)
- Ropes Or Cables (AREA)
Abstract
Description
- This application is a continuation application of U.S. patent application Ser. No. 14/873,237, filed Oct. 2, 2015, which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/059,317, filed Oct. 3, 2014, the contents of each of which are incorporated herein by reference.
- The articles and methods described below generally relate to the field of preparing a wire to receive a contact element.
- Automotive cables, such as a battery cable, can include an aluminum conductor which can be lighter and less expensive than conventional copper conductors. A contact element, such as a ring terminal, is crimped or otherwise secured to a bare end of the aluminum conductor to form a terminated end. The contact element is typically made from copper based alloys such as brass, for example, or another material that is different than aluminum.
- The bare end of aluminum conductor, however, can be susceptible to oxidation (e.g., sapphire oxidation) which can inhibit conductivity between the bare end and the contact element and thus can prevent proper termination with a contact element. The aluminum conductor can also be susceptible to galvanic corrosion when it is terminated to a material that is more basic than aluminum, such as brass, and when moisture is present at the interface between the conductor and the contact element. The galvanic corrosion can cause aluminum dissolution which can adversely affect the conductivity between the aluminum conductor and the contact element. Once terminated, the aluminum conductor can be more susceptible to mechanical creep at its terminated end at low temperatures (e.g., 80 degrees C.) than conventional copper conductors which can result in undesirable impedances. The aluminum conductor is also weaker than a copper conductor which can result in the aluminum conductor being easier to pull out of the contact element after termination.
- In accordance with one embodiment, a method for preparing a wire to accept a contact element is provided. The wire comprises a conductor and an insulating layer surrounding the conductor. The conductor is formed of a first material. The method comprises removing the insulating layer from the conductor to expose a portion of the conductor. The method further comprises joining a conductive foil layer and at least a portion of the exposed portion of the conductor together. The conductive foil layer is formed of a second material.
- In accordance with another embodiment, a method for installing a contact element on a wire is provided. The wire comprises a conductor. The conductor comprises an exposed portion and is formed of a first material. The method comprises joining a conductive foil layer and the exposed portion of the conductor together. The method further comprises securing the contact element to the exposed portion of the conductor and the conductive foil layer. The conductive foil layer is formed of a second material. The terminal is formed of a third material.
- In accordance with yet another embodiment, a terminated wire comprises a conductor. The conductor comprises an exposed portion and is formed of a first material. The terminated wire is prepared by the process of joining a conductive foil layer and an exposed portion of the conductor together and securing a contact element to the exposed portion of the conductor and the conductive foil layer. The conductive foil layer is formed of a second material. The contact element is formed of a third material.
- In accordance with yet another embodiment, a terminated wire comprises a wire, a conductive foil layer, and a contact element. The wire comprises a conductor. The conductor comprises an exposed portion and is formed of a first material. The conductive foil layer is formed of a second material. The contact element is formed of a third material. The conductive foil layer is joined to the exposed portion of the conductor. The terminal is secured to the exposed portion of the conductor and the conductive foil layer.
- It is believed that certain embodiments will be better understood from the following description taken in conjunction with the accompanying drawings in which:
-
FIG. 1 is a perspective view depicting a wire, a conductive foil layer, and a terminal prior to the conductive foil layer being installed on a conductor of the wire, in accordance with one embodiment; -
FIG. 2 is a perspective view depicting the conductive foil layer installed on the wire ofFIG. 1 ; -
FIG. 3 is a perspective view of the terminal installed on the wire ofFIG. 1 ; -
FIG. 4 is a cross-sectional view taken along the line 4-4 inFIG. 3 ; -
FIG. 5 is a perspective view depicting a wire, a conductive foil layer, and a terminal prior to the conductive foil layer being installed on a conductor of the wire, in accordance with another embodiment; -
FIG. 6 is a perspective view of the terminal installed on the wire ofFIG. 5 ; -
FIG. 7 is a cross-sectional view taken along the line 7-7 inFIG. 6 ; -
FIG. 8 a perspective view depicting a wire, a conductive foil layer, and a terminal prior to the conductive foil layer being installed on a conductor of the wire, in accordance with another embodiment; -
FIG. 9 is a perspective view depicting a wire and ferrule prior to the ferrule being installed on a conductor of the wire, in accordance with another embodiment; and -
FIG. 10 is a perspective view of the wire ofFIG. 9 , but with the ferrule installed on the conductor. - In connection with the views and examples of
FIGS. 1-10 , wherein like numbers indicate the same or corresponding elements throughout the views,FIG. 1 illustrates awire 10 having aconductor 12 and aninsulating layer 14 surrounding theconductor 12. A portion of theinsulating layer 14 is shown to be removed from theconductor 12 to expose a bare of theconductor 12. The insulatinglayer 14 can be removed with any of a variety of suitable methods, such as through interaction with a set of wire strippers. Although a multi-strand insulated conductor is shown, it will be appreciated that any of a variety of suitable alternative conductors can be used having different quantities/sizes of strands, including a conductor having an individual strand (e.g., a solid conductor) and/or being devoid of insulation (e.g., a grounding conductor. - As illustrated in
FIGS. 1 and 2 , aconductive foil layer 18 can be attached to a portion of thebare portion 16 of theconductor 12. In one embodiment, theconductive foil layer 18 can be wrapped around thebare portion 16 of theconductor 12, as illustrated inFIG. 2 , and pressure can be applied to the conductive foil layer 18 (in the direction of the arrows P). In one embodiment, the application of pressure to theconductive foil layer 18 can be the result of simply overlying theconductive foil layer 18 onto thebare portion 16 of the conductor 12 (e.g., by grasping the ends of theconductive foil layer 18 and wrapping it around the bare portion 16). In certain embodiments, the desired pressure can be applied by hand, with a tool (e.g., pliers), or any of a variety of other suitable methods. - Once the
conductive foil layer 18 has been provided onto thebare portion 16 of theconductor 12, thebare portion 16 of theconductor 12 and theconductive foil layer 18 can be joined together. In one embodiment, thebare portion 16 and theconductive foil layer 18 can be joined together through welding, such as through ultrasonic welding, for example. Welding thebare portion 16 and theconductive foil layer 18 together can bond theconductive foil layer 18 to theconductor 12 as well as bond the strands of theconductor 12 together to form an amalgamated mass (e.g., a nugget). Welding can also help break apart any oxidation formed on theconductor 12 that might adversely affect the conductivity between theconductor 12 and theconductive foil layer 18. Welding can accordingly enhance the conductivity characteristics between theconductor 12 and theconductive foil layer 18. - Once the
conductor 12 and theconductive foil layer 18 have been joined together, a terminal 20 can be slid over theconductive foil layer 18 and secured to the amalgamated mass of thebare portion 16 and theconductor 12, such as with a crimping tool, for example, to create a terminatedwire 21, as illustrated inFIGS. 3 and 4 . In one embodiment, as illustrated inFIG. 3 , anexterior surface 22 of a crimpingportion 24 of the terminal 20 can be reinforced, such as by applyingsolder 26 at aseparation point 28 of the crimpingportion 24, to enhance the durability of the connection between the terminal 20 and theconductor 12. In certain embodiments, the terminal 20 can be nickel plated, or plated with another conductive material, prior to attachment of the terminal 20 to theconductor 12. In such an embodiment, the nickel plating can protect the terminal from galvanic corrosion to enhance the conductivity between theconductor 12 and the material that forms the terminal 20 (e.g., brass). The terminated end can additionally or alternatively be dipped in molten solder to enhance durability of the terminatedwire 21. It is to be appreciated that although the terminal 20 is shown to be a ring terminal, it is to be appreciated that any of a variety of suitable alternative contact elements, such as a slotted terminal, a bus bar, or a termination block, for example, can be attached to thewire 10. It is also to be appreciated that the terminatedwire 21 is contemplated for use in a variety of suitable applications, such as, for example, as a vehicular battery cable. - The
conductor 12 and theconductive foil layer 18 can be formed of different conductive materials with theconductive foil layer 18 having about the same or higher conductivity than theconductor 12. As a result, when theconductive foil layer 18 is interposed between theconductor 12 and the terminal 20, theconductive foil layer 18 can enhance the overall conductivity between theconductor 12 and the terminal 20 as compared to theconductive foil layer 18 not being present (i.e., theconductor 12 and the terminal 20 being entirely in contact with each other). In one embodiment, theconductor 12 can be formed of aluminum or an aluminum alloy, theconductive foil layer 18 can be formed of copper, and the terminal 20 can be formed of brass. In such an embodiment, the copper of theconductive foil layer 18 can allow the interaction between thealuminum conductor 12 and thebrass terminal 20 to be more conductive than crimping thebrass terminal 20 directly to the aluminum conductor 12 (which in some instances can be non-conductive). It is to be appreciated that theconductive foil layer 18 can be formed of a material that is as conductive as or more conductive than theconductor 12. In certain embodiments, theconductor 12 can be formed of a conductive material having a conductivity of about 3.5*107 S/m (at 20 degrees C.) or less, and theconductive foil layer 18 can be formed of conductive material having a conductivity of about 4.1*107 S/m (at 20 degrees C.) or more. In other embodiments, theconductor 12 can be formed of a conductive material that is substantially susceptible to oxidation, such as an aluminum alloy, a chromium alloy, and/or a magnesium alloy, and theconductive foil layer 18 can be formed of conductive material that is not substantially susceptible to oxidization such as a copper alloy, silver, nickel, and/or gold. It is to be appreciated that the different metals described above for theconductor 12, theconductive foil layer 18, and the terminal 20 can be any of a variety of different metals or metal alloys, such as, for example copper or copper alloys, such as brass. - As illustrated in
FIG. 1 , theconductive foil layer 18 is shown to have a length L1, a width W, and a thickness T and thebare portion 16 of theconductor 12 is shown to have a length L2, a diameter D, and a circumference C. In one embodiment, the length L1 and width W of theconductive foil layer 18 can be less than the circumference C and the length L2 of thebare portion 16 of theconductor 12, respectively, such that when theconductive foil layer 18 is attached to theconductor 12, theconductive foil layer 18 neither reaches the end of theconductor 12 nor completely surrounds it. In another embodiment, the length L1 of theconductive foil layer 18 can be more than the circumference C of thebare portion 16 of theconductor 12, respectively, such that when theconductive foil layer 18 is attached to theconductor 12, theconductive foil layer 18 overlaps at its ends such that it entirely surrounds thebare portion 16. In certain embodiments, the diameter D of the conductor can be significantly more than the thickness T of theconductive foil layer 18, and can in certain embodiments have a ratio of between about 100:1 and about 500:1 and in certain embodiments can have a ratio of about 200:1. In one embodiment, for a 0 AWG wire, the length L1 can be about 40 mm, the width W can be about 18 mm, the thickness T can be about 0.035 mm, the length L2 can be about 20 mm, the diameter D can be about 8 mm, and the circumference C can be about 25 mm. It will be appreciated that a layer described herein as being a foil, such asconductive foil layer 18, should be understood to mean that the layer is a sheet-like substrate having a length and width that are substantially greater than the thickness of the substrate. In certain embodiments, ratio of the combined length and width of the layer to the thickness of the layer can be between about 500:1 to about 100,000:1. In certain embodiments, the ratio can be about 10,000:1 to about 25,000:1 and preferably about 14,000:1 - In some embodiments, the
bare portion 16 of theconductor 12, alone or in combination with theconductive foil layer 18, can be cleaned before or after application of theconductive foil layer 18 to remove any oxides on theconductor 12 and/or between theconductor 12 and the conductive foil layer thus enhancing the effectiveness of the conductivity between theconductor 12, theconductive foil layer 18, and the terminal 20. In one embodiment, theconductor 12 and/orconductive foil layer 18 can be cleaned via a plasma treatment performed by a blown-ion air system (not shown). The blown-ion air system can force pressurized air towards an electrode, through a narrow nozzle, and onto thebare portion 16. The electrode creates positively charged ions in the pressurized air which is then accelerated by the nozzle and provided onto thebare portion 16 of theconductor 12. The positively charged ions in the airstream positively charge the outer surface of thebare portion 16 thereby increasing its surface energy to remove any oxides. In another embodiment, theconductor 12 and/orconductive foil layer 18 can be cleaned via a high temperature induction heating process that applies a flame to theconductor 12 and/orconductive foil layer 18 using any of a variety of fuels, such as, for example, hydrogen gas, alcohol, and/or acetylene. - In certain embodiments, the
bare portion 16 of theconductor 12 and theconductive foil layer 18 can be joined by soldering such as by dipping thebare portion 16 and theconductive foil layer 18 together in a molten material (e.g., such as molten tin) or resistance soldering thebare portion 16 and theconductive foil layer 18 together, for example, both of which can enhance the conductivity between thebare portion 16, theconductive foil layer 18, and the terminal 20. It is to be appreciated that cleaning thebare portion 16 and/or theconductive foil layer 18 can encourage the application of solder. However, the soldering can be performed in addition to the welding or in addition to or in lieu of the cleaning described above. It is also to be appreciated that thebare portion 16 and/or theconductive foil layer 18 can undergo any of a variety of other suitable treatment processes to prepare for affixation of the terminal 20. -
FIGS. 5-7 illustrate awire 110, aconductive foil layer 118 and a terminal 120 that are similar to, or the same in many respects as, thewire 10, theconductive foil layer 18 and the terminal 120, respectively, illustrated inFIGS. 1-4 . For example, thewire 110 can include aconductor 112, an insulating layer 114, abare portion 116, and aconductive foil layer 118. However, theconductive foil layer 118 can be joined to thebare portion 116 of theconductor 112 by applying pressure to the conductive foil layer 118 (in the direction of the arrows P) and without any welding (ultrasonic or otherwise). In such an arrangement, the terminal 20 can be slid over the bundle of strands (e.g., 123) at thebare portion 16 and secured to the bundle of strands (e.g., 123), such as with a crimping tool, for example. Anexterior surface 122 of a crimpingportion 124 of the terminal 120 can be reinforced, such as by applyingsolder 126 at aseparation point 128 of the crimpingportion 124. -
FIG. 8 illustrates awire 210, aconductive foil layer 218 and a terminal 220 that are similar to, or the same, in many respects as thewire 10, theconductive foil layer 18 and the terminal 20, respectively, illustrated inFIGS. 1-4 . For example, thewire 210 can include aconductor 212, an insulatinglayer 214, and abare portion 216. Theconductive foil layer 218, however, can be a corrugated screen having a plurality of elevated portions (e.g., points) distributed along upper and lower surfaces (upper surface 230 shown). When theconductive foil layer 218 is attached to thebare portion 216 of theconductor 212, the points can abrade thebare portion 216 of the conductor 212 (e.g., remove any oxidation) to facilitate effective electrical contact between the bare portion and theconductive foil layer 218. If thebare portion 216 and theconductive foil layer 218 are joined by soldering, as described above, the solder can collect in pockets defined between the points to facilitate effective bonding between thebare portion 216 and theconductive foil layer 218. In one embodiment, theconductive foil layer 218 can be formed of nickel and theconductor 212 can be formed ofaluminum 212. -
FIGS. 9-10 illustrate awire 310 that is similar to, or the same, in many respects as thewire 10 illustrated inFIGS. 1-4 . For example, thewire 310 can include aconductor 312, an insulatinglayer 314, and abare portion 316. Aferrule 331, however, can be provided in lieu of, or in addition to, a conductive foil layer (e.g., 18). Theferrule 331 can be joined to the bare portion similarly as described above and a terminal (not shown) can then be secured thereto. - Another alternative embodiment of a terminated wire (e.g., an alternative terminated wire) is also contemplated. The alternative terminated wire can be similar in many respects to the terminated
wire 21 described above except that the alternative terminated wire does not include a conductive foil layer (e.g., 18). To prepare the alternative terminated wire, a portion of an insulating layer (e.g., 14) can be removed from a conductor (e.g., 12) to expose a bare portion (e.g., 16) of the conductor (e.g., 12). The bare portion can then be cleaned (e.g., with a plasma treatment) and welded (e.g., through ultrasonic welding) to bind individual strands of the conductor together. The steps of cleaning and welding can be performed in any order. Once welded, the bare portion can be soldered (e.g., through tin dipping or resistive soldering). A terminal (e.g., 20) can then be attached to the bare portion insulating layer to create the alternative terminated wire. In one embodiment, theconductor 112 can be formed of aluminum and the conductive foil layer can be formed of nickel. - Testing was conducted on a terminated wire similar to the terminated
wire 21 described above. The terminated wire that was tested was a 0 AWG (I/O) aluminum wire having a bare portion (e.g., 14) measuring about 20 mm, a copper conductive foil layer (e.g., 18) having a length (e.g., L1) of about 40 mm, a width (e.g., W) of about 18 mm, and a thickness (e.g., T) of about 0.035 mm, and a brass terminal. The copper conductive foil layer was manually wrapped onto the bare portion and then was ultrasonically welded to form a nugget. A terminal was then crimped onto the nugget. Ten separate resistance tests were then performed to measure the resistance between the conductor and the terminal (e.g., between points A and B illustrated onFIG. 3 ). Each test resulted in a resistance between 0.041 Ohms and 0.045 Ohms, having an example resistance of 0.043 Ohms. The maximum allowable resistance for use as a vehicular battery cable is 0.057 Ohms. - Comparative testing was also conducted to compare the results for different terminations of a 0 AWG (I/O) aluminum wire having a bare portion (e.g., 14) measuring about 20 mm, a copper conductive foil layer (e.g., 18) having a length (e.g., L1) of about 40 mm, a width (e.g., W) of about 20 mm, and a thickness (e.g., T) of about 0.035 mm, and a brass terminal. A variety of different terminated wires were assembled using certain of the methodologies described above and resistance tests were performed on the terminated wires. The results of the resistance tests are as follows:
-
Example Termination Method Resistance (Ohms) Example #1 Bare Conductor with Terminal Open Circuit Crimped Directly to Bare Conductor (high resistance) Example #2 Terminated Conductor Prepared 0.345 milliohms and Terminated Without Conductive Foil Layer as Follows: 1. Ultrasonically Weld Bare Conductor 2. Plasma Clean Welded Bare Conductor 3. Dip Bare Conductor in Molten Solder 4. Crimp Terminal to Soldered End of Bare Conductor. 5. Resistance Solder Outer Surface of Terminal Example #3 Terminated Conductor Prepared 0.179 milliohms and Terminated Without Conductive Foil Layer as Follows: 1. Plasma Clean Bare Conductor 2. Ultrasonically Weld Bare Conductor 3. Plasma Clean Bare Conductor 4. Dip Bare Conductor in Molten Solder 5. Crimp Terminal to Soldered End of Bare Conductor. 6. Resistance Solder Outer Surface of Terminal Example # 4 Terminated Conductor Prepared 0.046 milliohms and Terminated With Solid Copper Conductive Foil Layer as Follows: 1. Ultrasonically Weld Bare Conductor and Conductive Foil Layer Together 2. Dip Welded End in Molten Solder 3. Crimp Terminal to Soldered End of Bare Conductor. 4. Resistance Solder Outer Surface of Terminal - The foregoing description of embodiments and examples of the disclosure has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed and others will be understood by those skilled in the art. The embodiments were chosen and described in order to best illustrate the principles of the disclosure and various embodiments as are suited to the particular use contemplated. The scope of the disclosure is, of course, not limited to the examples or embodiments set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art. Rather it is hereby intended the scope of the invention be defined by the claims appended hereto. Also, for any methods claimed and/or described, regardless of whether the method is described in conjunction with a flow diagram, it should be understood that unless otherwise specified or required by context, any explicit or implicit ordering of steps performed in the execution of a method does not imply that those steps must be performed in the order presented and may be performed in a different order or in parallel.
Claims (8)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/185,272 US20160294072A1 (en) | 2014-10-03 | 2016-06-17 | Wire and methods for preparing a wire to receive a contact element |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201462059317P | 2014-10-03 | 2014-10-03 | |
US14/873,237 US9647348B2 (en) | 2014-10-03 | 2015-10-02 | Method for preparing a wire to receive a contact element |
US15/185,272 US20160294072A1 (en) | 2014-10-03 | 2016-06-17 | Wire and methods for preparing a wire to receive a contact element |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/873,237 Continuation US9647348B2 (en) | 2014-10-03 | 2015-10-02 | Method for preparing a wire to receive a contact element |
Publications (1)
Publication Number | Publication Date |
---|---|
US20160294072A1 true US20160294072A1 (en) | 2016-10-06 |
Family
ID=55631613
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/873,237 Active US9647348B2 (en) | 2014-10-03 | 2015-10-02 | Method for preparing a wire to receive a contact element |
US15/185,272 Abandoned US20160294072A1 (en) | 2014-10-03 | 2016-06-17 | Wire and methods for preparing a wire to receive a contact element |
US15/587,799 Active US9991608B2 (en) | 2014-10-03 | 2017-05-05 | Wire and methods for preparing a wire to receive a contact element |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/873,237 Active US9647348B2 (en) | 2014-10-03 | 2015-10-02 | Method for preparing a wire to receive a contact element |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/587,799 Active US9991608B2 (en) | 2014-10-03 | 2017-05-05 | Wire and methods for preparing a wire to receive a contact element |
Country Status (5)
Country | Link |
---|---|
US (3) | US9647348B2 (en) |
JP (1) | JP6704391B2 (en) |
CA (1) | CA2963462C (en) |
MX (1) | MX2017004178A (en) |
WO (1) | WO2016054516A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11611173B2 (en) * | 2018-01-08 | 2023-03-21 | K-Tronics (Suzhou) Technology Co., Ltd. | Mounting seat for electronic device and electronic apparatus |
Families Citing this family (19)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102013201167A1 (en) * | 2013-01-24 | 2014-08-07 | Elringklinger Ag | A method of making an electrically conductive connection between an electrical lead and an electrically conductive member and assembly manufactured by the method |
US20180219303A1 (en) * | 2017-02-02 | 2018-08-02 | Hubbell Incorporated | Terminal connectors |
DE102017106742B3 (en) * | 2017-03-29 | 2018-03-08 | Auto-Kabel Management Gmbh | Connection of a connection part with a stranded wire |
DE102017113837B3 (en) * | 2017-06-22 | 2018-03-29 | Lisa Dräxlmaier GmbH | METHOD FOR SEALING A JOINT AREA OF AN ELECTRICAL CONNECTION ASSEMBLY AND ELECTRICAL CONNECTION ASSEMBLY |
DE102017121908B4 (en) | 2017-09-21 | 2023-12-07 | Tdk Electronics Ag | Electrical component with stranded contact and method for producing a stranded contact |
DE102017121924B3 (en) * | 2017-09-21 | 2019-02-21 | Tdk Electronics Ag | Electrical component with connection area and method for producing a connection area |
DE102017124693B3 (en) * | 2017-10-23 | 2018-11-29 | Lisa Dräxlmaier GmbH | Method for integrally joining an electrical line to an electrical contact part |
WO2019090043A1 (en) | 2017-11-03 | 2019-05-09 | Elco Enterprises, Inc. | Ultrasonic welded cable for a welding system |
WO2020018510A1 (en) | 2018-07-20 | 2020-01-23 | Elco Enterprises, Inc. | Electrical cable having at least one consolidated end |
DE102018121239A1 (en) * | 2018-08-30 | 2020-03-05 | Rosenberger Hochfrequenztechnik Gmbh & Co. Kg | MULTI-WIRE CABLE |
HUE057988T2 (en) * | 2018-11-14 | 2022-06-28 | Rogers Bv | Method for manufacturing a busbar and such a busbar |
DE102018008994A1 (en) * | 2018-11-15 | 2020-05-20 | Gentherm Gmbh | Assembly |
JP6743927B1 (en) * | 2019-02-14 | 2020-08-19 | 住友電装株式会社 | Ground terminal and wire harness |
DE102019119453A1 (en) * | 2019-04-17 | 2020-10-22 | Metzner Maschinenbau Gmbh | Method, device and system for assembling an electrical cable |
JP2021111576A (en) * | 2020-01-15 | 2021-08-02 | 住友電装株式会社 | Connection component, electric wire with terminal, and wire harness |
USD936011S1 (en) * | 2020-02-06 | 2021-11-16 | Aptiv Technologies Limited | Electrical terminal |
CN111462946A (en) * | 2020-04-01 | 2020-07-28 | 吉林省中赢高科技有限公司 | Copper-aluminum composite electric energy transmission system and processing method thereof |
JP7225166B2 (en) * | 2020-07-22 | 2023-02-20 | 矢崎総業株式会社 | Electric wire manufacturing method and electric wire manufacturing apparatus |
DE102021125134B3 (en) * | 2021-09-28 | 2023-02-02 | Strunk Connect automated solutions GmbH & Co. KG | Process for welding an aluminum electrical cable to a connection element made from a dissimilar metal material |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3364460A (en) * | 1964-11-09 | 1968-01-16 | Thomas & Betts Corp | Seamed sleeve connector |
US20120329343A1 (en) * | 2010-04-01 | 2012-12-27 | Yazaki Corporation | Connection structure of crimping terminal to electric wire |
Family Cites Families (29)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2655641A (en) | 1948-10-29 | 1953-10-13 | Aircraft Marine Prod Inc | Electrical connector having a mercury amalgam coating on its inner surface |
US2815497A (en) | 1953-04-23 | 1957-12-03 | Amp Inc | Connector for aluminum wire |
US3247316A (en) * | 1964-04-22 | 1966-04-19 | Amp Inc | Electrical connector for terminating aluminum foil |
US3541227A (en) * | 1968-11-13 | 1970-11-17 | Amp Inc | Terminal for interconnecting foil conductor and wire conductor |
US3656092A (en) | 1970-08-07 | 1972-04-11 | Amp Inc | Terminal device for welded termination of electrical leads |
US3955044A (en) | 1970-12-03 | 1976-05-04 | Amp Incorporated | Corrosion proof terminal for aluminum wire |
US3716909A (en) * | 1972-04-13 | 1973-02-20 | Aluminum Co Of America | Improved method of soldering |
US3988563A (en) * | 1972-11-09 | 1976-10-26 | Amp Incorporated | Welding method and means using foil electrode |
US4030967A (en) | 1976-08-16 | 1977-06-21 | Northern Telecom Limited | Gaseous plasma etching of aluminum and aluminum oxide |
US5425832A (en) * | 1990-10-05 | 1995-06-20 | Bridgestone Corporation | Surface treatment of fluoropolymer members and preparation of composite products therefrom |
JPH07115276A (en) * | 1992-03-12 | 1995-05-02 | Hitachi Chem Co Ltd | Manufacture of wiring board circuit board and manufacture of wiring board using the wiring board circuit board |
JP2000299140A (en) | 1999-04-15 | 2000-10-24 | Yazaki Corp | Connection method and structure between electric wire and connection terminal |
US6730848B1 (en) * | 2001-06-29 | 2004-05-04 | Antaya Technologies Corporation | Techniques for connecting a lead to a conductor |
DE10223397B4 (en) | 2003-10-04 | 2004-05-06 | Feindrahtwerk Adolf Edelhoff Gmbh & Co | Method and connection for contacting an aluminum cable with a metallic, tin-plated contact terminal |
JP4326797B2 (en) | 2002-12-26 | 2009-09-09 | 株式会社オートネットワーク技術研究所 | Connection structure between wires and terminal fittings |
DE10357048A1 (en) | 2003-12-04 | 2005-07-21 | Leoni Bordnetz-Systeme Gmbh & Co Kg | Method for producing an electrical connection between an aluminum conductor and a contact element |
DE102004030784A1 (en) | 2004-06-25 | 2006-01-19 | Leoni Ag | Electrical contact connection and method for forming such a contact connection |
JP2007305314A (en) * | 2006-05-08 | 2007-11-22 | Hitachi Cable Ltd | Cable with terminal, manufacturing method therefor, ultrasonic welding method for joining terminal and cable, and ultrasonic welder |
JP5235369B2 (en) | 2007-09-18 | 2013-07-10 | 株式会社オートネットワーク技術研究所 | Wire harness, method for manufacturing the same, and method for connecting insulated wires |
DE102008031588B4 (en) | 2008-07-03 | 2011-03-24 | Lisa Dräxlmaier GmbH | Contacting of light metal cables |
JP5447071B2 (en) * | 2010-03-25 | 2014-03-19 | 株式会社オートネットワーク技術研究所 | Electric wire with terminal fitting and method for manufacturing the same |
JP5539009B2 (en) | 2010-05-14 | 2014-07-02 | 矢崎総業株式会社 | Connection structure of crimp terminal to wire |
WO2012048103A1 (en) * | 2010-10-06 | 2012-04-12 | Sonics & Materials Inc. | System and method for terminating aluminum conductors |
JP2013105648A (en) * | 2011-11-15 | 2013-05-30 | Tabuchi Electric Co Ltd | Terminal connection structure |
KR20140134329A (en) | 2012-03-30 | 2014-11-21 | 야자키 소교 가부시키가이샤 | Terminal crimped wire |
JP5593354B2 (en) * | 2012-07-19 | 2014-09-24 | 昭和電線ケーブルシステム株式会社 | Terminal fittings and covered electric wires with terminal fittings |
JP5621826B2 (en) | 2012-10-05 | 2014-11-12 | トヨタ自動車株式会社 | Collective conducting wire and manufacturing method thereof |
DE102013201167A1 (en) * | 2013-01-24 | 2014-08-07 | Elringklinger Ag | A method of making an electrically conductive connection between an electrical lead and an electrically conductive member and assembly manufactured by the method |
JP2014164904A (en) * | 2013-02-22 | 2014-09-08 | Furukawa Electric Co Ltd:The | Brass terminal |
-
2015
- 2015-10-02 MX MX2017004178A patent/MX2017004178A/en active IP Right Grant
- 2015-10-02 WO PCT/US2015/053738 patent/WO2016054516A1/en active Application Filing
- 2015-10-02 JP JP2017517769A patent/JP6704391B2/en active Active
- 2015-10-02 US US14/873,237 patent/US9647348B2/en active Active
- 2015-10-02 CA CA2963462A patent/CA2963462C/en active Active
-
2016
- 2016-06-17 US US15/185,272 patent/US20160294072A1/en not_active Abandoned
-
2017
- 2017-05-05 US US15/587,799 patent/US9991608B2/en active Active
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3364460A (en) * | 1964-11-09 | 1968-01-16 | Thomas & Betts Corp | Seamed sleeve connector |
US20120329343A1 (en) * | 2010-04-01 | 2012-12-27 | Yazaki Corporation | Connection structure of crimping terminal to electric wire |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11611173B2 (en) * | 2018-01-08 | 2023-03-21 | K-Tronics (Suzhou) Technology Co., Ltd. | Mounting seat for electronic device and electronic apparatus |
Also Published As
Publication number | Publication date |
---|---|
MX2017004178A (en) | 2017-07-19 |
US9647348B2 (en) | 2017-05-09 |
JP2017530267A (en) | 2017-10-12 |
US9991608B2 (en) | 2018-06-05 |
WO2016054516A1 (en) | 2016-04-07 |
CA2963462A1 (en) | 2016-04-07 |
US20170244178A1 (en) | 2017-08-24 |
CA2963462C (en) | 2021-06-15 |
US20160099510A1 (en) | 2016-04-07 |
JP6704391B2 (en) | 2020-06-03 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US9991608B2 (en) | Wire and methods for preparing a wire to receive a contact element | |
JP4580445B2 (en) | Terminal and coil device using the same | |
WO2011096527A1 (en) | Connecting structure | |
US20140011411A1 (en) | Connection structure of crimping connection part of aluminum electric wire and metal terminal and method for manufacturing the same | |
WO2013032030A1 (en) | Electric cable end processing method and electric cable end structure with solder coating and sheath protection | |
JP2014044832A (en) | Terminal connection method for litz wire and litz wire with terminal fitting | |
JP6373077B2 (en) | Electric wire with crimp terminal | |
US10038292B2 (en) | Method for connecting insulated wires | |
WO2016017013A1 (en) | Method for joining terminal and electric wire and electric wire connection terminal | |
JP2013020761A (en) | Terminal connection method and terminal connection part of aluminum litz wire | |
EP3201989B1 (en) | Wire and methods for preparing a wire to receive a contact element | |
JP6941731B2 (en) | Manufacturing method of stranded wire connector and stranded wire connector for electric devices | |
JP6013417B2 (en) | Covered wire joining method | |
JP2011258468A (en) | Terminal, electric wire with terminal and method for producing the same | |
WO2015122268A1 (en) | Aluminum wire terminal connection structure | |
JP2011048929A (en) | Terminal-equipped wire | |
KR101282631B1 (en) | Connecting method of wire and terminal | |
JP6276820B2 (en) | Covered wire joining method | |
JPH0982447A (en) | Electric wire connecting method | |
JP2017152094A (en) | Terminal member | |
WO2015064667A1 (en) | Litz wire terminal | |
JPH0982377A (en) | Electric wire connecting method | |
JP2019003827A (en) | Battery state detection sensor and method of connecting covered wire | |
JP6232368B2 (en) | Terminal connection method | |
JP2021190241A (en) | Terminal-equipped wire and manufacturing method thereof |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: GENERAL CABLE TECHNOLOGIES CORPORATION, KENTUCKY Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:TRAFTON, MICHAEL L.;REEL/FRAME:038943/0318 Effective date: 20141028 |
|
AS | Assignment |
Owner name: GENERAL CABLE TECHNOLOGIES CORPORATION, KENTUCKY Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:STEINER, ROBERT D.;REEL/FRAME:040285/0091 Effective date: 20161110 |
|
AS | Assignment |
Owner name: JPMORGAN CHASE BANK, N.A., OHIO Free format text: SECURITY INTEREST;ASSIGNORS:GENERAL CABLE TECHNOLOGIES CORPORATION;GENERAL CABLE INDUSTRIES, INC.;REEL/FRAME:042554/0286 Effective date: 20170522 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |
|
AS | Assignment |
Owner name: GENERAL CABLE TECHNOLOGIES CORPORATION, KENTUCKY Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:JPMORGAN CHASE BANK, N.A.;REEL/FRAME:046307/0316 Effective date: 20180606 Owner name: GENERAL CABLE INDUSTRIES, INC., KENTUCKY Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:JPMORGAN CHASE BANK, N.A.;REEL/FRAME:046307/0316 Effective date: 20180606 |