US2806215A - Aluminum ferrule-copper tongue terminal and method of making - Google Patents

Aluminum ferrule-copper tongue terminal and method of making Download PDF

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US2806215A
US2806215A US390182A US39018253A US2806215A US 2806215 A US2806215 A US 2806215A US 390182 A US390182 A US 390182A US 39018253 A US39018253 A US 39018253A US 2806215 A US2806215 A US 2806215A
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ferrule
aluminum
copper
terminal
tongue
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US390182A
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Jean J Redslob
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TE Connectivity Corp
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Aircraft Marine Products Inc
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • 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
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending

Definitions

  • This invention relates to electrical terminals, particularly to the type to be secured by crimping to aluminum wire.
  • the invention is described as embodied in a ter minal for aluminum wire and which is adapted to make connection with a copper conductor, such as a bolt or other terminal securing means.
  • a copper or brass terminal means such as a spade tongue
  • a copper or brass terminal means is provided with an upstanding annular ring which is welded around its periphery to a short length of aluminum tubing which serves as the barrel or ferrule of the terminal. This aluminum ferrule is crimped to the aluminum conductor.
  • the crimped connection is between two aluminum members, thus eliminating loosening of the connection because of differential expansion with changes in temperature, and minimizing battery action and corrosion.
  • Figure l is a perspective view of the parts of a connector embodying the invention ready to be assembled to an insulated aluminum cable;
  • Figure 2 shows the connector of Figure 1 after being assembled with and crimped to the cable
  • Figure 3 is a perspective view illustrating the first step in fabricating the terminal portion of the connector
  • Figure 4 is a perspective view of the partially fabricated terminal portion
  • Figure 5 is an elevational view of the completed terminal and ferrule portions of the connector ready to be welded together;
  • Figure 6 illustrates the first step in an alternative method of making the terminal portion
  • Figure 7 shows a completed terminal portion fabricated from the metal shown in Figure 6;
  • Figure 8 shows another form of connector which eliminates the need for a separate thimble insert.
  • the connector includes a tubular ferrule or barrel portion 2 having a closed end as at 4 to which is secured an extending terminal tongue or eyelet 6.
  • the main portion of the ferrule 2 is formed of aluminum tubing, but the closed end 4 and an adjacent ring portion 8 are formed of copper, the ring and tubing being welded or soldered together along a peripheral line 10.
  • the tongue 6, which may be any desired form of terminal connecting means, is formed integrally with the ring portion 8 and is also of copper.
  • a thin-Walled drawn aluminum thimble 12 with the terminal.
  • This thimble which advantageously is tin-plated, has a tubular insert portion 14, which is adapted to fit within the ferrule 2, and an enlarged insulation-support portion 16 which fits over the outside of. the insulation 18 of an aluminum wire cable 20.
  • the thimble 12 is partially filled with a corrosion-inhibiting jelly, such as petrolatum, silicone grease, or the like, in which are dispersed fine particles of an abrasive material such as nickel powder, alundum, zinc dust, etc.
  • a corrosion-inhibiting jelly such as petrolatum, silicone grease, or the like, in which are dispersed fine particles of an abrasive material such as nickel powder, alundum, zinc dust, etc.
  • This composition is for the purpose of aiding in the removal of the oxide coating and later in retarding its reformation.
  • the insulation is trimmed from the end portion of the cable 20 and the bared aluminum wire 22 is inserted into the insert portion 14 of the thimble 12, the wire extending almost to the closed end of the thimble 12.
  • the insulation support 16 fits over the end portion of the insulation 18 which extends into the thimble the full depth of the insulation support.
  • the insert portion 14 of the thimble is then inserted all the way into the ferrule 2 so that its closed end is adjacent one end of the ferrule and the junction of the thimble insert 14 and insulation support 16 is adjacent the other end.
  • the ferrule 2 is then crimped in a confining die to the wire 22 and the support 16 is crirnped tightly around the insulation 18.
  • the assembled terminal after crimping is shown in Figure 2.
  • the quality of the resulting connection will depend upon the shape of the crimping dies, the extent of the extrusion produced by the crimping, the composition of the jelly and other factors which do not form part of the present invention but which are discussed more fully in my copending application Serial No. 350,653, filed April 23, 1953.
  • the outer surface of the ferrule is coated with a moisture-resistant coating to retard electrolytic corrosion at the outer surface of the junction between the aluminum and copper.
  • the outer surface of the ferrule 2 may be painted, coated with plastic or otherwise treated to minimize the electrolytic action.
  • the tongue portion 6 and ring or cup portion 8 advantageously are formed from sheet copper.
  • a shallow depression or cup 24 ( Figure 3) can be drawn in the copper sheet as shown in Figure 3.
  • a blank 26 is then formed by cutting along the broken line 28 and punching out the hole 30 in the tongue.
  • the blank 26 then appears as shown in Figure 4.
  • the tongue portion 6 is then bent backwardly perpendicularly to the end surface 4 of the ring 8 so that it appears as shown in Figure 5.
  • the ring 8 is shown in Figure 5 in position to be buttwelded to the aluminum tubing which forms the ferrule 2.
  • the welding can be performed in any desired manner; a synchronized flash and upsetting electric welding ope ration gives good results.
  • Apparatus for making such welds between aluminum and copper is manufactured by Thompson Electric Welder Company, Lynn, Massachusetts. After the welding operation, the excess metal on the outside of the welding joint 10 is ground oil to produce a reasonably smooth surface.
  • the ferrule 2 preferably is then painted or coated with other moisture resistant material.
  • the aluminum ferrule with tin As pointed out in the aboveidentified copending application, it is of advantage to plate the aluminum ferrule with tin.
  • This tin plate may be applied before the welding operation, for example in accordance with the procedure set forth in said copending application, or the entire assembly after the ferrule 2 and tongue portion 6 are welded together can be plated with tin.
  • a preferred plating method is to treat only the alum inum portion of the fabricated terminal with the zincate solution (as described in the previously identified copending application) after which the entire connector, both copper and aluminum parts, is given a copper flash and then plated with tin.
  • the ring 8 is provided with the solid end portion 4 as shown in Figure l as this helps to seal the interior of the ferrule against moisture and retards electrolytic corrosion and oxide formation within the ferrule 2.
  • the end portion 4 may be punched out or the ring portion 8 can be formed from a strip of copper which is shaped into an annular ring, the adjacent ends being brazed or otherwise secured together. The ring can then be welded to a separate tongue portion 6.
  • Figure 6 Another method of forming the ring 6 and tongue 8 is illustrated by Figure 6.
  • a blank is cut, as indicated by the broken lines, from a sheet 34 of copper.
  • the two strip-like arms 36 are then bent upwardly and around into the ring 8 as shown in Figure 7, and the ends are brazed or otherwise secured together as along the line 38.
  • the end of the ring 8 When the end of the ring 8 is left open in the lastdescribed construction, it is particularly important to use the thimble 12 to insure that the pressure connection with the aluminum wire is protected from the atmosphere, the connection between the outer surface of the thimble 12 and the inner surface of the ferrule 2 being more resistant to corrosion and oxidation if both surfaces are plated with tin or other suitable metal.
  • the present invention makes it convenient to use seamless aluminum tubing for the ferrule thus avoiding the necessity for a longitudinal weld or braze along the ferrule.
  • This arrangement thus has advantage in the construction of an all-copper terminal in which a short length of seamless copper tubing is Welded to the ring 8 in the manner described above.
  • Figure 8 shows a construction by which it is possible to eliminate the thimble l2 and still provide a satisfactory seal for the connection.
  • the tubular ferrule portion of this connector is aluminum and is formed by drawing to have a thick-walled portion 40, which is to be crirnped to the wire, and a thin-walled portion 42, which is to be crimped around the insulation.
  • the trick-walled portion of the ferrule is welded to a copper end plate 44, in the manner described above, the end plate may be formed from sheet copper by blank ing, coining an annular nib 46, and bending the tongue portion 48 as shown.
  • the ferrule portion 40 is welded at 50 in end-toend position with the annular nib 46 and the excess metal is removed by grinding.
  • the connector is then plated with tin as already described. No insert thimblc is required as the end plate 44 seals one end of the connection and the insulation-crimping portion 42 seals the other end.
  • the use of corrosion-inhibiting jelly as described above is, of course, desirable.
  • a terminal for making connection between a copper conductor and an aluminum wire comprising a copper tongue, copper ferrule-connecting por tion comprising a cup formed integrally with said tongue. said cup having walls and a closed end positioned in a ill plane substantially perpendicular to the plane of said tongue, and a tubular aluminum ferrule Welded in endtoend relationship to the walls of said cup.
  • a connector for making connection between an aluminum wire and a conductor of dissimilar metal comprising a tubular ferrule formed of metal composed predominantly of aluminum, and a tongue portion formed of metal composed predominantly of copper, said tongue portion including an extension connectiblc to said conductor and an upstanding ferrule-securing por tion including an annular ring portion having a diameter substantially equal to that of said ferrule, said collar and ferrule being welded together in end-to-end abutting re lationship.
  • a terminal for making connection between an aluminum wire and a conductor of dissimilar metal comprising a contact portion including tongucdikc extension and an annular ferrule-connecting ring portion extending at an angle from and integrally connected to.
  • said extension said contact portion being formed of metal composed predominantly of copper, and a tubular forrule in end-to-end relationship with and welded to said ring portion, said ferrule being formed of metal composed predominantly of aluminum.
  • a connector for making connection between an aluminum wire and a releasable fastener of dissimilar metal comprising a tubular ferrule formed of metal composed predominantly of aluminum, and a tongue portion formed of metal composed predominantly of copper, said tongue portion including a substantially planar extension connectiblc to said releasable fastener and an upstanding ferrule-securing portion including an annular ring portion having a diameter substantially equal to that of said ferrule, said ring portion and ferrule being welded to gether in cnd-tc-end abutting relationship, the axial length of said ferrule being substantially greater than the length of said ring portion.
  • a terminal suitable for use in connecting an aluminum wire and a conductor of dissimilar metal comprising forming from sheet metal composed predominantly of copper :1 blank in cluding a tongue portion integral with a ring portion, bending the ring portion into a position subst'i. 1 pendicular to said tongue portion, assembling a tubular ferrule of metal composed prcdominantly of aluminum into abutting relation with said ring portion, and welding; said ferrule and ring portion.
  • a terminal for making connection between a conductor and an aluminum wire said terminal including a tongue portion formed of metal com-posed predominantly of copper and a ferrule-end portion extending at an angle from said tongue portion, said ferrule-end portion being of the same metal as said tongue portion and integral therewith, a tubular ferrule portion formed of metal. composed predominantly of aluminum, said ferrule portion being butt welded with said ferruloend portion, and a thimble formed of metal composed predoniimintly of aluminum, said thimble fitting within said ferrule portion and being adapted to receive the end of the wire.
  • a terminal for making connection between two condoctors of dissimilar metals said terminal including a tongue portion formed from a sheet of a first metal, a fcrrule-end portion integral with said tongue portion and formed from said sheet, and a ferrule portion formed o tubing of another metal, butt welded with acid ferruleend portion, one of said meta s being composed predominantly of copper, the other of said metals being predominantly of aluminum.
  • a solderless type connector adapted to be crirnpcd to an insulated wire comprising a tubular ferrule portion, a tongue portion extending from one end of said ferrule, and a tubular insulation-supporting portion extending from the opposite end of said ferrule, said insulation-supporting portion being integral with said ferrule portion and having a wall thickness significantly less than axial that of said ferrule portion, the internal diameter of the insulation-supporting portion being larger than that of the ferrule portion, and said conector having an end plate formed integrally with said tongue portion and extending at an angle thereto, said end plate having a raised annular ring portion soldered to said ferrule portion.
  • a solderless type connector adapted to be erimped to an insulated wire comprising an aluminum tubular ferrule portion, a copper tongue portion extending from one end of said ferrule, and a tubular insulation-supporting portion extending from the opposite end of said ferrule, said insulation-supporting portion being integral with said ferrule portion and having a wall thickness significantly less than that of said ferrule portion, the internal diameter of the insulation-supporting portion being larger than that of the ferrule portion, and said connector having a copper end plate formed integrally with said tongue portion and extending at an angle thereto and said end plate having a raised annular ring portion welded to said ferrule.

Description

p 1957 J. J. REDSLOB 2,806,215
ALUMINUM FERRULEI-COPPER TONGUE TERMINAL AND METHOD OF MAKING Filed Nov. 4. 1953 COPPER 0R BRASS A BRASS COPPER 01? BRA-3.5
(UPPER 0R BRASS INVE TOR, (Zs-w/v 0. 501108 ATTORN S.
United States Patent ALUMINUM FERRULE-COPPER TONGUE TERMINAL AND METHOD OF MAKING Jean J. Redslob, Harrisburg, Pa., assignor to Aircraft Marine Products, Inc., Harrisburg, Pa.
Application November 4, 1953, Serial No. 392,182
9 Claims. (Cl. 339-476) This invention relates to electrical terminals, particularly to the type to be secured by crimping to aluminum wire. The invention is described as embodied in a ter minal for aluminum wire and which is adapted to make connection with a copper conductor, such as a bolt or other terminal securing means.
It has been found most difficult to make electrical connections between aluminum wires and circuit elements of other metals such as copper. The more important factors in causing these difiiculties are the insulating oxide coating that forms on the aluminum, the battery action between the two dissimilar metals, corrosion, and the differential expansion rates for the different metals with changes in temperature.
The present invention provides a terminal connection in which these troubles are eliminated, or at least alleviated to a large degree. In a preferred embodiment of the invention, a copper or brass terminal means, such as a spade tongue, is provided with an upstanding annular ring which is welded around its periphery to a short length of aluminum tubing which serves as the barrel or ferrule of the terminal. This aluminum ferrule is crimped to the aluminum conductor.
By this construction, as will be described more fully later, the crimped connection is between two aluminum members, thus eliminating loosening of the connection because of differential expansion with changes in temperature, and minimizing battery action and corrosion.
These broad objectives and others more specific will be made more apparent by the following description considered in conjunction with the accompanying drawings, in which:
Figure l is a perspective view of the parts of a connector embodying the invention ready to be assembled to an insulated aluminum cable;
Figure 2 shows the connector of Figure 1 after being assembled with and crimped to the cable;
Figure 3 is a perspective view illustrating the first step in fabricating the terminal portion of the connector;
Figure 4 is a perspective view of the partially fabricated terminal portion;
Figure 5 is an elevational view of the completed terminal and ferrule portions of the connector ready to be welded together;
Figure 6 illustrates the first step in an alternative method of making the terminal portion;
Figure 7 shows a completed terminal portion fabricated from the metal shown in Figure 6; and
Figure 8 shows another form of connector which eliminates the need for a separate thimble insert.
As shown in Figure l, the connector includes a tubular ferrule or barrel portion 2 having a closed end as at 4 to which is secured an extending terminal tongue or eyelet 6.
The main portion of the ferrule 2 is formed of aluminum tubing, but the closed end 4 and an adjacent ring portion 8 are formed of copper, the ring and tubing being welded or soldered together along a peripheral line 10. The tongue 6, which may be any desired form of terminal connecting means, is formed integrally with the ring portion 8 and is also of copper.
In use, it is preferred to uSe a thin-Walled drawn aluminum thimble 12 with the terminal. This thimble, which advantageously is tin-plated, has a tubular insert portion 14, which is adapted to fit within the ferrule 2, and an enlarged insulation-support portion 16 which fits over the outside of. the insulation 18 of an aluminum wire cable 20.
The thimble 12 is partially filled with a corrosion-inhibiting jelly, such as petrolatum, silicone grease, or the like, in which are dispersed fine particles of an abrasive material such as nickel powder, alundum, zinc dust, etc. This composition is for the purpose of aiding in the removal of the oxide coating and later in retarding its reformation.
To assemble the connector the insulation is trimmed from the end portion of the cable 20 and the bared aluminum wire 22 is inserted into the insert portion 14 of the thimble 12, the wire extending almost to the closed end of the thimble 12. The insulation support 16 fits over the end portion of the insulation 18 which extends into the thimble the full depth of the insulation support. The insert portion 14 of the thimble is then inserted all the way into the ferrule 2 so that its closed end is adjacent one end of the ferrule and the junction of the thimble insert 14 and insulation support 16 is adjacent the other end.
The ferrule 2 is then crimped in a confining die to the wire 22 and the support 16 is crirnped tightly around the insulation 18. The assembled terminal after crimping is shown in Figure 2.
The quality of the resulting connection will depend upon the shape of the crimping dies, the extent of the extrusion produced by the crimping, the composition of the jelly and other factors which do not form part of the present invention but which are discussed more fully in my copending application Serial No. 350,653, filed April 23, 1953.
Preferably the outer surface of the ferrule is coated with a moisture-resistant coating to retard electrolytic corrosion at the outer surface of the junction between the aluminum and copper. Thus, the outer surface of the ferrule 2 may be painted, coated with plastic or otherwise treated to minimize the electrolytic action.
The tongue portion 6 and ring or cup portion 8 advantageously are formed from sheet copper. For example, a shallow depression or cup 24 (Figure 3) can be drawn in the copper sheet as shown in Figure 3. A blank 26 is then formed by cutting along the broken line 28 and punching out the hole 30 in the tongue. The blank 26 then appears as shown in Figure 4. The tongue portion 6 is then bent backwardly perpendicularly to the end surface 4 of the ring 8 so that it appears as shown in Figure 5.
The ring 8 is shown in Figure 5 in position to be buttwelded to the aluminum tubing which forms the ferrule 2. The welding can be performed in any desired manner; a synchronized flash and upsetting electric welding ope ration gives good results. Apparatus for making such welds between aluminum and copper is manufactured by Thompson Electric Welder Company, Lynn, Massachusetts. After the welding operation, the excess metal on the outside of the welding joint 10 is ground oil to produce a reasonably smooth surface. The ferrule 2 preferably is then painted or coated with other moisture resistant material.
As pointed out in the aboveidentified copending application, it is of advantage to plate the aluminum ferrule with tin. This tin plate may be applied before the welding operation, for example in accordance with the procedure set forth in said copending application, or the entire assembly after the ferrule 2 and tongue portion 6 are welded together can be plated with tin. Usually, however. it is the better practice to apply the tin plating after the connector is completely fabricated. If the tin plating is applied prior to the welding operation, part of it is re moved during the welding and the subsequent grinding operation which removes the flash. After the welding operation a moisture resistant outer coating is applied.
A preferred plating method is to treat only the alum inum portion of the fabricated terminal with the zincate solution (as described in the previously identified copending application) after which the entire connector, both copper and aluminum parts, is given a copper flash and then plated with tin.
Preferably the ring 8 is provided with the solid end portion 4 as shown in Figure l as this helps to seal the interior of the ferrule against moisture and retards electrolytic corrosion and oxide formation within the ferrule 2. However, where such corrosion or oxidation are not considered detrimental in the particular applica tion, the end portion 4 may be punched out or the ring portion 8 can be formed from a strip of copper which is shaped into an annular ring, the adjacent ends being brazed or otherwise secured together. The ring can then be welded to a separate tongue portion 6.
Another method of forming the ring 6 and tongue 8 is illustrated by Figure 6. A blank is cut, as indicated by the broken lines, from a sheet 34 of copper. The two strip-like arms 36 are then bent upwardly and around into the ring 8 as shown in Figure 7, and the ends are brazed or otherwise secured together as along the line 38.
When the end of the ring 8 is left open in the lastdescribed construction, it is particularly important to use the thimble 12 to insure that the pressure connection with the aluminum wire is protected from the atmosphere, the connection between the outer surface of the thimble 12 and the inner surface of the ferrule 2 being more resistant to corrosion and oxidation if both surfaces are plated with tin or other suitable metal.
It will be noted also that the present invention makes it convenient to use seamless aluminum tubing for the ferrule thus avoiding the necessity for a longitudinal weld or braze along the ferrule. This arrangement thus has advantage in the construction of an all-copper terminal in which a short length of seamless copper tubing is Welded to the ring 8 in the manner described above.
Figure 8 shows a construction by which it is possible to eliminate the thimble l2 and still provide a satisfactory seal for the connection. The tubular ferrule portion of this connector is aluminum and is formed by drawing to have a thick-walled portion 40, which is to be crirnped to the wire, and a thin-walled portion 42, which is to be crimped around the insulation.
The trick-walled portion of the ferrule is welded to a copper end plate 44, in the manner described above, the end plate may be formed from sheet copper by blank ing, coining an annular nib 46, and bending the tongue portion 48 as shown. The ferrule portion 40 is welded at 50 in end-toend position with the annular nib 46 and the excess metal is removed by grinding. The connector is then plated with tin as already described. No insert thimblc is required as the end plate 44 seals one end of the connection and the insulation-crimping portion 42 seals the other end. The use of corrosion-inhibiting jelly as described above is, of course, desirable.
From the foregoing, it will be seen that the improved connection embodying the present invention is well adapted to be manufactured by conventional techniques from readily obtainable materials and that it can be modified in various ways to meet the particular needs of each use.
What is claimed is:
l. A terminal for making connection between a copper conductor and an aluminum wire, said terminal comprising a copper tongue, copper ferrule-connecting por tion comprising a cup formed integrally with said tongue. said cup having walls and a closed end positioned in a ill plane substantially perpendicular to the plane of said tongue, and a tubular aluminum ferrule Welded in endtoend relationship to the walls of said cup.
2. A connector for making connection between an aluminum wire and a conductor of dissimilar metal, said connector comprising a tubular ferrule formed of metal composed predominantly of aluminum, and a tongue portion formed of metal composed predominantly of copper, said tongue portion including an extension connectiblc to said conductor and an upstanding ferrule-securing por tion including an annular ring portion having a diameter substantially equal to that of said ferrule, said collar and ferrule being welded together in end-to-end abutting re lationship.
3. A terminal for making connection between an aluminum wire and a conductor of dissimilar metal, said terminal comprising a contact portion including tongucdikc extension and an annular ferrule-connecting ring portion extending at an angle from and integrally connected to. said extension, said contact portion being formed of metal composed predominantly of copper, and a tubular forrule in end-to-end relationship with and welded to said ring portion, said ferrule being formed of metal composed predominantly of aluminum.
4. A connector for making connection between an aluminum wire and a releasable fastener of dissimilar metal comprising a tubular ferrule formed of metal composed predominantly of aluminum, and a tongue portion formed of metal composed predominantly of copper, said tongue portion including a substantially planar extension connectiblc to said releasable fastener and an upstanding ferrule-securing portion including an annular ring portion having a diameter substantially equal to that of said ferrule, said ring portion and ferrule being welded to gether in cnd-tc-end abutting relationship, the axial length of said ferrule being substantially greater than the length of said ring portion.
5. The method of making a terminal suitable for use in connecting an aluminum wire and a conductor of dissimilar metal, said method comprising forming from sheet metal composed predominantly of copper :1 blank in cluding a tongue portion integral with a ring portion, bending the ring portion into a position subst'i. 1 pendicular to said tongue portion, assembling a tubular ferrule of metal composed prcdominantly of aluminum into abutting relation with said ring portion, and welding; said ferrule and ring portion.
6. A terminal for making connection between a conductor and an aluminum wire, said terminal including a tongue portion formed of metal com-posed predominantly of copper and a ferrule-end portion extending at an angle from said tongue portion, said ferrule-end portion being of the same metal as said tongue portion and integral therewith, a tubular ferrule portion formed of metal. composed predominantly of aluminum, said ferrule portion being butt welded with said ferruloend portion, and a thimble formed of metal composed predoniimintly of aluminum, said thimble fitting within said ferrule portion and being adapted to receive the end of the wire.
7. A terminal for making connection between two condoctors of dissimilar metals, said terminal including a tongue portion formed from a sheet of a first metal, a fcrrule-end portion integral with said tongue portion and formed from said sheet, and a ferrule portion formed o tubing of another metal, butt welded with acid ferruleend portion, one of said meta s being composed predominantly of copper, the other of said metals being predominantly of aluminum.
8. A solderless type connector adapted to be crirnpcd to an insulated wire comprising a tubular ferrule portion, a tongue portion extending from one end of said ferrule, and a tubular insulation-supporting portion extending from the opposite end of said ferrule, said insulation-supporting portion being integral with said ferrule portion and having a wall thickness significantly less than axial that of said ferrule portion, the internal diameter of the insulation-supporting portion being larger than that of the ferrule portion, and said conector having an end plate formed integrally with said tongue portion and extending at an angle thereto, said end plate having a raised annular ring portion soldered to said ferrule portion.
9. A solderless type connector adapted to be erimped to an insulated wire comprising an aluminum tubular ferrule portion, a copper tongue portion extending from one end of said ferrule, and a tubular insulation-supporting portion extending from the opposite end of said ferrule, said insulation-supporting portion being integral with said ferrule portion and having a wall thickness significantly less than that of said ferrule portion, the internal diameter of the insulation-supporting portion being larger than that of the ferrule portion, and said connector having a copper end plate formed integrally with said tongue portion and extending at an angle thereto and said end plate having a raised annular ring portion welded to said ferrule.
References Cited in the file of this patent UNITED STATES PATENTS
US390182A 1953-11-04 1953-11-04 Aluminum ferrule-copper tongue terminal and method of making Expired - Lifetime US2806215A (en)

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Cited By (55)

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US3656092A (en) * 1970-08-07 1972-04-11 Amp Inc Terminal device for welded termination of electrical leads
US3670294A (en) * 1970-10-19 1972-06-13 Sylvania Electric Prod Multiple contact electrical connector
US3717842A (en) * 1971-02-26 1973-02-20 Perfection Electrical Prod Inc Method of connecting aluminum wire to electrical terminals
US3876280A (en) * 1973-10-02 1975-04-08 Coatings Inc Electric terminator comprising one-piece bimetallic connector and method for making such connector
US3916518A (en) * 1973-10-02 1975-11-04 Coatings Inc Method for making one-piece bimetallic connector
US3949466A (en) * 1974-05-28 1976-04-13 Arthur D. Little Inc. Process for forming an aluminum electrical conducting wire junction end piece
US3955044A (en) * 1970-12-03 1976-05-04 Amp Incorporated Corrosion proof terminal for aluminum wire
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US4442182A (en) * 1982-05-26 1984-04-10 Teledyne Penn-Union One-piece, composite electrical connector
US5035655A (en) * 1989-07-18 1991-07-30 Phoenix Lighting Products Corporation Light bulb receptacle and method of assembly
US5614120A (en) * 1994-11-14 1997-03-25 Stresstech Sleeving for a wire used with a tail connected to a heating element and a method for heating
EP1030405A2 (en) * 1999-02-16 2000-08-23 Ensto Sekko Oy Jointing sleeve or connector for splice or branch connections in electric cables
EP1032077A2 (en) 1999-02-24 2000-08-30 Auto Kabel Managementgesellschaft mbH Connection of an electrical aluminium cable with terminal made of copper or like metal
US6376808B2 (en) * 2000-05-12 2002-04-23 Nhk Spring Co., Ltd. Heating apparatus
WO2005091439A1 (en) * 2004-03-23 2005-09-29 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. Method for joining a connecting element to an electric conductor made of aluminium and electric conductor produced according to said method
US20060014412A1 (en) * 2004-07-13 2006-01-19 Yazaki Europe Ltd. Connection between a cable end piece and a cable end
FR2893193A1 (en) * 2005-11-09 2007-05-11 Rh Innovation Sarl CRIMPING METHOD
US20080139056A1 (en) * 2005-02-28 2008-06-12 Yazaki Corporation Method for forming a terminal metal and terminal metal formed by the method
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EP2378611A1 (en) 2010-04-13 2011-10-19 Nexans Method for producing cables with aluminium wires
DE102010027033A1 (en) 2010-07-14 2012-01-19 Kromberg & Schubert Kg Conductor for electrical cable in car, has contact part connected with connector having crimping connections, where conductor and contact part are connected are joined by laser welding
EP2410612A1 (en) 2010-07-22 2012-01-25 Nexans Method for producing cables with aluminium wires
EP2458687A1 (en) * 2010-11-25 2012-05-30 Mecatraction Bonding assembly made up of a high-voltage power cable and a connection device
EP2472551A1 (en) * 2009-08-25 2012-07-04 Fuji Electric Fa Components & Systems Co., Ltd. Circuit breaker
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US8801444B2 (en) 2010-03-29 2014-08-12 Kobe Steel, Ltd. Busbar and busbar manufacturing method
US8851522B1 (en) * 2013-03-14 2014-10-07 Autoliv Asp, Inc. Seatbelt anchor assembly
TWI482342B (en) * 2010-03-29 2015-04-21 Kobe Steel Ltd Electrode terminal and electrode terminal manufacturing method
US20150173208A1 (en) * 2012-05-30 2015-06-18 Shenzhen China Star Optoelectronics Technology Co., Ltd. Connection wire structure of direct light bar and connection method thereof
US20150325930A1 (en) * 2013-01-24 2015-11-12 Elringklinger Ag Method for producing an electrically conductive bond between an electrical line and an electrically conductive component and assembly produced using the method
DE102014119116A1 (en) 2014-12-18 2016-06-23 Amphenol-Tuchel Electronics Gmbh Crimp contact and connection arrangement with a crimp contact
US9827946B2 (en) 2014-02-27 2017-11-28 Autoliv Development Ab Belt buckle having a fastening device for a cable
DE102016217516A1 (en) 2016-09-14 2018-03-15 Seg Automotive Germany Gmbh An electric rotor and method for providing electrical contact between a rotor winding and a contact lug
US9985362B2 (en) 2015-10-22 2018-05-29 Carlisle Interconnect Technologies, Inc. Arc resistant power terminal
US20180240611A1 (en) * 2017-02-17 2018-08-23 Honeywell International Inc. Snap action switch contact with reduced stray arcing
US20180322983A1 (en) * 2015-11-12 2018-11-08 Sumitomo Wiring Systems, Ltd. Conductive member, terminal-equipped conductive member, and method of manufacturing conductive member
US10164348B2 (en) 2009-02-16 2018-12-25 Carlisle Interconnect Technologies, Inc. Terminal/connector having integral oxide breaker element
WO2019007454A1 (en) * 2017-07-05 2019-01-10 Lisa Dräxlmaier GmbH Method for producing an electrical line arrangement
US10515739B2 (en) * 2015-11-12 2019-12-24 Sumitomo Wiring Systems, Ltd. Conductive member and method for producing conductive member
EP3637552A4 (en) * 2017-06-05 2021-03-10 Jilin Zhong Ying High Technology Co., Ltd. Copper-aluminium connector

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Cited By (90)

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US3656092A (en) * 1970-08-07 1972-04-11 Amp Inc Terminal device for welded termination of electrical leads
US3670294A (en) * 1970-10-19 1972-06-13 Sylvania Electric Prod Multiple contact electrical connector
US3955044A (en) * 1970-12-03 1976-05-04 Amp Incorporated Corrosion proof terminal for aluminum wire
US3717842A (en) * 1971-02-26 1973-02-20 Perfection Electrical Prod Inc Method of connecting aluminum wire to electrical terminals
US3876280A (en) * 1973-10-02 1975-04-08 Coatings Inc Electric terminator comprising one-piece bimetallic connector and method for making such connector
US3916518A (en) * 1973-10-02 1975-11-04 Coatings Inc Method for making one-piece bimetallic connector
US3949466A (en) * 1974-05-28 1976-04-13 Arthur D. Little Inc. Process for forming an aluminum electrical conducting wire junction end piece
US3973823A (en) * 1974-09-06 1976-08-10 Square D Company Electrical terminal connector
DE2937916A1 (en) * 1978-09-19 1980-03-27 Sp Kt Bjuro Izoljatoram I Arma METHOD FOR PRODUCING CONTACT TERMINALS
EP0023880A1 (en) * 1979-08-01 1981-02-11 Siemens Aktiengesellschaft Crimping sleeve for a pre-fabricated cable fitting
US4290665A (en) * 1979-09-25 1981-09-22 Krasnov Valery A Method of manufacturing a contact clip
FR2498824A1 (en) * 1981-01-26 1982-07-30 Bendix Corp Three-part female contact for electrical connector - has inner sleeve provided with wire receiving part made from softer metal than that coupling part
US4398124A (en) * 1981-11-09 1983-08-09 Gte Products Corporation Electric lamp unit with improved fuse means
US4442182A (en) * 1982-05-26 1984-04-10 Teledyne Penn-Union One-piece, composite electrical connector
US5035655A (en) * 1989-07-18 1991-07-30 Phoenix Lighting Products Corporation Light bulb receptacle and method of assembly
US5614120A (en) * 1994-11-14 1997-03-25 Stresstech Sleeving for a wire used with a tail connected to a heating element and a method for heating
EP1030405A2 (en) * 1999-02-16 2000-08-23 Ensto Sekko Oy Jointing sleeve or connector for splice or branch connections in electric cables
EP1030405A3 (en) * 1999-02-16 2002-08-07 Ensto Sekko Oy Jointing sleeve or connector for splice or branch connections in electric cables
EP1032077A3 (en) * 1999-02-24 2001-06-27 Auto Kabel Managementgesellschaft mbH Connection of an electrical aluminium cable with terminal made of copper or like metal
DE19908031A1 (en) * 1999-02-24 2000-09-14 Auto Kabel Man Gmbh Connection of an electrical aluminum cable to a connector made of copper or the like metal
EP1032077A2 (en) 1999-02-24 2000-08-30 Auto Kabel Managementgesellschaft mbH Connection of an electrical aluminium cable with terminal made of copper or like metal
US6538203B1 (en) * 1999-02-24 2003-03-25 Auto Kabel Managementgesellschaft Mbh Connection of an electrical aluminum cable with a connection piece of copper or similar material
DE19908031B4 (en) * 1999-02-24 2009-08-13 Auto-Kabel Management Gmbh Connection of an electrical aluminum cable with a connector made of copper or the like metal
US6376808B2 (en) * 2000-05-12 2002-04-23 Nhk Spring Co., Ltd. Heating apparatus
WO2005091439A1 (en) * 2004-03-23 2005-09-29 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. Method for joining a connecting element to an electric conductor made of aluminium and electric conductor produced according to said method
US20060292922A1 (en) * 2004-03-23 2006-12-28 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. Process for connecting terminal elements to an electrical conductor consisting of aluminum, and electrical conductor produced by the process
US20060014412A1 (en) * 2004-07-13 2006-01-19 Yazaki Europe Ltd. Connection between a cable end piece and a cable end
US7048562B2 (en) * 2004-07-13 2006-05-23 Yazaki Europe Ltd. Connection between a cable end piece and a cable end
US20080139056A1 (en) * 2005-02-28 2008-06-12 Yazaki Corporation Method for forming a terminal metal and terminal metal formed by the method
US7442097B2 (en) * 2005-02-28 2008-10-28 Yazaki Corporation Method for forming a terminal metal and terminal metal formed by the method
US20090229880A1 (en) * 2005-04-01 2009-09-17 Autonetworks Technologies, Ltd. Conductor and Wire Harness
US7947904B2 (en) * 2005-04-01 2011-05-24 Autonetworks Technologies, Ltd. Conductor and wire harness
FR2893193A1 (en) * 2005-11-09 2007-05-11 Rh Innovation Sarl CRIMPING METHOD
WO2007054554A1 (en) * 2005-11-09 2007-05-18 Rh Innovation Crimping method and crimped wire
US20090314511A1 (en) * 2006-08-15 2009-12-24 Autonetworks Technologies, Ltd. Shielded Wire-Grounding construction
US8258402B2 (en) * 2006-08-15 2012-09-04 Autonetworks Technologies, Ltd. Shielded wire-grounding construction
US20110168423A1 (en) * 2006-08-15 2011-07-14 Autonetworks Technologies, Ltd. Shielded wire-grounding construction
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US7828610B2 (en) * 2008-07-03 2010-11-09 Lisa Draexlmaier Gmbh Connector for use with light-weight metal conductors
DE102008031588A1 (en) 2008-07-03 2010-01-14 Lisa Dräxlmaier GmbH Contacting of light metal cables
US20100003867A1 (en) * 2008-07-03 2010-01-07 Draexlmaier GmbH Connector for use with light-weight metal conductors
EP2141771A1 (en) 2008-07-03 2010-01-06 Lisa Dräxlmaier GmbH Contacting of light metal conductors
US10164348B2 (en) 2009-02-16 2018-12-25 Carlisle Interconnect Technologies, Inc. Terminal/connector having integral oxide breaker element
US8519267B2 (en) 2009-02-16 2013-08-27 Carlisle Interconnect Technologies, Inc. Terminal having integral oxide breaker
US8830025B2 (en) 2009-08-25 2014-09-09 Fuji Electronic Fa Components & Systems Co., Ltd. Circuit breaker
EP2472551A4 (en) * 2009-08-25 2014-06-11 Fuji Elec Fa Components & Sys Circuit breaker
EP2472551A1 (en) * 2009-08-25 2012-07-04 Fuji Electric Fa Components & Systems Co., Ltd. Circuit breaker
DE102009056799A1 (en) 2009-12-03 2011-06-09 Kromberg & Schubert Gmbh & Co. Kg Thin electrical conductor i.e. aluminum cable, for motor vehicle, has three crimp connections enclosing conductor partial areas, where conductor and contact part are connected with each other by weld joint in areas by areas
US20130040511A1 (en) * 2010-02-05 2013-02-14 Furukawa Automotive Systems Inc. Connection structural body
US8622775B2 (en) * 2010-02-05 2014-01-07 Furukawa Electric Co., Ltd. Connection structural body
TWI482342B (en) * 2010-03-29 2015-04-21 Kobe Steel Ltd Electrode terminal and electrode terminal manufacturing method
US8801444B2 (en) 2010-03-29 2014-08-12 Kobe Steel, Ltd. Busbar and busbar manufacturing method
US9023515B2 (en) 2010-03-29 2015-05-05 Kobe Steel, Ltd. Electrode terminal and method for producing electrode terminal
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EP2378611A1 (en) 2010-04-13 2011-10-19 Nexans Method for producing cables with aluminium wires
DE102010027033A1 (en) 2010-07-14 2012-01-19 Kromberg & Schubert Kg Conductor for electrical cable in car, has contact part connected with connector having crimping connections, where conductor and contact part are connected are joined by laser welding
EP2410612A1 (en) 2010-07-22 2012-01-25 Nexans Method for producing cables with aluminium wires
EP2458687A1 (en) * 2010-11-25 2012-05-30 Mecatraction Bonding assembly made up of a high-voltage power cable and a connection device
FR2968138A1 (en) * 2010-11-25 2012-06-01 Mecatraction ELECTRICAL CONNECTION ASSEMBLY FORMED BY HIGH VOLTAGE ELECTRIC CABLE AND CONNECTING DEVICE
DE202011110163U1 (en) 2011-04-08 2013-02-11 Kromberg & Schubert Kg Electrical contact device
DE102011016556A1 (en) 2011-04-08 2012-10-11 Kromberg & Schubert Kg Electrical contact device for electrical onboard network of motor car, has electric conductors made of aluminum and copper and connected with bus bar, where bus bar and contact regions of conductors are arranged in protective device
US20120318576A1 (en) * 2011-06-20 2012-12-20 Yazaki Corporation Connecting structure and connecting method for electric cables
US10263347B2 (en) * 2011-06-20 2019-04-16 Yazaki Corporation Connecting structure and connecting method for electric cables
US9350109B2 (en) * 2011-08-08 2016-05-24 Yazaki Corporation Compression method for electric wire and electric wire with terminal obtained thereby
US20140151083A1 (en) * 2011-08-08 2014-06-05 Yazaki Corporation Compression method for electric wire and electric wire with terminal obtained thereby
DE102011112936A1 (en) 2011-09-13 2013-03-14 Kromberg & Schubert Kg Electrical contact device for use in motor vehicle, has electrical conductor made from aluminum and comprising end piece, and contact part connected with vehicle-specifically designed contact part designed as punching or casting part
DE202011110046U1 (en) 2011-09-13 2012-11-20 Kromberg & Schubert Kg Electrical contact device
AT512881A1 (en) * 2012-05-11 2013-11-15 Gebauer & Griller Connection of an electrical cable to a contact part and method of making this connection
AT512881B1 (en) * 2012-05-11 2014-03-15 Gebauer & Griller Connection of an electrical cable to a contact part and method of making this connection
US20150173208A1 (en) * 2012-05-30 2015-06-18 Shenzhen China Star Optoelectronics Technology Co., Ltd. Connection wire structure of direct light bar and connection method thereof
US9693465B2 (en) * 2012-05-30 2017-06-27 Shenzhen China Star Optoelectronics Technology Co., Ltd. Connection method for connection wire structure of direct light bar
US20150325930A1 (en) * 2013-01-24 2015-11-12 Elringklinger Ag Method for producing an electrically conductive bond between an electrical line and an electrically conductive component and assembly produced using the method
US10833426B2 (en) * 2013-01-24 2020-11-10 Elringklinger Ag Method for producing an electrically conductive bond between an electrical line and an electrically conductive component and assembly produced using the method
US8851522B1 (en) * 2013-03-14 2014-10-07 Autoliv Asp, Inc. Seatbelt anchor assembly
US9827946B2 (en) 2014-02-27 2017-11-28 Autoliv Development Ab Belt buckle having a fastening device for a cable
DE102014119116B4 (en) 2014-12-18 2023-05-11 Amphenol-Tuchel Electronics Gmbh Crimp contact and connection arrangement with a crimp contact
DE102014119116A1 (en) 2014-12-18 2016-06-23 Amphenol-Tuchel Electronics Gmbh Crimp contact and connection arrangement with a crimp contact
US9985362B2 (en) 2015-10-22 2018-05-29 Carlisle Interconnect Technologies, Inc. Arc resistant power terminal
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US10515739B2 (en) * 2015-11-12 2019-12-24 Sumitomo Wiring Systems, Ltd. Conductive member and method for producing conductive member
WO2018050392A1 (en) 2016-09-14 2018-03-22 Seg Automotive Germany Gmbh Electric rotor and method for providing an electric contact between a rotor winding and a contact tab
DE102016217516A1 (en) 2016-09-14 2018-03-15 Seg Automotive Germany Gmbh An electric rotor and method for providing electrical contact between a rotor winding and a contact lug
US10283285B2 (en) * 2017-02-17 2019-05-07 Honeywell International Inc. Method of forming a contact involving the removal of flash
US20180240611A1 (en) * 2017-02-17 2018-08-23 Honeywell International Inc. Snap action switch contact with reduced stray arcing
EP3637552A4 (en) * 2017-06-05 2021-03-10 Jilin Zhong Ying High Technology Co., Ltd. Copper-aluminium connector
US11450975B2 (en) * 2017-06-05 2022-09-20 Jilin Zhong Ying High Technology Co., Ltd. Copper-aluminium connector
WO2019007454A1 (en) * 2017-07-05 2019-01-10 Lisa Dräxlmaier GmbH Method for producing an electrical line arrangement
US11158961B2 (en) * 2017-07-05 2021-10-26 Lisa Draexlmaier Gmbh Method for producing an electrical line arrangement

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