US2965147A - Crimping methods and apparatus - Google Patents

Crimping methods and apparatus Download PDF

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Publication number
US2965147A
US2965147A US441277A US44127754A US2965147A US 2965147 A US2965147 A US 2965147A US 441277 A US441277 A US 441277A US 44127754 A US44127754 A US 44127754A US 2965147 A US2965147 A US 2965147A
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United States
Prior art keywords
ferrule
nest
crimping
conductor
tynes
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US441277A
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English (en)
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Norman E Hoffman
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TE Connectivity Corp
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AMP Inc
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Publication date
Priority to NL198024D priority Critical patent/NL198024A/xx
Priority to NL102635D priority patent/NL102635C/xx
Application filed by AMP Inc filed Critical AMP Inc
Priority to US441277A priority patent/US2965147A/en
Priority to FR1137368D priority patent/FR1137368A/fr
Priority to DEA23006A priority patent/DE1084337B/de
Priority to CH344113D priority patent/CH344113A/de
Priority to GB19543/55A priority patent/GB811996A/en
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Publication of US2965147A publication Critical patent/US2965147A/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • 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
    • H01R4/22—End caps, i.e. of insulating or conductive material for covering or maintaining connections between wires entering the cap from the same end
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/058—Crimping mandrels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49181—Assembling terminal to elongated conductor by deforming
    • Y10T29/49183—Assembling terminal to elongated conductor by deforming of ferrule about conductor and terminal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49181—Assembling terminal to elongated conductor by deforming
    • Y10T29/49185—Assembling terminal to elongated conductor by deforming of terminal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming
    • Y10T29/49925—Inward deformation of aperture or hollow body wall
    • Y10T29/49927—Hollow body is axially joined cup or tube
    • Y10T29/49929—Joined to rod
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/5313—Means to assemble electrical device
    • Y10T29/532—Conductor
    • Y10T29/53209—Terminal or connector
    • Y10T29/53213—Assembled to wire-type conductor
    • Y10T29/53235—Means to fasten by deformation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/53987—Tube, sleeve or ferrule

Definitions

  • This invention is in the lield of electrical connectors of the type having ferrule portions adapted to receive conductors and be crimped thereto and relates to improved crimps and crimping dies and methods for applying the connectors to the conductors.
  • connection In order to produce a high quality connection in this field, there are a number of criteria which must be met both during the crimping of the ferrule onto the conductor and in the resulting crimp.
  • the connection should be mechanically strong to resist tension, vibration and torsion, and be tight against corrosion, and maintin a high electrical conductvity over a long period of time. It should be economical to make and to apply.
  • connection should be such that -the gradations in crimping pressures exerted upon the various areas of the outside of the ferrule are within reasonable limits and the maximum crimping pressures are not unduly high, thus preventing shearing or puncture in the wall of the ferrule; and yet the metals of the ferrnle and conductor must be forged together under the crimping pressures used so as to produce a connection .in which the ferrule and conductor are essentially integral. Where the ferrule is of the type that carries an external insulation sheath through which the crimping pressure is transmitted, these latter criteria are very important in providing a well insulated yet strong connection. Moreover,
  • Vthe amount of metal required to be used in the ferrule ⁇ should be as small as possible to reduce cost and weight, the latter being of prime importance in aircraft.
  • An important advantage of the present invention is that it enables connections to be formed with the use of lower maximum crimping pressures and smaller total crimping forces than those which have heretofore been required for the same size of conductor, while the resulting connections actually have a higher tensile strength and a greater strength against torsional stress than other crimped connections of comparable dimensions. These lower pressures and forces actually permit the use of thinner walled ferrules, and yet the resulting connections have superior mechanical and electrical properties.
  • Yet another advantage of the present invention is that it enables larger insulated connections to be made of the ice type having a ferrule surrounded by an insulation sheath, the crimping forces being applied through this insulation sheath, by virtue of the lower crimping forces and thinner ferrule walls which can be used with the present invention.
  • my invention provides a crimped connection which can be easily and economically made under mass production conditions and which is highly resistant to corrosion, is mechanically strong both in torsion and in tensile stress for both solid and stranded conductors.
  • the present invention produces excellent results not only with ordinary electrical copper but also with other metals, including for example, aluminum, brass, Phosphorbronze, berylliumcopper, hard-drawn copper, iron, etc.
  • One of the important advantages of the present invention is that during a crimping operation the curve of the required crimping force as a function of die travel has the highly desirable characteristic of a gentle slope over the major portion of die travel, whereby the effort required to close the dies over this major portion of the die travel is low; with a suddenly increased slope occurring when the connection is forged to solid cross-section, .whereby the normal operation of the dies is also the desired operation.
  • dies of this invention are used with toggle-type force-multiplying linkages connected so that themecnanical advantage (and therefore the force output) is low over most of the travel of the dies but increases greatly as the toggle nears its dead-center position, asy the dies near full closure, the result is substantially constant force during the full stroke of the handles.
  • This steep increase of crimping force near full closure acts as a stop to prevent over-crimping with mechanically- -actuated tools provided with a resilient member in the force linkages and with hydraulic tools having pre-set by-pass valves which release at a predetermined crimping force.
  • Figure 1 is a perspective view of an electrical connector applied to the end of a wire
  • Figure 2 is a cross sectional view of the connection taken through the center of the crimp, on the line 2-2 of Figure 1;
  • Figure 3 is a cross sectional view of a connection similar to that shown in Figure l but wherein a larger size conductor has been used with the same size of ferrule and dies;
  • Figure 4 is a perspective view of an electrically insulated end connector crimped onto a number of wires
  • Figure 5 is a transverse sectional view taken along the line 5--5 of Figure 4;
  • Figure 6 is a longitudinal sectional view taken along the line 6 6 of Figure 5;
  • Figure 7 is a sectional elevation view taken through a pair of crimping dies with a solid electrical conductor and the ferrule portion of an electrical connector between the dies in their fully open position;
  • Figure 8 is a View similar to that of Figure 7 but showing the dies in a partially closed position
  • Figure 9 is a view similar to that of Figures 7 and 8 but showing the dies nearing their fully closed position
  • Figure 10 is a plan sectional view of the dies taken along the lines 10-10 of Figure 9;
  • Figure l1 is an enlarged geometrical diagram of 'the outline of a crimped connection made in accordance with the present invention for example as shown in Figure 2;
  • Figure l2 is an enlargement of the upper Vertex p0rtion of the outline of Figure ll, for purposes of further explanation.
  • Figures 13 and 14 show enlarged elevational views of the nest die and indenter die, respectively.
  • an electrical connector generally indicated at 20, including a ferrule portion 22 telescoped over and crimped to the bare end 24 of an insulated electrical conductor 26 with a contact portion 28 integrally extending from the ferrule, shown here as a ring tongue.
  • an integral connection is Vformed by crimping the ferrule 22 inwardly against the bare end 24 of conductor 26 and compressing it by three approximately equally spaced elongated longitudinally extending indentations 30, 30, 32, respectively.
  • indentations are parallel-sided with rounded ends 34 and rounded bottoms and are impressed in the wall of the ferrule to engage it with the conductor 24 and to coin and cold ow the metal of the ferrule into a substantially solid integral body with the metalV of the conductor. It is an advantage of this invention that compression forging of the metal can proceed to the stage where the cross-section is free from voids before the mechanical strength and integrity of the connection are seriously impaired at any part. Two of these indentations 30 are ofthe same size but the third indentation 32 is somewhat wider.
  • the resulting body of the ferrule and conductor as seen in Figure 2 in cross section presents a generally three-sided configuration with the appearance of a scalloped triangle having concave sides formed by the indentations 30 and 32 which are defined transversely by circular arcs of radii R2 ( Figure 1l) and having vertices 3S, 35, and 36, respectively, rounded to circular arcs of smaller radii R1 and R3 tangent to the concave arcs.
  • the two vertices 35 adjacent the larger indentation 32 are more actute than the third vertex 36 so that the over-all cross section of the connection has a generally isoceles-triangular appearance.
  • one of the advantages of the present invention is that in a connection with a terminal tongue the outline of the connection blends with the tongue portion 28, the two actute vertices 35 being more ,l
  • indentations V30 and 32v may be voriented in any position with respect to a seam in the ferrule.
  • the connection has been made with a seam 38 lying near the center of the wider indentation 32.
  • This is particularly advantageous with through-type (butt or parallel connectors) or acorn type (end connectors).
  • the searn will ordinarily be brazed, but the invention is of great advantage with butt seams because it subjects the ferrule to peripheral compression.
  • Figure 3 is a cross sectional view ofa connection madev wit-hthe same dies and with a ferrule 22 of the same size ⁇ as 'that shown in Figures 1 and 2, but with a conductor crimping operation is performed in a press or tool with sufficient force to move the dies to the same extent as in Figure 2, the result will be that the ferrule wall and the wire are thinned by greater longitudinal extrusion under the action of the crimping dies, leaving a larger area within the ferrule 22 to accommodate the larger (although reduced) cross section of conductor end 24a. It is desirable thus to provide a limited percentage reduction i cross section of the conductor 24a.
  • the metal of ferrule 22 and of conductor 24a are integrallyforged together in Figure 3, as in Figure 2, to produce 'a connection of great tensile and torsional strength.
  • junction 39 has a very high resistance to-torsional stress.
  • the crimped conductor cross section has a generally triangular shape with concave sides.
  • Theresulting three fairly sharp interface vertices 40, 40 and 41, respectively, of junction 39 create abutments extending almost radially outwardly from the axis of the connection substantially at right angles to the torsional stressto resist it.
  • a dotted radial line 42 is drawn from the axis of the connection vthrough an interface vertex 40. It is seen that a tangent 43 to one of the abutments is almost parallel to line 42.
  • these abutment faces near interface vertices ⁇ 40 and 42 are at maximum radial distances from the axis 'of the connection, whereby to have maximum effective moment arms in resisting torsion.
  • the ribs formed by the rounded vertices 35 and 36 of the ferrule provide reinforcement adjacent -both sides of each of the indentations 30 and 32 and thus serve to hold the indented metal of the ferrule firmly against the conductor therein and to resist any tendency for the ferrule indentations to spring ,back away from the conductor.
  • these ribs reinforce the connection in the regions of the iunction vertices 40 and 42 to aid in resisting the torsional stresses discussed above.
  • FIG 4 In Figure 4 is shown an insulated end connection on four insulated conductors 26, 26a of different sizes.
  • the end connector 20a used to make the connection includes a metal ferrule 22a telescoped over the bared conductor ends 24.
  • an insulation sheath 50 Surrounding ferrule 22a is an insulation sheath 50 having a closed end portion of smaller diameter tightly embracing the out- 'side of the metal ferrule 22a and having an open skirt the ferrule and conductor therein.
  • the orientation of the crimp away from the ferrule seam 38 is not essential, but it is advantageous as the crimp tends to subject the portions 35, 36 to the ⁇ highest circumferential compression.
  • the deformation from circular to triangular form may thus take place at any convenient angular orientation, for the insulation layer reduces the variations in circumferential stress differences in the ferrule.
  • a set of dies for making a connection as described includes a Afemale Die 60 has .a nest, generally indicated at 63, adapted to receive the ferrule longitudinally therein and having substantially straight ,sides 64 inclined'inwardly at a small angleI with respect to fthe direction of closing shown by a dashed line 66 (see Figure 8).
  • the bottom of nest 63 is defined by a longitudinal central indenter, shown as au arcuate hump 68 between concave valleys '6 9 of small radius and' ⁇ tangent fwith the straight sides 64vas well as with the hump 68;
  • Male die 62 includes a pair of longitudinally extending lateral camming tynes 70 having polished camming surfaces 72, with -a longitudinally extending forming throat 73 therebetween.
  • the indenter 68 and tynes 70 are arranged longitudinally of the ferrule and are a little shorter than the outside diameter of the ferrule so that they make indents as shown in Figures 1 and 4.
  • the ferrule with the conductor therein is placed within nest 63 ( Figure 7) which has an average width only slightly greater than the O.D. of the ferrule.
  • the nest sides and die faces 72, 73 confine the ferrule and align it over the hump 68.
  • the dies close ( Figure 8) together along the direction 66, which, although shown straight, for use in straightaction type tools, can also be arcuate for pliers-type and other types of tools. Accordingly, where parts are designated as parallel to the die path 66, it includes concentric orientation for arcuate action.
  • the tynes 70 enter the nest with their outsides 74 extending parallel with the direction 66 and in sliding con'- tact or spaced only a slight distance from the respective sides 64 of the nest.
  • Sides 64 advantageously converge slightly (see also Figure 13), which may compress the ferrule slightly. This slight convergency is advantageous for it provides positive lateral supporting by action of the sides of the nest, as the male die 62 drives the ferrule down into the nest.
  • the tynes 70 provide force multiplication and deflection action to squeeze the ferrule Itransversely until the ferrule is deformed into sub'- stantial conformity with the cooperating die Afori-hing surfaces and the conductor into substantial conformityI tothe inside of the deformed ferrule.
  • This initial transverse squeezing and camming of the ferrule and conductor occur before the voids are eliminated, and when the throat 73 is filled, then the major force is imposed on the ferrule and conductor by a direct ycompression action by the force of the male die driven into the nest to assure a solid cross section.
  • the final compression more readily obtains a solid cross section without excessive reduction in cross section of conductor or ferrule.
  • tynes 70 are supported, tynes 70 are supported laterally by sides 6 4 of the nest to prevent undue stress on throat 73 of die 62.
  • throat 73 is protected from undue stress, for as the applied force is increased during the fin-al stages of crimping, throat 73 is filled and the camming action ceases.
  • the sides of the nest may advantageously each be inclined to the direction 66 by an anglein the range from 1/2 to 3 (i.e., an included angle of convergence from l to 6). An inclination of about 1 for each side (an included convergence angle of about,2) is considered an optimum.
  • the present invention provides both the advantages of close lateral confining of the ferrule during substantially the entire crimping operation and also ease of removal of 4the completed connection from the nest.
  • the camming surfaces 72 contact an increasing portion of the circumference of the ferrule and drive it inwardto overcome the arch strength of the conductor, and eventually to forge the ferrule and conductor together with substantial metal ow.
  • the buckling of the ferrule Wall produces an initial indent which lits itself substantially to the hump 68 and surfaces 73 and further indenting increases the area of eng-agement by the camming surfaces.
  • This is advantageous, for, as the crimping forces increase, there is a concomitant increase in the area of the ferrule wall used to transmit the crimping forces to the conductor, so that the lpressures on the outside of the ferrule are not excessively increased in any point, and puncture or objectionable weakening of the ferrule wall can then be avoided. This is particularly ⁇ adr/antagemis for insulated fer'ru'les.
  • connection has become substantially voidles's.
  • connection is now completely confined between the male and female dies, and longitudinal extrusion must, therefore, occur during the final increment of closing motion, i.e., in moving from the position shown in Figure 9 until the limit elements 80 on the male die cooperate With limit elements 82 on the female die to limit further entry of the tynes 72 into Vnest 63.
  • This final longitudinal extrusion assures fresh metal contact and conforming of the conductor to the ferrule, reduces spring back, and increases the strength of the completed connection by work hardening the metal.
  • the heavy line l90 in Figure 1l shows the outline of an enlarged cross section of the crimped connection at the longitudinal center of the crimp.
  • One important factor in attaining the yhigh quality and performance of such a connection is longitudinalv extrusion of the metal, which may be expressed as percent reduction in the cross sectional area of metal in the region of the crimp, including the metal of the conductor and of the ferrule.
  • This percent reduction (also called the reduction ratio) is preferably in the range from to 48%, for this range provides the maximum torsion andi tension strengths in the completed connection.
  • the optimum size for the dimens-fon Z is equal to the maximum diameter 'of the ferrule plus gasli'ght clearance, eg. from .001 of an inch to .010 of top portion 92 of this curve being dotted.
  • This curve 90, Y92 is referred to as a scalloped 'equilatera curve, and the curve ,'90, without the portion 92, is referred to as a scalloped isosceles curve.
  • FIG 11 shows a large equilateral triangle ABC formed by four-identical smaller e'quilateral triangles AED, BFE, CDF, and DEF, the latter central triangle 91 being the one around which the scalloped equilateral curve is circumscribed.
  • the angle preferably is in the range from about 10 to about 30, and over a wide variety of applications a value of 20 proves a good compromise, with a thus having a value of 70.
  • the ratio .R2/R1 may be varied from about 6 to 9, with 6.5 being very nearly the value shown in Figure 11 and with 7.5 or 8 being used in certain instances where it is desired to obtain somewhat more pronounced ribs in the completed connection.
  • the ratio of R3/R1 may lie in the range from about 1.2 to 1.7 with approximately 11.5 being most advantageous for many applications.
  • the ratio of the height HI of the scalloped isosceles c urve to its width Z may lie in the range from about .5 to .8 with about two-thirds being most satisfactory for many applications.
  • conductor is intended to include any solid or stranded Wires or groups of them or any conductor regardless of cross sectional shape.
  • the method of making an electrical connection between a ferrule and a conductor comprising the steps of applying a first force over a relatively small area of a ferrule-forming connector portion, said force being directed inwardly of the ferrule, applying a second opposing force, with force multiplication and deflection by camming actions on the ferrule to two spaced areas on the opposite sides of an axial plane of the ferrule parallel to the direction in which the first-named force is applied, said camming actions producing radially in- Wardly directed forces on said second-named areas, respectively, all of said inwardly directed forces being comparable in magnitude, to indent the wall of said ferrule inwardly in three places against the conductor, increasing said inwardly directed forces and also increasing the circumferential extent of the indented areas until the entire periphery of the ferrule is confined by said inwardly directed forces and the ferrule and connector are forged together into substantially solid cross section, coining the connection with forces exerted on the entire periphery
  • the method of making an electrical connection be- .tween a ferrule and a conductor comprising the steps of applying a first force to a first area of the ferrule of relatively small circumferential extent, said force being directed radially inwardly of the ferrule, applying camming actions to second and third spaced areas of the ferrule, said second and third areas both being on the ⁇ opposite side of an axial plane of the ferrule from said first area and each being spaced from said first area a distance approximately equal to the spacing between said second and third areas, said camming actions producing second and third forces on said second and third areas, respectively, which are directed radially inwardly of the ferrule, said second and third forces each being comparable in magnitude to the magnitude of said first force, to collapse the wall of said ferrule inwardly in three places against the conductor therein, increasing said first force and said camming actions while increasing the circumferential extent of said first, second, and third areas until said areas extend around substantially the entire circumferences of the ferrule
  • Apparatus for crimping a ferrule into a generally triangular cross sectional form comprising a first die member having a nest adapted to receive the ferrule longitudinally therein and a second die member having a pair ⁇ of spaced tynes, said die members being adapted to close along a path with said tynes straddling the full width of the ferrule and entering said nest, sad nest having a ⁇ pair of straight sides almost parallel with said path and converging in a direction toward the bottom of the nest at an angle in the range from about 1 to about 6, each of said tynes having an outer surface and an inner carn- .ming surface a tangent to which at the mid point thereof is oriented at an acute angle with respect to said path, :said inner camming surfaces converging toward each lother with the inner portions of said cammingv surfaces defining a throat therebetween, theouter surfaces of said tynes near their ends engaging said straight sides before said die members are fully closed, thereby
  • App'aratus for crimping a ferrule into a generally triangular cross sectional form comprising a first -die l@ member having a nest adapted to receive the ferrule longi tudinally therein and a second die member having a pair of spaced tynes, said die members being adapted to close along a path with said tynes straddling the full width of the ferrule and entering said nest, said nest having a pair of sides almost parallel with said path and converging toward the bottom of the nest at an angle in the range from about 1 to about 6, each of said tynes having an inner camming surface a tangent to which at the mid point is oriented at an acute angle with respect to said path, said inner camming surfaces converging toward each other with the inner portions *of said camming surfaces defining a throat therebetween,- the extremities of said ferrule camming surfaces beingl spaced apart a distance greater than the width of the ferrule, said tynes
  • Apparatus for crimping a ferrule into a generally scalloped isosceles triangular cross sectional form comprising first and second die members movable toward each other along a path, said first die members having a nest adapted to receive the ferrule longitudinally therein, said nest being defined by a pair of spaced sides extending almost parallel with said path but converging in a direction toward the bottom of the nest at a small angle lying in the range from about 1 to about 6 and with the bottom of the nest being defined by a pair of concavities each near one of said sides with a hump therebetween, said second die member having a pair of spaced ⁇ tynes entering said nest when said die members; are
  • each of said tynes having anv inner camming surface a tangent to which at the point of initial contact with the ferrule is oriented at an acute angle with respect to said path, said inner camming surfaces converging toward each other with the inner portions of said camming surfaces defining a throat therebetween, said die members in their fully closed position defining an opening having a scalloped isosceles triangular shape as seen in cross section including three rounded vertices and three concave sides between respective vertices, the over-all height HI of the isosceles triangular shape being in the range from .5 to .8 times the over-all width Z.
  • Apparatus for crimping a ferrule into a generally scalloped triangular cross sectional form comprising first and second die members movable toward eachother along a path, said first die member having -a nest adapted to receive the ferrule longitudinally therein, said nest being defined bya pair of spaced sides extending almost parallel with said path but converging toward the bottom of the nest at a small angle lying in the range from about 1 to about 6 and with the bottom of the nest being defined by a pair of concavities each near one of said sides with a hump therebetween, said second die member having a pair of spaced tynes entering said nest when said die members are moved along said path, each of said tynes having an inner camming surface a tangent to which at the point of initial contact with the ferrule is oriented at an acute angle with respect to said path, said tynes having tps spaced apart a distance greater than the width of the bottom of the nest, said tynes having outer surfaces bearing against
  • said second die member having a pair of spaced tynes entering said nest when said die members are moved along said path, each of said tynes having an inner convex camming surface which con'- verges toward the convex camming surface of the other tyne in a direction away from said nest.
  • Apparatus for crimping a 'ferijule into a generally scalloped triangular cross sectional form comprising rst and second die members movable toward each other along a path, said first die member as seen in elevation having a nest adapted to receive the ferrule longitudinally therein, said nest being defined by a pair of spaced sides extending almost parallel with said path but converging at a small angle toward the bottom of the nest and with the bottom of the nest being defined by a pair of concavities each near one of said sides with an arcuate longitudinally extending hump therebetween, said second die member as seen in elevation having a pair of spaced tynes entering said nest when said die members are 'moved along said path, each of said tynes having a camming surface, tangent to all portions of said respective camming surfaces being oriented at acute angles with respect vto said path, each of said camming surfaces including longitudinally extending convex surfaces, with the inner portions of both of
  • Crimping apparatus for crimping ferrules onto electrical conductors vforming electrical connections having scalloped triangular cross sectional form comprising rst and second die members movable toward each other along a path, said first die member having a nest adapted to receive the ferrule longitudinally therein, said nest including a pair of spaced sides extending almost parallel with -said path but converging at a small angle lying in the range from about 1 to about 6, the bottom of the nest being defined by a pair of concavities extending longitudinally and each tangent to a respective one of said sides with a longitudinally extending hump therebetween and tangent to said concavities, said concavities having a radius of curvature R1 and said hump having -a radius of curvature R2, ysaid second die member including a pair of spaced tynes straddling the full width of the ferrule and entering said nest, the outer surfaces of said tynes engaging said nest sides in the
  • Crimping apparatus for crimping ferrules onto electrical conductors for forming electrical connections having scalloped triangular cross-'sectional shape comprising rst and second die members movable toward each other along a path, said vfirst die member having a nest adapted to receive the terrine longitudinally therein, said nest including a pair of spaced sides converging toward the bottom of the nest, the bottom of the nest being defined by a pairof longitudinally 'extending ccnl cave cylindrical surfaces each tangent to a respective ⁇ side with 'a longitudinally extending convex cylindrical hump 'therebetween tangent to both of said concave surfaces, said second die member including a pair of spaced tynes entering opposite sides of the nest closely adjacent to said converging side surfaces of the nest and straddling the full width of the ferrule, said tynes having a longitudinally extending central concave cylindrical cavity therebetween, said tynes each having an inner converging camming face tang
  • Crimping apparatus as claimed in claim l1 and wherein said three convex sides have a radius of curvature lying in the range from 6 to 9 times the radius of curvature of the concave vertices.
  • Crimping apparatus for forming crimped electrical connections between ferrules and conductors inserted therein including rst and second dies movable toward each other along a path, said first die having a nest for receiving a ferrule longitudinally therein and including a pair of spaced side walls 'each converging with 'respect to said path toward the bottom of 'the nest, the bottom of the nest being defined by a central longitudinally extending cylindrical hump and by a pair of longitudinally extending cylindrical cavities each tangent to said hump and to respective side 'walls of the nest, said second die including a pair of spaced tynes entering opposite sides of the nest adjacent to said side Walls, said tynes having a central longitudinally extending cylindrical hollow therebetween and each having a longitudinally extending convexvcylndrical camming surface tangent to opposite sides of said hollow, said tynes each having a longitudinally extending cylindrical cavity near the end and tangent to the camming surface
  • Crimping apparatus for forming crimped electrical connections between ferrules and electrical conductors telescoped therein, 'said apparatus including first and second crimping dies adapted to move towards each other along a path, said rst die having a nest for receiving a ferrule longitudinally therein, said nest having a pair of spaced side walls each converging with respect to said path, the bottom of said nest being defined by a central humpy and by a pair of cavities tangent to opposite sides of said hump and to a respective side wall, said second die including a pair of spaced tynes entering opposite Vsides of the nest and closely adjacent to respective side walls in the fully closed position, said tynes having a central hollow therebetween and convex camming surfaces tangent to opposite sides of said hollow, with a cavity near the end of each tangent to the camming surface, said hump having a convex surface between 15% and 40% wider than said convex camming surfaces, said dies in their fully
  • Crimping apparatus for forming crimped electrical connections between ferrules and electrical conductors telescoped therein, said apparatus includingvfir'st andsecond crimping dies adapted to move towards each other, said first die having a nest including a pair of spaced side walls, the bottom of the nest including a central hump and Aa pair of concavities tangent to opposite sides of the hump and to a respective side wall, said second die including a pair of spaced types entering opposite sides of the nest and closely adjacent to the respective side walls when the dies are in their fully closed position, said tynes having a central hollow therebetween and convex camming surfaces tangent to opposite sides of said hollow and with a concavity near the end of each tyne tangent with the convex cammng surface, said hump and said convex camming surfaces when said dies are in their fully closed position being tangent to the respective sides of an equilateral triangle, said concavities at opposite sides of the first

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
US441277A 1954-07-06 1954-07-06 Crimping methods and apparatus Expired - Lifetime US2965147A (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
NL198024D NL198024A (ko) 1954-07-06
NL102635D NL102635C (ko) 1954-07-06
US441277A US2965147A (en) 1954-07-06 1954-07-06 Crimping methods and apparatus
FR1137368D FR1137368A (fr) 1954-07-06 1955-06-22 Procédé et appareil de sertissage
DEA23006A DE1084337B (de) 1954-07-06 1955-07-04 Verfahren zur Herstellung einer elektrischen Verbindung zwischen einer zylindrischenZwinge und einem eingelegten Leiter
CH344113D CH344113A (de) 1954-07-06 1955-07-06 Verfahren und Vorrichtung zur Herstellung einer elektrischen Verbindung und eine nach diesem Verfahren hergestellte Verbindung
GB19543/55A GB811996A (en) 1954-07-06 1955-07-06 Improvements in or relating to electrical connections and to methods of and apparatus for use in making same

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US441277A US2965147A (en) 1954-07-06 1954-07-06 Crimping methods and apparatus

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US2965147A true US2965147A (en) 1960-12-20

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US441277A Expired - Lifetime US2965147A (en) 1954-07-06 1954-07-06 Crimping methods and apparatus

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US (1) US2965147A (ko)
CH (1) CH344113A (ko)
DE (1) DE1084337B (ko)
FR (1) FR1137368A (ko)
GB (1) GB811996A (ko)
NL (2) NL102635C (ko)

Cited By (28)

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Publication number Priority date Publication date Assignee Title
US3067489A (en) * 1956-12-28 1962-12-11 Amp Inc Method of making an electrical connection
US3089532A (en) * 1960-02-23 1963-05-14 Amp Inc Dies for crimping electrical connectors
US3728889A (en) * 1969-07-29 1973-04-24 Itt Crimping device
US3739470A (en) * 1971-09-16 1973-06-19 Thomas & Betts Corp Connector
US3768146A (en) * 1972-02-22 1973-10-30 Bell Telephone Labor Inc Method of splicing optical fibers
US3807021A (en) * 1972-12-01 1974-04-30 Birkett Automation Ind Ltd Ignition boot hoppering and assembly device
US4005522A (en) * 1975-02-13 1977-02-01 Northern Telecom Limited Method of connecting two optical fibres in end to end relationship
US4654478A (en) * 1978-03-02 1987-03-31 Ngk Insulators, Ltd. Electrical insulator including metal sleeve compressed onto a fiber reinforced plastic rod and method of assembling the same
US4828516A (en) * 1983-12-30 1989-05-09 Amp Incorporated Crimped electrical connection and crimping dies therefore
US4890384A (en) * 1988-08-25 1990-01-02 Amp Incorporated Method of crimping an electrical connection
US4976132A (en) * 1983-12-30 1990-12-11 Amp Incorporated Dies for crimping an electrical connection
US5301421A (en) * 1991-10-28 1994-04-12 Electro-Max Mfg. Co. Method and apparatus for making fluid cooled conductor
WO1997020363A1 (en) * 1995-11-30 1997-06-05 The Whitaker Corporation Tools for crimping an electrical contact onto a conductor
US5654527A (en) * 1994-07-19 1997-08-05 The Deutsch Company Method and apparatus for connecting electric bus
US5960540A (en) * 1996-11-08 1999-10-05 The Whitaker Corporation Insulated wire with integral terminals
WO2006000743A1 (en) * 2004-06-24 2006-01-05 Tyco Electronics Raychem Ireland A method of manufacturing a crimped assembly, and related apparatuses
EP2251935A1 (de) * 2009-05-11 2010-11-17 Bremi Fahrzeug-Elektrik GmbH + Co. KG Anschlusskabel
WO2011102536A1 (en) * 2010-02-17 2011-08-25 Yazaki Corporation Crimping apparatus for shielded wire and method for end-processing shielded wire
US20120100763A1 (en) * 2009-06-30 2012-04-26 Siemens Aktiengesellschaft End fitting of an electrical part and method for pressing an end fitting
EP2738885A1 (en) * 2011-07-26 2014-06-04 Sumitomo Wiring Systems, Ltd. Crimping die and method for manufacturing electric wire with terminal
US20140194014A1 (en) * 2011-09-12 2014-07-10 Fuji Electric Wire Industries Co., Ltd. Electric wire connection structure
US20150085420A1 (en) * 2013-09-26 2015-03-26 Inpro/Seal Llc Conductive Assembly
US20170069975A1 (en) * 2014-04-28 2017-03-09 Rosenberger Hochfrequenztechnik Gmbh & Co. Kg Crimped and welded connection
US20180100560A1 (en) * 2014-02-14 2018-04-12 The National Telephone Supply Company Connector for synthetic and coated wire rope
US20180318897A1 (en) * 2015-11-12 2018-11-08 Sumitomo Wiring Systems, Ltd. Method of manufacturing band-shaped metal wire member including bonded portion, method of manufacturing terminal-equipped band-shaped metal wire member, die, and band-shaped metal wire member including bonded portion
US10374334B2 (en) * 2017-01-24 2019-08-06 Tyco Electronics (Shanghai) Co. Ltd. Cable connector
US11011858B2 (en) * 2018-06-06 2021-05-18 Te Connectivity India Private Limited Multiple bussed terminations
US11069991B2 (en) * 2017-06-05 2021-07-20 Jilin Zhong Ying High Technology Co., Ltd. Joint between copper terminal and aluminum wire, and magnetic induction welding method therefor

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DE1131766B (de) * 1959-09-28 1962-06-20 Ernst Peters Dr Verfahren zum Verbinden von elektrischen Leitungen und Verbinderhuelse fuer diese
DE3127284C2 (de) * 1981-07-10 1985-02-21 Karl Pfisterer Elektrotechnische Spezialartikel Gmbh & Co Kg, 7000 Stuttgart Batterieklemme
DE3127283C2 (de) * 1981-07-10 1983-12-08 Karl Pfisterer Elektrotechnische Spezialartikel Gmbh & Co Kg, 7000 Stuttgart Verfahren zum Herstellen einer elektrischen Verbindung zwischen einer Preßhülse und einem Leiter
DE9117167U1 (de) * 1991-05-08 1996-08-01 GLW-Elektronische Bauteile Kunststoffverarbeitung GmbH, 88353 Kißlegg Aderendhülse
DE9408005U1 (de) * 1994-04-16 1995-05-18 Schneider, Horst, 88371 Ebersbach-Musbach Mehrfach-Aderendhülsen

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US2256457A (en) * 1937-11-26 1941-09-16 H A Douglas Mfg Co Hand swaging tool
US2396913A (en) * 1944-07-15 1946-03-19 Aircraft Marine Prod Inc Apparatus for severing and crimping electrical connectors
US2452932A (en) * 1944-04-10 1948-11-02 Aircraft Marine Prod Inc Electrical connector
US2457538A (en) * 1944-11-11 1948-12-28 Burndy Engineering Co Inc Crimping tool
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US2564874A (en) * 1947-04-04 1951-08-21 Artos Engineering Co Terminal wiring method and apparatus
US2685076A (en) * 1951-05-05 1954-07-27 Aircraft Marine Prod Inc Electrical connector
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US2109837A (en) * 1936-01-02 1938-03-01 Grace P Davis Method of joining power transmitting cables
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US2467012A (en) * 1945-01-27 1949-04-12 Buchanan Electrical Prod Corp Tool for making electrical connectors
US2587095A (en) * 1947-04-08 1952-02-26 Thomas & Betts Corp Electric cable connector
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US1324177A (en) * 1919-12-09 Zjegtoes
US308087A (en) * 1884-11-18 Device for attaching loops to ropes or cords
FR359800A (fr) * 1905-11-25 1906-04-04 Sueddeutsche Jsolierrohr-Werke G. M. B. H. Pince à cintrer les tubes isolants pourvus d'enveloppes métalliques
US1858418A (en) * 1930-09-12 1932-05-17 Rajah Company Tool
US2002220A (en) * 1932-12-29 1935-05-21 Harry A Douglas Swaging means
US2226849A (en) * 1936-07-03 1940-12-31 Kingston Products Corp Electrical connection means
US2256457A (en) * 1937-11-26 1941-09-16 H A Douglas Mfg Co Hand swaging tool
US2251709A (en) * 1940-01-04 1941-08-05 Nat Telephone Supply Co Method of connecting wires to sleeves
US2452932A (en) * 1944-04-10 1948-11-02 Aircraft Marine Prod Inc Electrical connector
US2396913A (en) * 1944-07-15 1946-03-19 Aircraft Marine Prod Inc Apparatus for severing and crimping electrical connectors
US2457538A (en) * 1944-11-11 1948-12-28 Burndy Engineering Co Inc Crimping tool
US2535013A (en) * 1946-03-20 1950-12-19 Aircraft Marine Prod Inc Electrical connector
US2564874A (en) * 1947-04-04 1951-08-21 Artos Engineering Co Terminal wiring method and apparatus
US2704358A (en) * 1947-10-24 1955-03-15 Aircraft Marine Prod Inc Electrical connection and method
US2685076A (en) * 1951-05-05 1954-07-27 Aircraft Marine Prod Inc Electrical connector

Cited By (36)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3067489A (en) * 1956-12-28 1962-12-11 Amp Inc Method of making an electrical connection
US3089532A (en) * 1960-02-23 1963-05-14 Amp Inc Dies for crimping electrical connectors
US3728889A (en) * 1969-07-29 1973-04-24 Itt Crimping device
US3739470A (en) * 1971-09-16 1973-06-19 Thomas & Betts Corp Connector
US3768146A (en) * 1972-02-22 1973-10-30 Bell Telephone Labor Inc Method of splicing optical fibers
US3807021A (en) * 1972-12-01 1974-04-30 Birkett Automation Ind Ltd Ignition boot hoppering and assembly device
US4005522A (en) * 1975-02-13 1977-02-01 Northern Telecom Limited Method of connecting two optical fibres in end to end relationship
US4654478A (en) * 1978-03-02 1987-03-31 Ngk Insulators, Ltd. Electrical insulator including metal sleeve compressed onto a fiber reinforced plastic rod and method of assembling the same
US4828516A (en) * 1983-12-30 1989-05-09 Amp Incorporated Crimped electrical connection and crimping dies therefore
US4976132A (en) * 1983-12-30 1990-12-11 Amp Incorporated Dies for crimping an electrical connection
US4890384A (en) * 1988-08-25 1990-01-02 Amp Incorporated Method of crimping an electrical connection
US5301421A (en) * 1991-10-28 1994-04-12 Electro-Max Mfg. Co. Method and apparatus for making fluid cooled conductor
US5654527A (en) * 1994-07-19 1997-08-05 The Deutsch Company Method and apparatus for connecting electric bus
US5692294A (en) * 1995-06-09 1997-12-02 The Whitaker Corporation Tools for crimping an electrical contact onto a conductor
WO1997020363A1 (en) * 1995-11-30 1997-06-05 The Whitaker Corporation Tools for crimping an electrical contact onto a conductor
US5960540A (en) * 1996-11-08 1999-10-05 The Whitaker Corporation Insulated wire with integral terminals
WO2006000743A1 (en) * 2004-06-24 2006-01-05 Tyco Electronics Raychem Ireland A method of manufacturing a crimped assembly, and related apparatuses
JP2008503354A (ja) * 2004-06-24 2008-02-07 タイコ・エレクトロニクス・レイケム・アイルランド 圧着組立体の製造方法及び関連する装置
US8375552B2 (en) 2004-06-24 2013-02-19 Tyco Electronics Raychem Ireland Method of manufacturing a crimped assembly, and related apparatuses
EP2251935A1 (de) * 2009-05-11 2010-11-17 Bremi Fahrzeug-Elektrik GmbH + Co. KG Anschlusskabel
US20120100763A1 (en) * 2009-06-30 2012-04-26 Siemens Aktiengesellschaft End fitting of an electrical part and method for pressing an end fitting
WO2011102536A1 (en) * 2010-02-17 2011-08-25 Yazaki Corporation Crimping apparatus for shielded wire and method for end-processing shielded wire
US9698553B2 (en) 2011-07-26 2017-07-04 Sumitomo Wiring Systems, Ltd. Method for manufacturing terminal-fitted wire
EP2738885A1 (en) * 2011-07-26 2014-06-04 Sumitomo Wiring Systems, Ltd. Crimping die and method for manufacturing electric wire with terminal
EP2738885A4 (en) * 2011-07-26 2014-12-17 Sumitomo Wiring Systems CRIMPING MATRIX AND METHOD FOR MANUFACTURING ELECTRIC WIRE WITH TERMINAL TERMINAL
US9543726B2 (en) 2011-07-26 2017-01-10 Sumitomo Wiring Systems, Ltd. Crimping die for terminal fitted wire
US20140194014A1 (en) * 2011-09-12 2014-07-10 Fuji Electric Wire Industries Co., Ltd. Electric wire connection structure
US20150085420A1 (en) * 2013-09-26 2015-03-26 Inpro/Seal Llc Conductive Assembly
US20180100560A1 (en) * 2014-02-14 2018-04-12 The National Telephone Supply Company Connector for synthetic and coated wire rope
US20170069975A1 (en) * 2014-04-28 2017-03-09 Rosenberger Hochfrequenztechnik Gmbh & Co. Kg Crimped and welded connection
US10396472B2 (en) * 2014-04-28 2019-08-27 Rosenberger Hochfrequenztechnik Gmbh & Co. Kg Crimped and welded connection
US20180318897A1 (en) * 2015-11-12 2018-11-08 Sumitomo Wiring Systems, Ltd. Method of manufacturing band-shaped metal wire member including bonded portion, method of manufacturing terminal-equipped band-shaped metal wire member, die, and band-shaped metal wire member including bonded portion
US10919079B2 (en) * 2015-11-12 2021-02-16 Sumitomo Wiring Systems, Ltd. Method of manufacturing band-shaped metal wire member including bonded portion
US10374334B2 (en) * 2017-01-24 2019-08-06 Tyco Electronics (Shanghai) Co. Ltd. Cable connector
US11069991B2 (en) * 2017-06-05 2021-07-20 Jilin Zhong Ying High Technology Co., Ltd. Joint between copper terminal and aluminum wire, and magnetic induction welding method therefor
US11011858B2 (en) * 2018-06-06 2021-05-18 Te Connectivity India Private Limited Multiple bussed terminations

Also Published As

Publication number Publication date
DE1084337B (de) 1960-06-30
NL198024A (ko)
FR1137368A (fr) 1957-05-28
NL102635C (ko)
GB811996A (en) 1959-04-15
CH344113A (de) 1960-01-31

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