US3221294A - Crimped electrical connections - Google Patents

Crimped electrical connections Download PDF

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Publication number
US3221294A
US3221294A US277749A US27774963A US3221294A US 3221294 A US3221294 A US 3221294A US 277749 A US277749 A US 277749A US 27774963 A US27774963 A US 27774963A US 3221294 A US3221294 A US 3221294A
Authority
US
United States
Prior art keywords
portions
web
sidewalls
wire
remote
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US277749A
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English (en)
Inventor
Lincoln E Roberts
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TE Connectivity Corp
Original Assignee
AMP Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AMP Inc filed Critical AMP Inc
Priority to US277749A priority Critical patent/US3221294A/en
Priority to GB15087/64A priority patent/GB1004391A/en
Priority to FR972305A priority patent/FR1392959A/fr
Priority to BE647185A priority patent/BE647185A/xx
Priority to NL646404672A priority patent/NL140109B/xx
Priority to DE19641615560 priority patent/DE1615560B2/de
Priority to CH572564A priority patent/CH421223A/fr
Application granted granted Critical
Publication of US3221294A publication Critical patent/US3221294A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H01R4/185—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
    • 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

Definitions

  • a common type of crimped electrical connection between a terminal and a wire is made by providing a channel-shaped or open-U ferrule on the terminal, positioning the wire between the sidewalls of the ferrule, and curling these sidewalls towards each other and downwardly towards the web of the ferrule.
  • This type of crimped connection has received a wide acceptance in the art for the reason that the open-U type ferrule can be easily formed by conventional die stamping and forming methods and it therefore lends itself to inexpensive manufacturing techniques.
  • An additional advantage of this type of connection is that the wire can be positioned in the channel-shaped ferrule with relative ease.
  • a further object is to provide a crimped connection between an open-U type ferrule and a wire which has an extremely small diameter relative to the cross sectional dimensions of the ferrule.
  • a further object is to provide a crimped connection, and a method of crimping, for open-U type ferrules which is amenable to usage with extremely hard and therefore non-formable metals.
  • a still further object of the invention is to provide a crimped electrical connection and method for open-U type ferrules which permits a wide variation in the size of the wire for a fixed ferrule size.
  • the wire is positioned on the web and between the sidewalls of the ferrule.
  • a compressive force is applied to each of the sidewalls at their upper edges. Since the sidewalls are relatively thin, with relation to their height, they behave in the same 3,221,294 Patented Nov. 30, 1965 manner as a compressively loaded column and buckle.
  • the compressive loading and the buckling of the sidewalls is controlled in a manner such that they buckle inwardly and towards each other until their opposed sides come into engagement with each other along a line extending parallel to the axis of the ferrule.
  • the displaced sections of the sidewalls are contained between lower portions of the sidewalls which are adjacent to the web.
  • the displaced sections additionally have their upper ends curled over the portions of the sidewalls which are adjacent to the web so that the parts are all tightly compacted and held together with the wire disposed between the opposed sides of the displaced sidewall sections.
  • the invention thus avoids the extreme degree of curling of the sidewalls, which would be imposed with very hard metal and permits the crimping of extremely fine wires to the contact terminal by virtue of the fact that most of the area within the ferrule is occupied by the severed sections of the sidewalls.
  • FIGURE 1 is a plan view of one form of contact terminal having an open-U type ferrule which is adapted to be crimped in accordance with the principles of the invention.
  • FIGURE 2 is a frontal view of .a crimping die and anvil for forming a crimped connection in accordance with the invention.
  • FIGURES 3-9 are fragmentary views illustrating the manner in which the sidewalls are deformed and fractured during the formation of a crimped connection in accordance with the invention.
  • FIGURE 10 is a cross-sectional view of a crimped connection in accordance with the invention in which the wire has a relatively larger cross section than in the embodiment of FIGURES 3-9.
  • FIGURE 1 shows a type of contact terminal which is more fully described in my co-pending application Serial Number 183,542, filed March 29, 1962, and now abandoned.
  • This type of contact terminal has an intermediate channel-shaped section 4 from which a pair of arms 6 and e 8 extend, these arms being formed in a manner such that contact terminals of this type are matable with identical terminals as fully explained in my above-mentioned copending application.
  • the channel-shaped section 10 constitutes a ferrule forming portion which is adapted to be crimped onto a wire core.
  • the channelshaped section 12 is intended for crimping onto the insulation of the wire and the section 14 functions as a stabilizing device for retaining the contact against undue lateral movement after the contact has been inserted into an insulating block.
  • My above-mentioned co-pending application shows the ferrule portion 10 as being crimped onto the wire in the manner known to the prior art, that is by curling of the sidewalls relatively towards each other and towards the web while the section 12 is shown as being conventionally crimped onto the insulation of the wire.
  • the ferrule portion 10 is crimped onto an extremely fine wire in accordance with the principles of the present invention and the insulation crimp 12 is not utilized.
  • the ferrule portion 10 comprises a web 16 having sidewalls extending upwardly from its longitudinal sides.
  • the portions of the sidewalls 18 which are adjacent to the Web 16 extend substantially parallel to each other and normally of the plane of the web 16 while the sidewall portions 20 which are remote from the web diverge slightly.
  • the cross-sectional shape of ferrule portion 10 differs from that shown in application, Serial Number 183,542, particularly with regard to the divergent remote sidewall sections 20.
  • the upper edges 22 of the sidewalls are slightly chamfered on their inner sides as shown at 23.
  • a fine wire 24 to which the ferrule is to be crimped is positioned between the sidewalls and on the web.
  • FIG- URE 3 shows the approximate size of the wire with relation to the size of the ferrule where the invention is being practiced for purposes of forming a crimped connection between an extremely small wire (e.g. A.W.G. 40) and a ferrule which is grossly oversized with relation to the wire.
  • an extremely small wire e.g. A.W.G. 40
  • the crimped connection is formed with an anvil 26 and a crimping die 28 movable towards and away from the anvil.
  • This anvil and die will ordinarily be mounted in a conventional bench press or a hand tool.
  • Anvil 26 has an upper surface 27 on which the Web of the ferrule is supported during crimping.
  • the anvil is adapted to be received within a recess in the die 28 as the parts move relatively towards each other.
  • This recess in the crimping die has inwardly convergent forming surfaces 30 which merge with forming surfaces 32 adjacent to the upper end of the recess.
  • the surfaces 32 converge silghtly and in turn merge with semi-circular curved surfaces 34 on each side of the center line of the recess. These curved surfaces 34 are symmetrical about the center line and intersect each other to form a central cusp 36.
  • the wire ferrule When it is desired to form a crimped connection, the wire ferrule is positioned on the anvil surface 27 and the wire is positioned on the web 16 and between the sidewalls as shown in FIGURE 3.
  • the crimping die 28 is thereafter moved relatively towards the anvil 26 until the surface portions 30 of the die recess engage the outside edges of the upper sidewall portions 20.
  • the surface portions 30 and later the surface portions 32 of the die recess bend the sidewalls towards each other.
  • the sidewalls each bend as a unit during this point of the crimping cycle until the remote sidewall portions 20 extend substantially parallel to each other and the adjacent sidewall portions 18 extend slightly convergently towards each other.
  • the surfaces 34 engage the upper ends of remote sidewall portions 20 and further bend the sidewalls inwardly until the remote sidewall portions are slightly divergent as shown in FIGURE and the sidewall edges bear against the center portions of the surfaces 34.
  • the sidewalls will be under a substantially vertical compressive load (as viewed in the drawing) which will be applied on the outside edge portions of the upper ends of the sidewalls, that is beside the charnfered portions 23.
  • the sidewalls do not bend about their lower ends beyond the position of FIGURE 5 for the reason that they are being compressed by a vertical load Without a substantial horizontal component.
  • the sidewalls buckle after the stage shown in FIGURE 5 has been reached until the cross section of the ferrule is as shown in FIG- URE 6 with opposed internal surfaces of the remote sidewall portions bearing against each other and with the external surfaces of the adjacent sidewall portions bearing against the surfaces 32 of the die recess.
  • the compressive loading which causes the buckling also causes an increase in the thickness of the metal stock as is indicated in FIGURE 6.
  • the cusp of the forming surface of the die will be disposed between the opposed surfaces of sidewall portions 20 and the upper edges of these sidewall portions will have been deformed to conform to the curvature of the surfaces 34 of the die.
  • the two remote sidewall portions are then displaced downwardly as shown in FIGURE 8 until they move against the surface of the web 16 on each side of the wire.
  • the term displaced as used above is intended to imply that the remote sidewall portions are moved as units downwardly against the surface of the web 16. These remote sidewall portions do not lose their identity during the process.
  • the upper longitudinal edges of the remote portions 20 will assume a surface configuration corresponding to the curvature of the surfaces 34.
  • the final increment of downward movement of the crimping die relative to the anvil compacts the severed remote sidewall portions between the remaining integral sidewall portions 18 and compresses the entire system until the opposed sides of the remote portions 20 compressively confine the wire against the web surface 16.
  • the finished crimped connection has been found to possess a high degree of stability against relaxation for the reason that the severed sidewall sections 20 are rigidly held between the adjacent sidewall sections 18 and the wire, in turn, is held between the sides of the remote sections 20.
  • FIGURE 9 clearly shows that the crosssectional area of the wire is extremely small as compared to the cross-sectional area of the entire crimped connection however, because of the high degree of compacting the wire is tightly held in the crimp.
  • FIGURES 8 and 9 a substantial-1y triangular opening extends centrally through the crimp which is defined by the sides of the sidewall portions 20 and by the web and that the Wire is deformed until it assumes a cross-sectional shape corresponding to this triangular opening. It has been found that this triangular cross-section i ordinarily obtained although its size will vary when the wire size is changed; that is the larger the wire, the larger the triangular space.
  • FIGURES 3-9 assume that the wire was centrally positioned by the operator on the web and remained so located during the crimping process. In practice, the wire will not always be centered by the operator however, as the severed remote sidewall portions move through the positions of FIGURES 7-9, they will push the wire rightwardly or leftward'ly until it is centered during the final stages of the crimping operation.
  • FIGURE 10 shows a cross-section of a crimped connection in accordance with the invention where a relatively larger wire is involved.
  • the remote portions 20' of the sidewalls were displaced towards the Web along the shear planes 40' so that remote portions are, as in the previously described embodiment, contained between the opposed faces of the adjacent portions 18'.
  • FIGURE 10 differs from the previously described embodiment of the invention in that fracturing did not take place along the shear planes 40' although it is apparent that there was a substantial displacement of the remote portions of the sidewalls along these planes. Fracture did not take place in the embodiment of FIG- URE for the reason that the relatively large wire W became compressed between the opposed faces of the remote portions and prevented further downward displacement of the remote portions before complete shearing has taken place. It is thus apparent that shearing along the planes 40 or 40' may or may not take place depending upon the size of the wire relative to the size of the ferrule and the hardness or ductility of the metal.
  • the remote sidewall portions and the adjacent sidewall portions extend generally normally from the plane of the web 16 and that these remote sidewall portions and adjacent portions extend generally parallel to each other.
  • a salient advantage of the invention is that it permits a relatively large channel-shaped ferrule to be crimped onto an extremely small wire since a substantial portion of a crimp cross-section is occupied by the severed sidewall sections 20.
  • An additional feature of the invention is that it does not require an extremely high degree of bending of the ferrule but rather relies upon limited bending of the ferrule sidewalls coupled with the fracturing step illustrated in FIGURE 7 and the utilization of the fractured or displaced portions of the sidewall to confine the wire.
  • This feature of the invention permits the crimping of ferrules made of extremely hard materials which would not be capable of being bent and formed in accordance with previously known methods of crimping.
  • a crimped electrical connection between a wire and a ferrule portion of a terminal said ferrule portion having been substantially U-shaped in cross-section and having comprised a web with upstanding sidewalls on two opposite sides thereof prior to crimping, each of said sidewalls having comprised an adjacent portion and a remote portion with respect to said web, said remote portions having been displaced as units during crimping towards said web and being at least partially telescopically disposed between the opposed faces of said adjacent portions, the planes of said remote portions in said crimped connection extending beside the planes of said adjacent portions and the planes of said remote and adjacent portions extending substantially normally of the plane of said web, said wire being confined by the opposed faces of said remote portions and said web.
US277749A 1963-05-03 1963-05-03 Crimped electrical connections Expired - Lifetime US3221294A (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
US277749A US3221294A (en) 1963-05-03 1963-05-03 Crimped electrical connections
GB15087/64A GB1004391A (en) 1963-05-03 1964-04-13 Crimping an electrical connector to a wire
FR972305A FR1392959A (fr) 1963-05-03 1964-04-24 Liaisons électriques serties
BE647185A BE647185A (de) 1963-05-03 1964-04-27
NL646404672A NL140109B (nl) 1963-05-03 1964-04-28 Werkwijze voor het krimpen van een buisorgaan van een elektrisch verbindingsorgaan om een draad en elektrische verbinding vervaardigd volgens deze werkwijze.
DE19641615560 DE1615560B2 (de) 1963-05-03 1964-04-29 Verfahren zum Andrucken der U förmigen Zwinge einer elektrischen Anschlußklemme an einen Draht und danach hergestellte Ver bindung
CH572564A CH421223A (fr) 1963-05-03 1964-05-01 Procédé de sertissage de la virole dhun connecteur électrique sur un fil et connecteur serti obtenu par ce procédé

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US277749A US3221294A (en) 1963-05-03 1963-05-03 Crimped electrical connections

Publications (1)

Publication Number Publication Date
US3221294A true US3221294A (en) 1965-11-30

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ID=23062191

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Application Number Title Priority Date Filing Date
US277749A Expired - Lifetime US3221294A (en) 1963-05-03 1963-05-03 Crimped electrical connections

Country Status (6)

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US (1) US3221294A (de)
BE (1) BE647185A (de)
CH (1) CH421223A (de)
DE (1) DE1615560B2 (de)
GB (1) GB1004391A (de)
NL (1) NL140109B (de)

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3404368A (en) * 1965-08-04 1968-10-01 Amp Inc Electrical connector of the plug or socket variety
US3568137A (en) * 1969-02-24 1971-03-02 Maurice E Youngblut Adapter for contact with crimp tail
US3825881A (en) * 1972-12-29 1974-07-23 Burndy Corp Termination device for flat electrical conductors
DE2555709A1 (de) * 1975-12-11 1977-06-23 Grote & Hartmann Leiterkralle sowie verfahren und vorrichtung zu ihrer formgebung
US4738640A (en) * 1986-11-24 1988-04-19 Noel Lee Spade lug
US4802870A (en) * 1987-10-19 1989-02-07 Noel Lee Universal electrical connector
US4834666A (en) * 1987-03-30 1989-05-30 Noel Lee Electrical pin with bend
US4963101A (en) * 1987-03-30 1990-10-16 Noel Lee Electrical pin with bend
DE8914951U1 (de) * 1989-12-18 1991-04-18 Grote & Hartmann Gmbh & Co Kg, 5600 Wuppertal, De
DE4339749A1 (de) * 1993-11-22 1995-05-24 Grote & Hartmann Crimp sowie Crimpoberstempel zur Herstellung des Crimps und Verfahren zur Herstellung des Crimpoberstempels
US5529506A (en) * 1993-04-28 1996-06-25 Yazaki Corporation Terminal for shielding connectors and shielding connector
DE29705134U1 (de) * 1997-03-20 1997-05-07 Ingos Elektronik Handelsgesell Steckerbuchse
US20090275247A1 (en) * 2008-05-03 2009-11-05 Michael Richter Contact for a connection box
US20200076179A1 (en) * 2018-08-30 2020-03-05 Rosenberger Hochfrequenztechnik Gmbh & Co. Kg Multi-core cable

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT17305U1 (de) * 2020-03-10 2021-12-15 Pollmann Int Gmbh Verbindungselement, Verbindungsvorrichtung sowie Verfahren zum elektrisch leitenden lötfreien Verbinden eines elektrischen Elements

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2535013A (en) * 1946-03-20 1950-12-19 Aircraft Marine Prod Inc Electrical connector
US2693216A (en) * 1951-10-11 1954-11-02 Aircraft Marine Prod Inc Tool for electrical connectors
US2789277A (en) * 1953-02-03 1957-04-16 Amp Inc Electrical connection and method

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2535013A (en) * 1946-03-20 1950-12-19 Aircraft Marine Prod Inc Electrical connector
US2693216A (en) * 1951-10-11 1954-11-02 Aircraft Marine Prod Inc Tool for electrical connectors
US2789277A (en) * 1953-02-03 1957-04-16 Amp Inc Electrical connection and method

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3404368A (en) * 1965-08-04 1968-10-01 Amp Inc Electrical connector of the plug or socket variety
US3568137A (en) * 1969-02-24 1971-03-02 Maurice E Youngblut Adapter for contact with crimp tail
US3825881A (en) * 1972-12-29 1974-07-23 Burndy Corp Termination device for flat electrical conductors
DE2555709A1 (de) * 1975-12-11 1977-06-23 Grote & Hartmann Leiterkralle sowie verfahren und vorrichtung zu ihrer formgebung
US4738640A (en) * 1986-11-24 1988-04-19 Noel Lee Spade lug
US4834666A (en) * 1987-03-30 1989-05-30 Noel Lee Electrical pin with bend
US4963101A (en) * 1987-03-30 1990-10-16 Noel Lee Electrical pin with bend
US4802870A (en) * 1987-10-19 1989-02-07 Noel Lee Universal electrical connector
DE8914951U1 (de) * 1989-12-18 1991-04-18 Grote & Hartmann Gmbh & Co Kg, 5600 Wuppertal, De
US5529506A (en) * 1993-04-28 1996-06-25 Yazaki Corporation Terminal for shielding connectors and shielding connector
DE4339749A1 (de) * 1993-11-22 1995-05-24 Grote & Hartmann Crimp sowie Crimpoberstempel zur Herstellung des Crimps und Verfahren zur Herstellung des Crimpoberstempels
DE29705134U1 (de) * 1997-03-20 1997-05-07 Ingos Elektronik Handelsgesell Steckerbuchse
US20090275247A1 (en) * 2008-05-03 2009-11-05 Michael Richter Contact for a connection box
US7819709B2 (en) * 2008-05-03 2010-10-26 Lumberg Connect Gmbh Contact for a connection box
US20200076179A1 (en) * 2018-08-30 2020-03-05 Rosenberger Hochfrequenztechnik Gmbh & Co. Kg Multi-core cable
US10886720B2 (en) * 2018-08-30 2021-01-05 Rosenberger Hochfrequenztechnik Gmbh & Co. Kg Multi-core cable

Also Published As

Publication number Publication date
DE1615560B2 (de) 1971-02-11
BE647185A (de) 1964-08-17
NL6404672A (de) 1964-11-04
NL140109B (nl) 1973-10-15
DE1615560A1 (de) 1969-09-04
GB1004391A (en) 1965-09-15
CH421223A (fr) 1966-09-30

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