US3696322A - Insulated flat wire terminal - Google Patents

Insulated flat wire terminal Download PDF

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Publication number
US3696322A
US3696322A US41789A US3696322DA US3696322A US 3696322 A US3696322 A US 3696322A US 41789 A US41789 A US 41789A US 3696322D A US3696322D A US 3696322DA US 3696322 A US3696322 A US 3696322A
Authority
US
United States
Prior art keywords
connector
flat wire
ferrule
side walls
section
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
US41789A
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English (en)
Inventor
Paul J Spangler
Thomas E Morgan
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.)
TDK Micronas GmbH
ITT Inc
Original Assignee
Deutsche ITT Industries GmbH
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 Deutsche ITT Industries GmbH filed Critical Deutsche ITT Industries GmbH
Application granted granted Critical
Publication of US3696322A publication Critical patent/US3696322A/en
Assigned to ITT CORPORATION reassignment ITT CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: INTERNATIONAL TELEPHONE AND TELEGRAPH CORPORATION
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
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/50—Fixed connections
    • H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
    • H01R12/65—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures characterised by the terminal
    • H01R12/67—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures characterised by the terminal insulation penetrating terminals
    • H01R12/68—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures characterised by the terminal insulation penetrating terminals comprising deformable portions
    • 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
    • H01R4/182—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 flat conductive elements, e.g. flat cables
    • 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
    • H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
    • H01R4/2404—Connections using contact members penetrating or cutting insulation or cable strands the contact members having teeth, prongs, pins or needles penetrating the insulation
    • H01R4/2406—Connections using contact members penetrating or cutting insulation or cable strands the contact members having teeth, prongs, pins or needles penetrating the insulation having needles or pins
    • 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
    • H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
    • H01R4/2495—Insulation penetration combined with permanent deformation of the contact member, e.g. crimping
    • 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 flat wire connector Before crimping, a flat wire connector has a cross-section which is somewhat U-shaped with upstanding side plates having serrations on the top and a rosette of upstanding tines in the floor.
  • the flat wire When the connector is crimped, the flat wire is pressed down over the rosette, the tines of which pierce the insulation.
  • the two upstanding side walls are rolled in toward the middle of the U, and the serrations are driven downwardly to pierce the insulation and stake the flat wire.
  • the length of the side walls is such that the flat wire may be badly out of alignment with respect to the connector and yet insure a good electrical connection.
  • This invention relates to terminals for crimping onto the end of insulated wires and more particularly to terminals for crimping onto the ends of insulated flat wires.
  • the tinsel is a strip of foil (usually copper) which is about one-thirty-second to one-sixthfourth of an inch wide and about as thick as tissue paper.
  • the foil is embedded in or surrounded by an insulating material which is almost impossible to strip off the foil. Even if it were possible to strip the insulation from the foil, the resultant exposed foil conductor would be too weak to support itself. It could not withstand any kind of strain which might occur in even the most carefully guarded environment.
  • an object of this invention is to provide new and improved crimped connectors for attachment to insulated wires and more particularly to connectors for insulated flat wires.
  • Yet another object is to provide connectors which pierce insulation and make connection with very fragile wires.
  • an object is to provide connectors which do not weaken extremely fragile conductors.
  • an object is to provide a connector which utilizes the strength of the insulation material to establish resting maintain a strong mechanical bond.
  • an object is to provide a strong mechanical bond and a good electrical connection to a tinsel wire.
  • an object is to provide the described type of connector which is free of virtually all mechanical stresses.
  • a flat wire connector stamped from a ribbon of contact metal.
  • the cross-section of the connector is somewhat U-shaped, a rosette of upstanding tines in the floor of the connector U.
  • the upstanding side plates of the U-shaped section have serrations on their top.
  • FIG. 1 is a perspective view of an inventive connector with a flat wire poised above an open U-shaped connector
  • FIG. 2 is a plan view looking down on top of the connector of FIG. 1;
  • FIG. 3 shows a side elevation view of the connector taken along line 33 of FIG. 2;
  • FIG. 4 is a back elevation view of a connector taken along line 4-4 of FIG. 2;
  • FIG. 5 is an elevation view of the back end of the connector (taken along line 4-4) after crimping;
  • FIG. 6 is an elevation view of the front end of the connector (taken along line 6-6) after crimping;
  • FIG. 7 shows a perspective view of a confined die for crimping the inventive connector
  • FIGS. 8A-8D includes four stop motion views which are four successive steps in the crimping process.
  • FIG. 9 is a perspective view of a crimped connector with the side walls broken away to show the mushroomed rosette of tines.
  • the original form of the connector 20 includes a forked spade terminal 21 and a ferrule 22 having an initially U-shaped cross-section.
  • the flat wire comprises a very thin tinsel-like foil 36 (preferably of copper) embedded in a plastic coating 37 which completely surrounds and protects the foil on all of its sides.
  • the ferrule side walls 23, 24 of the U-shape are serrated along the top edge for a substantial length L.
  • the rear parts 25, 26 of the side walls are not serrated to provide gripping ears which fold over to hold the flat wires and provide strain relief.
  • the rear most edges 28-30 of the ferrule are chamfered, rounded, or otherwise shaped to prevent the wire from bending over a sharp angle.
  • the parts 25, 26 hold the wire against withdrawal, and the rounded edges 28-30 allow the wire to wrap around a radius and thereby distribute fatiguing forces.
  • a rosette 31 of upstanding tines is in the floor of the ferrule part 22 of the connector 20.
  • Each tine has a sharp point with the mechanical strength required to pierce a flat wire.
  • the rosette is positioned to mushroom over the top of the flat wire, and apply a contact pressure which is adequate to give good electrical contact at the connection between the flat wire and the connector, throughout the life time of the terminal.
  • the crimping tool, die, and process are seen in FIGS. 7 and 8.
  • This tool and die makes a crimp known in the art as an F-crimp.
  • One-half of the crimping tool is an indenter 41 (FIG. 7) having a top surface 42 which conforms to the shape of the lower side of the crimp.
  • the other half of the crimping tool is a nest 43 having a pair of generally semi-circular surfaces 44, 45 conforming to the shape of the upper side of the crimp.
  • the indenter top surface 42 is somewhat U- shaped, with a rather flat bottom section.
  • the nest 43 has a somewhat M-shape, rounded to guide and direct the side walls, 23, 24 of the connector so that they roll inwardly toward the center of the crimp as the punch is lowered into the die.
  • the nest for crimping the rear parts of the terminal (25 and 26) should not be M- shaped but should have a generally flat bottom.
  • the flat wire is positioned in the bottom of the U- shaped ferrule and over the rosette of tines. Thereafter, the ferrule 22 is placed in the confined die 42.
  • FIGS. 8A-8D the connector 20 is placed on the indenter 42 with the bottom of the connector resting against the bottom of the die 42.
  • upstanding tines in rosette 31 are forced through the flat wire.
  • the force of the serrated edgesdriving into the insulation tend to mushroom the rosette tines and bend them over toward the floor of the connector ferrule.
  • FIG. 9 is a perspective view of the crimped connector with the side walls 23, 24 broken away to show the rosette tines 31 which have pierced the fiat wire 35 and mushroomed over.
  • the crimping forces are removed when the nest 43 is raised, there might be some minor relaxation of the connector material.
  • the double reiliability of the mushroomed tines 31. driven downwardly under the force of the rolled serrated edges provides a contact pressure which is more than adequate to maintain a good electrical connection throughout thelifetime of the crimp.
  • louver like tines may be sequentially placed in the floor of the connector. Or a pair of tines may be positioned to project upwardly and crimp over, somewhat as a paper staple is crimped. Still other rivet-like connections may be provided.
  • the rosette or other tines are crimped, as with a paper stapler or a rivet. Then, the serrated side walls,are rolled in toward the center. These two steps may be performed by a two part nest and single indenter.
  • one part of the nest moves in to crimp the rosette tines
  • This two-step operation can be done in a single stroke.
  • a flat wire connector comprising a terminal member and an integral ferrule member, said ferrule being U-shaped in cross-section having upstanding side walls connected by a fl r section the top edges of said side walls being serrate along at least a partial length,
  • said serrations extending longitudinally from a position adjacent said terminal, said ferrule including a non-serrated gripping portionextending from a position adjacent the opposite end of said ferrule and along the top edges of said side walls, said gripping portion terminating in an outwardly extending edge portion having an outwardly decreasing cross-sectional thickness for relieving mechanical fatigue atthe point where said flat wire enters said connector.
  • a flat wire connector comprising a ferrule portion having somewhat U-shaped cross-section with serrations extending longitudinally along a first section on the tops of the side walls of the U-shaped cross-section and at least one upstanding sharp pointed tine in the bottom of the- U-shaped cross-section, said side walls rolling over during crimping to drive said serrations and said tine through said flatwire, and having chamfered means at the end of said ferrule for relieving mechanical fatigue at the point where said flat wire enters said connector.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Multi-Conductor Connections (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
US41789A 1970-06-01 1970-06-01 Insulated flat wire terminal Expired - Lifetime US3696322A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US4178970A 1970-06-01 1970-06-01

Publications (1)

Publication Number Publication Date
US3696322A true US3696322A (en) 1972-10-03

Family

ID=21918327

Family Applications (1)

Application Number Title Priority Date Filing Date
US41789A Expired - Lifetime US3696322A (en) 1970-06-01 1970-06-01 Insulated flat wire terminal

Country Status (3)

Country Link
US (1) US3696322A (enrdf_load_stackoverflow)
CA (1) CA979506A (enrdf_load_stackoverflow)
FR (1) FR2095734A5 (enrdf_load_stackoverflow)

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3950070A (en) * 1974-06-25 1976-04-13 Amp Incorporated Flat flexible cable terminal and electrical interconnection system
DE2529852A1 (de) * 1975-07-04 1977-01-13 Licentia Gmbh Elektrische kontaktierung einer auf einem isolierenden traeger aufgebrachten elektrisch leitfaehigen schicht
US4012101A (en) * 1974-07-18 1977-03-15 Itt Industries, Inc. Circuit termination device
US4304454A (en) * 1979-10-05 1981-12-08 Sumitomo Electric Industries, Ltd. Insulation piercing connector
FR2488059A1 (fr) * 1980-07-31 1982-02-05 Thomas & Betts Corp Connecteur electrique destine a etre dispose a l'extremite d'un cable electrique plat a plusieurs conducteurs
US4436359A (en) 1977-10-14 1984-03-13 Allied Corporation Electrical connector termination system for quick field service
WO1998011629A1 (en) * 1996-09-10 1998-03-19 The Whitaker Corporation Electrical contact
DE19812093C1 (de) * 1998-03-19 1999-10-07 Framatome Connectors Int Crimpverbindung
US6152763A (en) * 1996-09-10 2000-11-28 The Whitaker Corporation Electrical contact for termination to flat conductive member
EP1081810A1 (en) * 1999-08-30 2001-03-07 F.C.I. - Framatome Connectors International Die for crimping tools and release tool for inserts located in dies
EP1408586A1 (en) * 2002-10-07 2004-04-14 Tyco Electronics AMP GmbH Crimp connector
US20040137802A1 (en) * 2002-10-07 2004-07-15 Wendling Hannes Jahn Crimp connector
US20050233638A1 (en) * 2004-04-20 2005-10-20 Robert Taylor Crimp connector
US20070093101A1 (en) * 2005-10-25 2007-04-26 Yazaki Corporation Terminal fitting and method of attaching the same
DE10320536B4 (de) * 2002-05-07 2008-03-27 Lear Corp., Southfield Crimpkralle eines elektrischen Kontaktelements
US20190252841A1 (en) * 2018-02-13 2019-08-15 Sumida Corporation Tip structure of flat wire and method for manufacturing the tip structure
US20220006207A1 (en) * 2020-07-02 2022-01-06 TE Connectivity Services Gmbh Electrical Terminal For Flat Flexible Cables

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1416813A (en) * 1973-01-11 1975-12-10 Cannon Electric Great Britain Electrical terminations
FR2565421B1 (fr) * 1984-05-30 1987-09-04 Proner Sa Ets Perfectionnements aux futs a sertir pour contacts electriques

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR617955A (fr) * 1926-06-21 1927-03-01 Materiel Telephonique Perfectionnements apportés aux prises de courant et à leurs méthodes de fabrication
US2302767A (en) * 1940-12-21 1942-11-24 Western Electric Co Terminal for electrical conductors
US2515105A (en) * 1947-08-08 1950-07-11 Allied Electric Products Inc Method of making an electrical connection to an insulated wire
US2943293A (en) * 1957-06-20 1960-06-28 Amp Inc Electrical connector
US3335392A (en) * 1965-07-19 1967-08-08 Essex Wire Corp Terminal construction
US3388367A (en) * 1966-06-20 1968-06-11 Hughes Aircraft Co Electrical connector for either flat or round conductors
US3395381A (en) * 1966-11-25 1968-07-30 Amp Inc Crimpable connecting device for flat conductor cable

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR617955A (fr) * 1926-06-21 1927-03-01 Materiel Telephonique Perfectionnements apportés aux prises de courant et à leurs méthodes de fabrication
US2302767A (en) * 1940-12-21 1942-11-24 Western Electric Co Terminal for electrical conductors
US2515105A (en) * 1947-08-08 1950-07-11 Allied Electric Products Inc Method of making an electrical connection to an insulated wire
US2943293A (en) * 1957-06-20 1960-06-28 Amp Inc Electrical connector
US3335392A (en) * 1965-07-19 1967-08-08 Essex Wire Corp Terminal construction
US3388367A (en) * 1966-06-20 1968-06-11 Hughes Aircraft Co Electrical connector for either flat or round conductors
US3395381A (en) * 1966-11-25 1968-07-30 Amp Inc Crimpable connecting device for flat conductor cable

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3950070A (en) * 1974-06-25 1976-04-13 Amp Incorporated Flat flexible cable terminal and electrical interconnection system
US4012101A (en) * 1974-07-18 1977-03-15 Itt Industries, Inc. Circuit termination device
DE2529852A1 (de) * 1975-07-04 1977-01-13 Licentia Gmbh Elektrische kontaktierung einer auf einem isolierenden traeger aufgebrachten elektrisch leitfaehigen schicht
US4436359A (en) 1977-10-14 1984-03-13 Allied Corporation Electrical connector termination system for quick field service
US4304454A (en) * 1979-10-05 1981-12-08 Sumitomo Electric Industries, Ltd. Insulation piercing connector
FR2488059A1 (fr) * 1980-07-31 1982-02-05 Thomas & Betts Corp Connecteur electrique destine a etre dispose a l'extremite d'un cable electrique plat a plusieurs conducteurs
WO1998011629A1 (en) * 1996-09-10 1998-03-19 The Whitaker Corporation Electrical contact
US6152763A (en) * 1996-09-10 2000-11-28 The Whitaker Corporation Electrical contact for termination to flat conductive member
DE19812093C1 (de) * 1998-03-19 1999-10-07 Framatome Connectors Int Crimpverbindung
US6232555B1 (en) * 1998-03-19 2001-05-15 Framatome Connectors International Crimp connection
EP1081810A1 (en) * 1999-08-30 2001-03-07 F.C.I. - Framatome Connectors International Die for crimping tools and release tool for inserts located in dies
DE19941185C1 (de) * 1999-08-30 2001-04-05 Framatome Connectors Int Gesenk für Crimpwerkzeuge
DE10320536B4 (de) * 2002-05-07 2008-03-27 Lear Corp., Southfield Crimpkralle eines elektrischen Kontaktelements
EP1408586A1 (en) * 2002-10-07 2004-04-14 Tyco Electronics AMP GmbH Crimp connector
US6799990B2 (en) 2002-10-07 2004-10-05 Tyco Electronics Amp Gmbh Crimp connector
US20040137802A1 (en) * 2002-10-07 2004-07-15 Wendling Hannes Jahn Crimp connector
US20050233638A1 (en) * 2004-04-20 2005-10-20 Robert Taylor Crimp connector
US6997746B2 (en) 2004-04-20 2006-02-14 Ark-Les Corporation Crimp connector
US20070093101A1 (en) * 2005-10-25 2007-04-26 Yazaki Corporation Terminal fitting and method of attaching the same
US7316581B2 (en) * 2005-10-25 2008-01-08 Yazaki Corporation Terminal fitting and method of attaching the same
US20190252841A1 (en) * 2018-02-13 2019-08-15 Sumida Corporation Tip structure of flat wire and method for manufacturing the tip structure
US10601196B2 (en) * 2018-02-13 2020-03-24 Sumida Corporation Tip structure of flat wire and method for manufacturing the tip structure
US20220006207A1 (en) * 2020-07-02 2022-01-06 TE Connectivity Services Gmbh Electrical Terminal For Flat Flexible Cables
US11296432B2 (en) * 2020-07-02 2022-04-05 TE Connectivity Services Gmbh Electrical terminal for flat flexible cables

Also Published As

Publication number Publication date
FR2095734A5 (enrdf_load_stackoverflow) 1972-02-11
CA979506A (en) 1975-12-09

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Legal Events

Date Code Title Description
AS Assignment

Owner name: ITT CORPORATION

Free format text: CHANGE OF NAME;ASSIGNOR:INTERNATIONAL TELEPHONE AND TELEGRAPH CORPORATION;REEL/FRAME:004389/0606

Effective date: 19831122