US3842487A - Terminating of electrical conductors - Google Patents

Terminating of electrical conductors Download PDF

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Publication number
US3842487A
US3842487A US00189980A US18998071A US3842487A US 3842487 A US3842487 A US 3842487A US 00189980 A US00189980 A US 00189980A US 18998071 A US18998071 A US 18998071A US 3842487 A US3842487 A US 3842487A
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US
United States
Prior art keywords
conductor
strands
metal
set forth
method set
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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
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US00189980A
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English (en)
Inventor
M Hartz
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Lear Corp EEDS and Interiors
Original Assignee
Essex International 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 Essex International Inc filed Critical Essex International Inc
Priority to US00189980A priority Critical patent/US3842487A/en
Priority to CA154,108A priority patent/CA970940A/en
Priority to GB4712972A priority patent/GB1389316A/en
Priority to IT30397/72A priority patent/IT970710B/it
Priority to DE19722250836 priority patent/DE2250836C3/de
Priority to FR7236774A priority patent/FR2156771B1/fr
Application granted granted Critical
Publication of US3842487A publication Critical patent/US3842487A/en
Assigned to UNITED TECHNOLOGIES AUTOMOTIVES, INC., A CORP. OF DE reassignment UNITED TECHNOLOGIES AUTOMOTIVES, INC., A CORP. OF DE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: ESSEX GROUP, INC.
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/28—End pieces consisting of a ferrule or sleeve
    • H01R11/281—End pieces consisting of a ferrule or sleeve for connections to batteries
    • H01R11/288—Interconnections between batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors

Definitions

  • ABSTRNCT Terminating an electrical conductor composed ofa plurality of conductive strands is accomplished by fusing together the strands at one end of the conductor and immersing the fused end of the: conductor in a tin- [56l References cued ning bath vibrated at ultrasonic speeds, followed by UNITED STATES PATENTS the securing of a terminal to the tinned end of the 1,387,426 9/1921 Merritt 339/275 T Conductor end preferably under a force sufficient to 2.222.609 1 H1940 Everett cause the tinning material to flow and create a metal- 2,397,400 3/1946 Barwich 117/D1G.
  • the invention herein disclosed relates to the terminating of electrical conductors and more particularly to the terminating of a conductor composed of a plurality of strands of aluminum wire especially adapted for use in the manufacture of vehicle battery cables.
  • An object of this invention is to provide a process especially adapted to obtain an excellent electrical and mechanical connection between an aluminum conductor and a terminal.
  • Another object of the invention is to provode a process of terminating stranded aluminum conductors which permits the use of conventional terminating equipment and cable processing methods.
  • An aluminum wire or cable exposed to air will oxidize rapidly and form a highly resistant oxide film on its surface. It is known that vibrating a rigid wire or strip of aluminum at ultrasonic speeds will abrade and remove a film of aluminum oxide from the wire or strip. It is also known that ultrasonic vibration of a rigid aluminum wire immersed in a bath of molten solder or zinc-tin alloy not only will abrade aluminum oxide from the wire, but also will enable the latter to be coated with the molten solder or alloy with an extremely good metallurgical bond therebetween.
  • a further object of the invention is to provide a stranded aluminum cable having at least one terminal thereon and possessing an excellent electrical and metallurgical interface between the conductor and the terminal.
  • FIG. l is a flow diagram illustrating the steps of the preferred process
  • FIG. 2 is a fragmentary elevational view illustrating one end of a stranded cable preparatory to its being tinned and terminated;
  • H6. 3 is an elevational view, partly in section, illustrating a typical battery cable constructed in accordance with the invention.
  • a battery cable produced according to the invention is designated generally by the reference character 1 and comprises a plurality of individual strands 2 of preferably aluminum wire twisted slightly to form an elongate conductor 3 of suitable length and diameter.
  • a typical cable is composed of 127 strands of 27 gauge wire.
  • the conductor conventionally has an outer layer of rubber or other insulation 4 which is stripped from the ends of the conductor by conventional stripping.
  • the exposed ends of the aluminum cable conventionally are provided with a coating 5 of solder or a zinc-tin alloy for the purpose of minimizing the electromotive potential between the aluminum cable and terminals formed of different metal and adapted to be mounted at opposite ends of the conductor.
  • a conventional copper-bearing terminal 6 a stranded conductor, and heretofore has necessitated use of the aforementioned chemical flux to remove the film.
  • a battery cable constructed according to the invention enables the advantageous effects of ultrasonic vibration of the conductor in a bath of molten solder or zinc-tin alloy to be achieved without the necessity of using a corrosive flux.
  • This result is obtained by fusing or welding the ends of the individual strands 2 together so as to produce at each end of the conductor 3 a solid tip 10.
  • the fusing of the strands at the ends of the conductor may be accomplished by a conventional carbon arc device which generates sufficient heat to puddle the individual strands. As soon as the strands are puddled, the conductor is removed from the carbon arc device whereupon the puddled strands solidify to form the tip 10 at which all of the strands are joined.
  • the ends of the exposed conductor may be tinned by immersion in an ultrasonically vibrated bath of molten solder or zinc-tin alloy having a temperature lower than the melting point of the aluminum strands 2.
  • the vibration is achieved by a conventional vibrating device such as that manufactured by Branson Ultrasonic instrument Company, of Stamford, Connecticut.
  • the conductor is immersed in the molten metal bath to a depth just short of the insulation and vibrated at an ultrasonic frequency in excess of 20 kilohertz. The thermal and chemical action thereby produced efficiently abrades the oxide film from the conductor and permits the tinning alloy to be bonded metallurgically to the aluminum strands.
  • the fused end of the conductor provides adequate mechanical rigidity for the individual strands of the conductor so as to prevent their oscillating individually in response to the applied ultrasonic frequency, thereby enabling the individual strands to be scrubbed clean of the oxide film and bonded metallurgically to the tinning alloy.
  • the terminals 6 and 8 may be applied thereto.
  • Application of the terminals may be by conventional means such as die casting or by sweating or shrinking a pre-tinned brass type terminal onto the conductor under sufficient force as to cause the coating 5 to flow or become somewhat plastic and thereby form a metallurgical bond between theterminal and the conductor.
  • Another advantage of fusing the ends of the strands 2 is that, since all of the strands are joined at their ends, all of the strands are capable of carrying current regardless of whether the aluminum oxide is removed from the interior strands of the cable.
  • a method of terminating an electrical conductor formed of a bundle of strands of conductive metal twisted so that all of said strands are engaged with one another over the length of said conductor comprising fusing the ends of the strands to form a solid tip at least at one end of said conductor; immersing said one end of said conductor in a bath of molten, electrically conductive metal having a temperature lower than the melting temperature of the metal of said strands; vibrating said one end of said conductor at a frequency sufficient to abrade oxides from the immersed end of said conductor and to coat the immersed end of said conductor with said molten metal; removing the coated end of said conductor from said bath; and solidifying the metal of the coating.
  • conductive metal is a zinc-tin alloy.
  • a method of terminating an electrical conductor formed of v a bundle of strands of conductive metal twisted so that all of said strands are engaged one with another over the length of said conductor comprising melting and puddling the ends of all of said strands at least at one end of said conductor; solidifying the ends of said strands to form a solid tip at said one end of said conductor; immersing said one end of said conductor in a bath of molten, electrically conductive metal having a temperature lower than the melting temperature of the metal of said strands; vibrating said one end of said conductor at an ultrasonic frequency one end of said conductor.

Landscapes

  • Coating With Molten Metal (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Processing Of Terminals (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
US00189980A 1971-10-18 1971-10-18 Terminating of electrical conductors Expired - Lifetime US3842487A (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US00189980A US3842487A (en) 1971-10-18 1971-10-18 Terminating of electrical conductors
CA154,108A CA970940A (en) 1971-10-18 1972-10-11 Terminating of electrical conductors
GB4712972A GB1389316A (en) 1971-10-18 1972-10-12 Terminating of electrical conductors
IT30397/72A IT970710B (it) 1971-10-18 1972-10-12 Terminazione di conduttori elettrici
DE19722250836 DE2250836C3 (de) 1971-10-18 1972-10-17 Verfahren zur Herstellung eines mit einer Verbindungsklemme verbindbaren Endstückes eines aus Aluminiumadern bestehenden elektrischen Leiters
FR7236774A FR2156771B1 (it) 1971-10-18 1972-10-17

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US00189980A US3842487A (en) 1971-10-18 1971-10-18 Terminating of electrical conductors

Publications (1)

Publication Number Publication Date
US3842487A true US3842487A (en) 1974-10-22

Family

ID=22699564

Family Applications (1)

Application Number Title Priority Date Filing Date
US00189980A Expired - Lifetime US3842487A (en) 1971-10-18 1971-10-18 Terminating of electrical conductors

Country Status (5)

Country Link
US (1) US3842487A (it)
CA (1) CA970940A (it)
FR (1) FR2156771B1 (it)
GB (1) GB1389316A (it)
IT (1) IT970710B (it)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3949466A (en) * 1974-05-28 1976-04-13 Arthur D. Little Inc. Process for forming an aluminum electrical conducting wire junction end piece
US4799899A (en) * 1985-11-06 1989-01-24 Yazaki Corporation Connective structure for conductive wires and a method of manufacturing the same
US5972122A (en) * 1997-06-11 1999-10-26 Eveready Battery Company, Inc. Method of degreasing anode cups
US6004170A (en) * 1996-10-25 1999-12-21 Yazaki Corporation Connection structure of a covered wire with resin encapsulation
US6012955A (en) * 1997-01-09 2000-01-11 Yazaki Corporation Terminal for ultrasonic connection and ultrasonic connection structure
US6240932B1 (en) * 1998-09-14 2001-06-05 The United States Of America As Represented By The Administrator Of Nasa Processes for cleaning a cathode tube and assemblies in a hollow cathode assembly
EP1383202A1 (fr) * 2002-07-17 2004-01-21 Souriau Dispositif de liaison entre un cable et un élément de contact
US20060292922A1 (en) * 2004-03-23 2006-12-28 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. Process for connecting terminal elements to an electrical conductor consisting of aluminum, and electrical conductor produced by the process
US20100003867A1 (en) * 2008-07-03 2010-01-07 Draexlmaier GmbH Connector for use with light-weight metal conductors
US20100090548A1 (en) * 2007-08-08 2010-04-15 Huashan Shi Permanent-magnet Synchronous Motor of Drainage Pump
US20110014825A1 (en) * 2009-07-16 2011-01-20 Delphi Technologies, Inc. Electrical terminal connection with galvanic sacrificial metal
US20150244133A1 (en) * 2014-02-27 2015-08-27 Yazaki Corporation Terminal-equipped wiring member
US9649717B2 (en) 2013-12-24 2017-05-16 Innovative Weld Solutions, Ltd. Welding assembly and method
US9937583B2 (en) 2013-12-24 2018-04-10 Innovative Weld Solutions Ltd. Welding assembly and method
US20190081446A1 (en) * 2017-09-11 2019-03-14 Strunk Connect automated solutions GmbH & Co. KG Method for connecting an aluminum electrical wire with an aluminum tube

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT208109Z2 (it) * 1986-09-16 1988-04-11 Fiat Auto Spa Dispositivo di collegamento elettrico di massa particolarmente per veicoli
FR2723483B1 (fr) * 1994-08-03 1996-09-06 Commissariat Energie Atomique Procede de protection de cosses electriques.
GB2333887A (en) * 1998-01-09 1999-08-04 Secr Defence Metal-Air Battery
DE10357048A1 (de) * 2003-12-04 2005-07-21 Leoni Bordnetz-Systeme Gmbh & Co Kg Verfahren zum Herstellen einer elektrischen Verbindung zwischen einem Aluminiumleiter und einem Kontaktelement
FR2910728A1 (fr) * 2006-12-22 2008-06-27 Thales Sa Procede de raccordement de conducteurs electriques par magnetostriction et dispositif generateur de magnetostriction.

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1387426A (en) * 1919-10-13 1921-08-09 Merritt Metals Company Method of soldering aluminum
GB365033A (en) * 1930-02-27 1932-01-07 Procedes Mahoux Soc D Expl Des Improvements in the treatment of metals and alloys
GB472582A (en) * 1936-02-27 1937-09-27 British Thomson Houston Co Ltd Improvements in and relating to connections for aluminium conductors of electricity
US2222609A (en) * 1937-08-02 1940-11-26 Matthew H Loughridge Attachment for securing a stranded conductor to a rail
US2397400A (en) * 1938-05-27 1946-03-26 Barwich Heinz Apparatus for and method of producing metallic coatings
US2522082A (en) * 1945-02-03 1950-09-12 Orlan M Arnold Method of bonding
US2655641A (en) * 1948-10-29 1953-10-13 Aircraft Marine Prod Inc Electrical connector having a mercury amalgam coating on its inner surface
US2984903A (en) * 1957-12-06 1961-05-23 Westinghouse Electric Corp Brazing alloy and ultrasonic process for using the same
GB910249A (en) * 1961-05-19 1962-11-14 Standard Telephones Cables Ltd Method of manufacturing hermetically sealed exposure devices
US3210843A (en) * 1959-10-06 1965-10-12 Seul Vincens Method of influencing the surface profile of solid elements, more especially of surface-improved or plated metal strips or sheets
US3287540A (en) * 1964-05-19 1966-11-22 Allied Chem Method and composition for joining of aluminum and dissimilar metals
US3400358A (en) * 1965-10-21 1968-09-03 Ibm Electrical connector

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR347257A (fr) * 1904-10-20 1905-03-02 Friedrich Prims Relève-jupe
US2333046A (en) * 1939-11-08 1943-10-26 American Steel & Wire Co Rail bond and method of making the same

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1387426A (en) * 1919-10-13 1921-08-09 Merritt Metals Company Method of soldering aluminum
GB365033A (en) * 1930-02-27 1932-01-07 Procedes Mahoux Soc D Expl Des Improvements in the treatment of metals and alloys
GB472582A (en) * 1936-02-27 1937-09-27 British Thomson Houston Co Ltd Improvements in and relating to connections for aluminium conductors of electricity
US2222609A (en) * 1937-08-02 1940-11-26 Matthew H Loughridge Attachment for securing a stranded conductor to a rail
US2397400A (en) * 1938-05-27 1946-03-26 Barwich Heinz Apparatus for and method of producing metallic coatings
US2522082A (en) * 1945-02-03 1950-09-12 Orlan M Arnold Method of bonding
US2655641A (en) * 1948-10-29 1953-10-13 Aircraft Marine Prod Inc Electrical connector having a mercury amalgam coating on its inner surface
US2984903A (en) * 1957-12-06 1961-05-23 Westinghouse Electric Corp Brazing alloy and ultrasonic process for using the same
US3210843A (en) * 1959-10-06 1965-10-12 Seul Vincens Method of influencing the surface profile of solid elements, more especially of surface-improved or plated metal strips or sheets
GB910249A (en) * 1961-05-19 1962-11-14 Standard Telephones Cables Ltd Method of manufacturing hermetically sealed exposure devices
US3287540A (en) * 1964-05-19 1966-11-22 Allied Chem Method and composition for joining of aluminum and dissimilar metals
US3400358A (en) * 1965-10-21 1968-09-03 Ibm Electrical connector

Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3949466A (en) * 1974-05-28 1976-04-13 Arthur D. Little Inc. Process for forming an aluminum electrical conducting wire junction end piece
US4799899A (en) * 1985-11-06 1989-01-24 Yazaki Corporation Connective structure for conductive wires and a method of manufacturing the same
US6004170A (en) * 1996-10-25 1999-12-21 Yazaki Corporation Connection structure of a covered wire with resin encapsulation
US6012955A (en) * 1997-01-09 2000-01-11 Yazaki Corporation Terminal for ultrasonic connection and ultrasonic connection structure
US5972122A (en) * 1997-06-11 1999-10-26 Eveready Battery Company, Inc. Method of degreasing anode cups
US6240932B1 (en) * 1998-09-14 2001-06-05 The United States Of America As Represented By The Administrator Of Nasa Processes for cleaning a cathode tube and assemblies in a hollow cathode assembly
EP1383202A1 (fr) * 2002-07-17 2004-01-21 Souriau Dispositif de liaison entre un cable et un élément de contact
FR2842657A1 (fr) * 2002-07-17 2004-01-23 Framatome Connectors Int Dispositif de liaison entre un cable et un element de contact
US20040137801A1 (en) * 2002-07-17 2004-07-15 Souriau Linking device between a cable and contact element
US6884127B2 (en) 2002-07-17 2005-04-26 Souriau Linking device between a cable and contact element
US20060292922A1 (en) * 2004-03-23 2006-12-28 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. Process for connecting terminal elements to an electrical conductor consisting of aluminum, and electrical conductor produced by the process
US20100090548A1 (en) * 2007-08-08 2010-04-15 Huashan Shi Permanent-magnet Synchronous Motor of Drainage Pump
US8624451B2 (en) * 2007-08-08 2014-01-07 Jiangmen Idear Hanyu Electrical Joint-Stock Co., Ltd. Permanent-magnet synchronous motor of drainage pump
US20100003867A1 (en) * 2008-07-03 2010-01-07 Draexlmaier GmbH Connector for use with light-weight metal conductors
US7828610B2 (en) * 2008-07-03 2010-11-09 Lisa Draexlmaier Gmbh Connector for use with light-weight metal conductors
US20110014825A1 (en) * 2009-07-16 2011-01-20 Delphi Technologies, Inc. Electrical terminal connection with galvanic sacrificial metal
US9649717B2 (en) 2013-12-24 2017-05-16 Innovative Weld Solutions, Ltd. Welding assembly and method
US9937583B2 (en) 2013-12-24 2018-04-10 Innovative Weld Solutions Ltd. Welding assembly and method
US20150244133A1 (en) * 2014-02-27 2015-08-27 Yazaki Corporation Terminal-equipped wiring member
US20190081446A1 (en) * 2017-09-11 2019-03-14 Strunk Connect automated solutions GmbH & Co. KG Method for connecting an aluminum electrical wire with an aluminum tube
US11038312B2 (en) * 2017-09-11 2021-06-15 Strunk Connect automated solutions GmbH & Co. KG Method for connecting an aluminum electrical wire with an aluminum tube

Also Published As

Publication number Publication date
IT970710B (it) 1974-04-20
FR2156771B1 (it) 1976-10-29
GB1389316A (en) 1975-04-03
CA970940A (en) 1975-07-15
DE2250836A1 (de) 1973-04-26
DE2250836B2 (de) 1975-09-25
FR2156771A1 (it) 1973-06-01

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Owner name: UNITED TECHNOLOGIES AUTOMOTIVES, INC., A CORP. OF

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:ESSEX GROUP, INC.;REEL/FRAME:004933/0578

Effective date: 19880223