WO1998054790A1 - Crimp connection for large conductors - Google Patents

Crimp connection for large conductors Download PDF

Info

Publication number
WO1998054790A1
WO1998054790A1 PCT/IB1998/000778 IB9800778W WO9854790A1 WO 1998054790 A1 WO1998054790 A1 WO 1998054790A1 IB 9800778 W IB9800778 W IB 9800778W WO 9854790 A1 WO9854790 A1 WO 9854790A1
Authority
WO
WIPO (PCT)
Prior art keywords
crimp connection
hump
crimp
base
connection
Prior art date
Application number
PCT/IB1998/000778
Other languages
French (fr)
Inventor
Catherine Andre
Joanny Daloz
Original Assignee
The Whitaker Corporation
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 The Whitaker Corporation filed Critical The Whitaker Corporation
Priority to AU70744/98A priority Critical patent/AU7074498A/en
Publication of WO1998054790A1 publication Critical patent/WO1998054790A1/en

Links

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
    • 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
    • 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

Definitions

  • This invention relates to a crimp connection for mechanically and electrically connecting an electrical terminal to a conductor, in particular a flexible or rigid stranded cable conductor for transmitting large electrical currents as used in electrical power transmission and distribution networks.
  • the terminal described therein comprises a contact portion for connection to a complementary conductor, and a crimp portion for mechanical and electrical attachment to a conducting cable.
  • the crimp portion comprises a cylindrical tube that receives an end of the conducting cable therein, the tube subsequently being deformed by a crimping die that collapses the tube locally, thereby forming a deep recess.
  • the recessed wall squashes the conducting strands of the cable in the tube for secure mechanical and electrical connection.
  • crimping portions in the shape of an open V or U whereby the conductor is received on the base of the V shaped barrel and the upstanding arms collapsed over the conductor during the crimping process.
  • crimping portions For large diameter cables (e.g. with a cross section area of 120 mm2) as used in electrical distribution networks, for example for distributing electrical power to factories and houses, it is typical to employ terminals with crimping portions that are closed tubular members. Closed tubular crimping members form a stronger mechanical crimp than an open barrel . There are however certain problems associated with the crimping of tubular crimping portions, in that the deep recessed portion may crush the cable excessively and thereby sever some of the conducting strands. The latter leads to reduced mechanical and electrical performance.
  • a further problem is that such crimp connections are not well adapted for crimping both flexible electrical cables (formed of many thin strands) and rigid stranded electrical cables (formed of a few strands) .
  • Flexible cables are more easily bendable and compressible than rigid standed cables, therefore a typical crimp connection for a rigid stranded cable may not sufficiently grip a flexible cable.
  • a crimp connection of an electrical terminal the crimp connection formed from a tubular connection section wall receiving a cable conductor therein, the crimp connection comprising a base portion and a recessed top portion facing the base portion joined thereto via side portions, wherein the top recessed portion comprises at least two grooves separated by a hump, the grooves and hump extending generally transversely to the direction of the cable, and wherein the base portion comprises a groove arranged opposite the hump .
  • a cable crushed within the connection is forced to bend at the position of the hump and corresponding base groove such that good mechanical and electrical connection for a stranded rigid or flexible cable is achieved.
  • figure 1 is a side view of a terminal crimped to a conducting cable, with the crimping die shown in outline;
  • figure 2 is a top view of the terminal of figure 1;
  • figure 3 is a cross-sectional view through line 3-3 of figure 2;
  • figure 4 is a cross-sectional view through line 4-4 of figure 2;
  • figure 5 is an isometric view of the electrical terminal of figure 1;
  • figure 6 is an isometric view of an anvil of a crimping die assembly for forming the crimp connection according to this invention;
  • figure 7 is an isometric view of a punch of the crimping punch assembly.
  • an electrical terminal 2 comprises a contact section 4 for connection to a complementary conductor, and a connection section 6 for connection to a bare end 8 of a cable 10 that is shown provided with an outer insulating layer 12.
  • the connection section 6 comprises a tubular portion 14 (that has a cylindrical shape prior to crimping and forming) with a cavity 4 receiving the cable end 8 therein.
  • the connection section 6 comprises a crimp connection that has a base portion 18 and opposed thereto a top portion 20 integrally joined to the base portion 18 via side portions 22.
  • the top portion 20 has a deep stamped recess, such that inner sides 24 of the top portion 20 form an acute angle with the outer side portions 22.
  • the top portion 20 comprises a pair of grooves extending generally transversely to the direction A of the conductor 10, the pair of grooves 26 separated by a hump 28.
  • the grooves and humps have approximately the same size curvature, and are arranged within the recess 21 below an upper edge 29 of the top portion that forms the corner joining the inner side wall 24 to the outer side wall 22.
  • the hump and grooves extend substantially prismatically across the recess 21 from one inner side 24 to the opposite inner side 24.
  • the base portion 18 comprises a groove 32 disposed, with respect to the axial direction, in alignment with the hump 28.
  • the base groove 32 extends from side portion 22 to the opposed side portion 22.
  • the grove 32 may extend around the base through roughly as much as 180°.
  • the "slalom” course that the deformed cable follows increases the contact surface area between the cable and crimping portion of the terminal, and increases axial retention strength of the terminal to the cable. Nevertheless, a deep stamping crimp for tube connector is provided that ensures high local crushing pressure needed for large conductor connections.
  • the "slalom” course enables the crushing height H (between top and base walls) to be slightly greater than in conventional deep stamped crimps for tube conductors, because of the increased mechanical retention and improved electrical contact arising from the larger contact surface area and increased pressure from the bent conductor against crimp portion walls.
  • the increased crush height H of the crimp connection enables connection to solid conductors and stranded conductors whilst ensuring sufficient mechanical retention.
  • the inner sides 24 of the recess 21 have a slightly tapered angle as is typical with deep stamped crimp recesses.
  • the base portion 18 comprises slightly recessed portions 33 either axial side of the groove 32, that are formed by the crimping assembly anvil that supports the base against the crushing force of the die.
  • the recesses 33 may be negligeable, depending on the die pressure and the corresponding support surface of the anvil.
  • the tool assembly comprises an anvil 42 against which the base portion of the terminal connection section 6 rests, and a crimping punch 44 for mounting on a moveable ram of a crimping machine or tool.
  • the crimping die 44 comprises an attachment portion 46 for fixing to the machine or tool .
  • the die 44 further comprises a profiled stamped portion 48 that has sides 50 for forming the crimp connection sides 21, and a pair of humps 52 flanking a groove 54 for stamping the complementary grooves 26 and hump 28 of the crimp connection.
  • the humps and grooves extend in a prismatic manner substantially orthogonally to the direction A of the cable.
  • the anvil 42 has a U shaped base 56 comprising a ridge 58 projecting from the base surface 57 for forming the base groove 32.
  • the ridge 58 is arranged substantially orthogonal to the (axial) direction A of the cable 10 and extends from one side wall 59 to an opposed side wall 60 of the base 56.
  • the axial position of the die and anvil with respect to the terminal is shown figure 1.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

A crimp connection for tubular connection sections comprises a deep stamped recess (21) having a pair of grooves (26) and a hump (28) positioned therebetween. A base portion (18) of the terminal comprises a groove (32) positioned in alignment with the top wall hump (28) thereby causing the crimped cable (8) to bend through a slalom path. The slalom in combination with the deep stamping crimp for closed tubular connection sections enables provision of a particularly good mechanical and electrical crimped connection to flexible or rigid stranded cable cores, particularly large cables for electrical power distribution.

Description

CRIMP CONNECTION FOR LARGE CONDUCTORS
This invention relates to a crimp connection for mechanically and electrically connecting an electrical terminal to a conductor, in particular a flexible or rigid stranded cable conductor for transmitting large electrical currents as used in electrical power transmission and distribution networks.
An example of a crimp connection for connecting a terminal to a cable is described in US 3 955 044. The terminal described therein comprises a contact portion for connection to a complementary conductor, and a crimp portion for mechanical and electrical attachment to a conducting cable. The crimp portion comprises a cylindrical tube that receives an end of the conducting cable therein, the tube subsequently being deformed by a crimping die that collapses the tube locally, thereby forming a deep recess. The recessed wall squashes the conducting strands of the cable in the tube for secure mechanical and electrical connection.
For small conducting wires, as used in the electrical appliance and electronics industry, it is typical to provide crimping portions in the shape of an open V or U whereby the conductor is received on the base of the V shaped barrel and the upstanding arms collapsed over the conductor during the crimping process.
For large diameter cables (e.g. with a cross section area of 120 mm2) as used in electrical distribution networks, for example for distributing electrical power to factories and houses, it is typical to employ terminals with crimping portions that are closed tubular members. Closed tubular crimping members form a stronger mechanical crimp than an open barrel . There are however certain problems associated with the crimping of tubular crimping portions, in that the deep recessed portion may crush the cable excessively and thereby sever some of the conducting strands. The latter leads to reduced mechanical and electrical performance. A further problem is that such crimp connections are not well adapted for crimping both flexible electrical cables (formed of many thin strands) and rigid stranded electrical cables (formed of a few strands) . Flexible cables are more easily bendable and compressible than rigid standed cables, therefore a typical crimp connection for a rigid stranded cable may not sufficiently grip a flexible cable. It would however be desirable to provide a crimp connection that is more versatile, particularly for use for both flexible and rigid stranded cables. It is an object of this invention to provide an improved crimp connection, particular crimp connections for tubular connection portions.
Objects of this invention have being achieved by providing the crimp connection according to claim 1. Disclosed herein is a crimp connection of an electrical terminal, the crimp connection formed from a tubular connection section wall receiving a cable conductor therein, the crimp connection comprising a base portion and a recessed top portion facing the base portion joined thereto via side portions, wherein the top recessed portion comprises at least two grooves separated by a hump, the grooves and hump extending generally transversely to the direction of the cable, and wherein the base portion comprises a groove arranged opposite the hump .
Advantageously, a cable crushed within the connection is forced to bend at the position of the hump and corresponding base groove such that good mechanical and electrical connection for a stranded rigid or flexible cable is achieved.
Further advantageous aspects of this invention will be described in the claims, or will be apparent from the following description and drawings.
An embodiment of this invention will now be described by way of example with reference the figures, in which ; figure 1 is a side view of a terminal crimped to a conducting cable, with the crimping die shown in outline; figure 2 is a top view of the terminal of figure 1; figure 3 is a cross-sectional view through line 3-3 of figure 2; figure 4 is a cross-sectional view through line 4-4 of figure 2; figure 5 is an isometric view of the electrical terminal of figure 1; figure 6 is an isometric view of an anvil of a crimping die assembly for forming the crimp connection according to this invention; figure 7 is an isometric view of a punch of the crimping punch assembly.
Referring to figures 1-5, an electrical terminal 2 comprises a contact section 4 for connection to a complementary conductor, and a connection section 6 for connection to a bare end 8 of a cable 10 that is shown provided with an outer insulating layer 12. The connection section 6 comprises a tubular portion 14 (that has a cylindrical shape prior to crimping and forming) with a cavity 4 receiving the cable end 8 therein.
The connection section 6 comprises a crimp connection that has a base portion 18 and opposed thereto a top portion 20 integrally joined to the base portion 18 via side portions 22. The top portion 20 has a deep stamped recess, such that inner sides 24 of the top portion 20 form an acute angle with the outer side portions 22. The top portion 20 comprises a pair of grooves extending generally transversely to the direction A of the conductor 10, the pair of grooves 26 separated by a hump 28. The grooves and humps have approximately the same size curvature, and are arranged within the recess 21 below an upper edge 29 of the top portion that forms the corner joining the inner side wall 24 to the outer side wall 22. The hump and grooves extend substantially prismatically across the recess 21 from one inner side 24 to the opposite inner side 24.
The base portion 18 comprises a groove 32 disposed, with respect to the axial direction, in alignment with the hump 28. The base groove 32 extends from side portion 22 to the opposed side portion 22. The grove 32 may extend around the base through roughly as much as 180°. The base groove 22 and top hump 28 on the one hand, and the top grooves 26 flanking the hump on the other hand, cause the conductor to be compressed into a bend path.
The "slalom" course that the deformed cable follows increases the contact surface area between the cable and crimping portion of the terminal, and increases axial retention strength of the terminal to the cable. Nevertheless, a deep stamping crimp for tube connector is provided that ensures high local crushing pressure needed for large conductor connections. The "slalom" course enables the crushing height H (between top and base walls) to be slightly greater than in conventional deep stamped crimps for tube conductors, because of the increased mechanical retention and improved electrical contact arising from the larger contact surface area and increased pressure from the bent conductor against crimp portion walls. The increased crush height H of the crimp connection enables connection to solid conductors and stranded conductors whilst ensuring sufficient mechanical retention.
The inner sides 24 of the recess 21 have a slightly tapered angle as is typical with deep stamped crimp recesses. The base portion 18 comprises slightly recessed portions 33 either axial side of the groove 32, that are formed by the crimping assembly anvil that supports the base against the crushing force of the die. The recesses 33 may be negligeable, depending on the die pressure and the corresponding support surface of the anvil.
Referring to figures 6 and 7, a tool assembly is shown for producing the crimp connection according to figures 1-5. The tool assembly comprises an anvil 42 against which the base portion of the terminal connection section 6 rests, and a crimping punch 44 for mounting on a moveable ram of a crimping machine or tool. The crimping die 44 comprises an attachment portion 46 for fixing to the machine or tool . The die 44 further comprises a profiled stamped portion 48 that has sides 50 for forming the crimp connection sides 21, and a pair of humps 52 flanking a groove 54 for stamping the complementary grooves 26 and hump 28 of the crimp connection. The humps and grooves extend in a prismatic manner substantially orthogonally to the direction A of the cable. The anvil 42 has a U shaped base 56 comprising a ridge 58 projecting from the base surface 57 for forming the base groove 32. The ridge 58 is arranged substantially orthogonal to the (axial) direction A of the cable 10 and extends from one side wall 59 to an opposed side wall 60 of the base 56. The axial position of the die and anvil with respect to the terminal is shown figure 1.

Claims

1. A crimp connection of an electrical terminal, the crimp connection formed from a tubular connection section wall receiving a cable conductor therein, the crimp connection comprising a base portion (18) and a deep recessed top portion (16,21) facing the base portion and joined thereto via side portions (22), wherein the top recessed portion comprises at least two grooves (26) separated by a hump (28) , the grooves and hump extending substantially orthogonally to the direction (A) of the cable, and wherein the base portion comprises a groove (32) arranged substantially opposite the hump.
2. The crimp connection of claim 1 wherein the hump is arranged within the crimp recess (21) below top edges (29) formed by the join between outer sides (22) of the crimp connection and inner sides (24) of the crimp recess .
3. The crimp connection of claim 1 or 2 wherein the hump and grooves of the top portion extend substantially prismatically .
4. The crimp connection of claim 3 wherein the hump and grooves extend from one inner side (24) to an opposite inner side (24) of the recess (21).
5. The crimp connection of claim 3 or 4 wherein the hump and grooves of the top portion have arcuate profiles of roughly equivalent curvature.
6. The crimp connection of any one of the preceding claims wherein the base groove (32) extends roughly 180┬░ from one side portion (22) to an opposite side portion (22) .
7. The crimp connection of any one of the preceding claims wherein the base groove (32) extends substantially orthogonally to the direction (A) of the cable (10) to be crimped.
8. The crimp connection of any one of claims 2-7 wherein the inner sides (24) are slightly tapered towards each other when considering a direction from top portion towards base portion.
9. A tool assembly adapted to form the crimp connection according to any one of claims 1-8, comprising a punch
(44) for mounting on a movable ram, and an anvil (42), wherein the punch comprises a stamping portion (48) projecting therefrom and having a pair of substantially prismatic humps (52) separated by a substantially prismatic groove (54) extending between opposed sides
(50) of the stamping portion.
10. The tool assembly of claim 9 wherein the anvil (42) has a substantially "U" - shaped base for receiving the terminal base portion (18) thereagainst, the anvil further comprising a ridge (58) extending from one side wall (59) to an opposed side wall (60) of the base (56).
PCT/IB1998/000778 1997-05-26 1998-05-20 Crimp connection for large conductors WO1998054790A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU70744/98A AU7074498A (en) 1997-05-26 1998-05-20 Crimp connection for large conductors

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP97401151.2 1997-05-26
EP97401151 1997-05-26

Publications (1)

Publication Number Publication Date
WO1998054790A1 true WO1998054790A1 (en) 1998-12-03

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB1998/000778 WO1998054790A1 (en) 1997-05-26 1998-05-20 Crimp connection for large conductors

Country Status (3)

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AU (1) AU7074498A (en)
TW (1) TW400985U (en)
WO (1) WO1998054790A1 (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2053693A1 (en) * 2007-10-26 2009-04-29 AMPHENOL-TUCHEL ELECTRONICS GmbH Connector socket cover
WO2012081552A1 (en) * 2010-12-13 2012-06-21 矢崎総業株式会社 Connector terminal wire connection structure and method of manufacturing same
EP2706616A1 (en) * 2012-09-07 2014-03-12 Mecatraction Method for assembling a connection device on an exposed terminal segment of an electrical cable and assembly comprising such a device securely assembled on such a cable segment
DE102012216780A1 (en) * 2012-09-19 2014-03-20 Lisa Dräxlmaier GmbH Crimp connector for interfaces of electric lines in automotive industry, has crimp sleeve providing central region that is defined in longitudinal direction of crimp barrel of adjoining edge area
US8827744B2 (en) 2011-07-29 2014-09-09 Delphi Technologies, Inc. Wire cable assembly
EP3940895A1 (en) 2020-07-13 2022-01-19 Hitachi Metals, Ltd. Electric wire with terminal and method for manufacturing the same

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104180317A (en) * 2013-05-22 2014-12-03 深圳市海洋王照明工程有限公司 LED (light emitting diode) aluminum base plate electric connecting structure

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2276140A (en) * 1940-04-18 1942-03-10 Artos Engineering Co Conductor terminal
US2810897A (en) * 1953-03-27 1957-10-22 Ideal Ind Crimp connector
DE2754341A1 (en) * 1977-12-07 1979-06-13 Kabel Metallwerke Ghh Wire contact pin attachment device - uses pin with hole placed on wire and deformed into sinusoidal shape between two punches

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2276140A (en) * 1940-04-18 1942-03-10 Artos Engineering Co Conductor terminal
US2810897A (en) * 1953-03-27 1957-10-22 Ideal Ind Crimp connector
DE2754341A1 (en) * 1977-12-07 1979-06-13 Kabel Metallwerke Ghh Wire contact pin attachment device - uses pin with hole placed on wire and deformed into sinusoidal shape between two punches

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2053693A1 (en) * 2007-10-26 2009-04-29 AMPHENOL-TUCHEL ELECTRONICS GmbH Connector socket cover
WO2012081552A1 (en) * 2010-12-13 2012-06-21 矢崎総業株式会社 Connector terminal wire connection structure and method of manufacturing same
US9028283B2 (en) 2010-12-13 2015-05-12 Yazaki Corporation Electric wire connection structure of connector terminal and method for fabricating the same
US8827744B2 (en) 2011-07-29 2014-09-09 Delphi Technologies, Inc. Wire cable assembly
EP2706616A1 (en) * 2012-09-07 2014-03-12 Mecatraction Method for assembling a connection device on an exposed terminal segment of an electrical cable and assembly comprising such a device securely assembled on such a cable segment
FR2995459A1 (en) * 2012-09-07 2014-03-14 Mecatraction METHOD FOR ASSEMBLING A CONNECTING DEVICE ON A TERMINAL STRIP DENUDE OF AN ELECTRIC CABLE AND ASSEMBLY COMPRISING SUCH A DEVICE ASSEMBLED SOLIDARILY ON SUCH A CABLE TRUNK
US9196971B2 (en) 2012-09-07 2015-11-24 Mecatraction Assembly having a tubular portion crimped to a cable at several locations with varying degrees of compression
DE102012216780A1 (en) * 2012-09-19 2014-03-20 Lisa Dräxlmaier GmbH Crimp connector for interfaces of electric lines in automotive industry, has crimp sleeve providing central region that is defined in longitudinal direction of crimp barrel of adjoining edge area
DE102012216780B4 (en) * 2012-09-19 2015-03-26 Lisa Dräxlmaier GmbH Aging resistant crimp connection
EP3940895A1 (en) 2020-07-13 2022-01-19 Hitachi Metals, Ltd. Electric wire with terminal and method for manufacturing the same

Also Published As

Publication number Publication date
TW400985U (en) 2000-08-01
AU7074498A (en) 1998-12-30

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