WO2002017436A1 - Solder-in-place axial-type connector - Google Patents
Solder-in-place axial-type connector Download PDFInfo
- Publication number
- WO2002017436A1 WO2002017436A1 PCT/US2000/023131 US0023131W WO0217436A1 WO 2002017436 A1 WO2002017436 A1 WO 2002017436A1 US 0023131 W US0023131 W US 0023131W WO 0217436 A1 WO0217436 A1 WO 0217436A1
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- WIPO (PCT)
- Prior art keywords
- cavity
- cable
- solder
- flux
- connector
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/023—Soldered or welded connections between cables or wires and terminals
- H01R4/024—Soldered or welded connections between cables or wires and terminals comprising preapplied solder
Definitions
- a significant shortcoming of the Faile device is that a thorough connection cannot be formed between the cable and the internal surfaces of the cavity -- i.e., the end and the sidewalls of the cavity. Such an incomplete connection can lead to electrical and structural deficiencies.
- the configuration will result in air pockets or voids adjacent to surfaces of the multi-strand cable -- surfaces therefore wasted in that they then fail to provide electrical pathways otherwise possible.
- internal surfaces of the Faile cable-receiving cavity are not protected from accumulation of contaminates and are not protected from corrosion, and such surface problems may then degrade effectiveness of the electrical union at surfaces of attachment. Not only would the electrical connection be wanting, but "cold solder" problems could result and structurally weak connections would result given that only a small portion of the end of the cable would be joined to the solder.
- Patent No. 3,519,982 discloses the use of pre-placed solder in conjunction with small wires in a process which also involves crimping. While maximizing electric contact along those points of contact after crimping, this device fails to provide contact along all surfaces of the cable and in the interstices between the cable. Moreover, materials conducive to the deformation process of crimping are inherently less structurally stable than a rigid cable attachment portion.
- Patent Nos. 3,243,211 (Wetmore) and 3,316,343 disclose connectors that are made of fusible materials that melt around the cable. These connectors may also employ pre-positioned solder to aid in attaching the cable to other protuberant conductors such as another cable.
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- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
The invention involves an axial-type connector (10) electrically connecting a multi-strand cable (12) to a terminal where the connector (10) is comprised of a connecting portion for engagement with a terminal (14) and a rigid cable-attachment portion (16) that includes a non-deformable neck (18) that extends from the connecting portion (14) and defines a cavity (20) having a depth (22), a closed inner end (24), an open outer end (26) and a cross-sectional area that is substantially equal along the entire depth (22) between the inner end (24) and the outer end (26) as well as substantially equal to the diameter of the cable (12). Solder (28) is secured within the cavity, and flux (30) is secured within the cavity (20) in contact with the solder (28). The solder (28) and flux (30) are both of amounts suitable for soldering engagement of the cable to the cable-attachment portion (16), thereby facilitating soldering of the cable (12) to the connector (10).
Description
SOLDER-IN-PLACE AXIAL-TYPE CONNECTOR
FIELD OF THE INVENTION
This invention is related generally to electrical connectors for removably connecting cables with terminals of the kind in which connection and disconnection involve application of along-cable force and, more particularly to methods for attaching electrical cables to such connectors.
BACKGROUND OF THE INVENTION
A great variety of connectors are used for connecting cables of various types with terminals of various types. Such connectors each have (1) a connecting portion by which the connector removably engages a terminal (e.g., a module, plug, clip or the like) and (2) a cable-attachment portion by which the cable is permanently assembled with the connector, at the appropriate time, so that the cable thereafter can easily and removably be electrically connected to a terminal. As used herein, "axial" refers to the axis of the cable. The term "axial-type connector" means an electrical connector to which an electrical cable is attached for installation with respect to a terminal, and for which the process of engagement with or disengagement from the terminal involves motion in alignment with the cable axis. Examples of axial connectors include, but are not limited to, modular types, flat types, and the DIN (according to specifications of the Deutsch Industrial Norm) type.
Attaching a cable to the cable-attachment portion of such a connector is carried out in a variety of ways -- e.g., crimping, soldering, winding, bolting, etc. The various methods of attachment, other than soldering, have a number of drawbacks. One significant drawback is the inability to withstand axial stress — i.e., stresses between the connector and the cable attached thereto imposed by pulling (or pushing) along the axis of the cable. This axial stress may be placed on the cable either intentionally or
inadvertently. Many cables for instance, are dislodged from an engaged position by purposely pulling on the cable body. This places axial pressure on the cable-to- connector junction. This phenomenon of axial stress is so well known within the industry that it has been given a measurable quantity denominated as "pull-out." A properly soldered joint is much more reliable than other methods of connection in regard to mechanical resistance to pulling.
Further, in a direct current circuit, power loss is directly proportional to increased electrical resistence. Electrical resistence across the terminal junction is minimized when all cable-to-terminal junctions are properly soldered. Soldering a cable to a connector involves a number of common steps, typically including the preheating of both the cable and the connector then introducing molten solder or solder pellets and flux at the point of attachment and then bringing the multi- strand cable and connector in simultaneous contact with the molten solder. This process is time-consuming. This process is also dependent on the considerable skill of the operator. The process requires careful control of the quantity of solder and flux, the temperature of the conductors, the manner of introduction of the solder to the component parts, the regulation of solder movement by temperature regulation, etc. and can result in attachments of widely varying strength, reliability, and electrical consistency. The process also carries with it certain risks involving the molten solder. Soldered attachment of a multi-strand cable to a connector using what might be referred to as "pre-positioned" solder has been published in the past. This is seen in the disclosure of U.S. Patent No. 1,188,055 (Faile). Such device, however, would be prone to have significant problems which would render it unacceptable, as hereafter explained. For one thing, the Faile connector has a cable-attachment cavity in which the diameter of the open end is smaller than the diameter of the inner end, a feature intended to prevent the solder from falling out before attachment of the cable with the connector. A significant shortcoming of the Faile device is that a thorough connection cannot be formed between the cable and the internal surfaces of the cavity -- i.e., the end and the sidewalls of the cavity. Such an incomplete connection can lead to electrical and structural deficiencies. The configuration will result in air pockets or
voids adjacent to surfaces of the multi-strand cable -- surfaces therefore wasted in that they then fail to provide electrical pathways otherwise possible. Furthermore, internal surfaces of the Faile cable-receiving cavity are not protected from accumulation of contaminates and are not protected from corrosion, and such surface problems may then degrade effectiveness of the electrical union at surfaces of attachment. Not only would the electrical connection be wanting, but "cold solder" problems could result and structurally weak connections would result given that only a small portion of the end of the cable would be joined to the solder. Over time, such connection can more readily break, thereby allowing the cable to be pulled from the connector. Prior connectors to which single-strand wire is attached by soldering using pre- placed solder, including connectors for use in radio, television and computer applications and the like, are disclosed in various United States patents.
For example, Patent No. 3,519,982 (White, Jr.) discloses the use of pre-placed solder in conjunction with small wires in a process which also involves crimping. While maximizing electric contact along those points of contact after crimping, this device fails to provide contact along all surfaces of the cable and in the interstices between the cable. Moreover, materials conducive to the deformation process of crimping are inherently less structurally stable than a rigid cable attachment portion. Patent Nos. 3,243,211 (Wetmore) and 3,316,343 (Sherlock) disclose connectors that are made of fusible materials that melt around the cable. These connectors may also employ pre-positioned solder to aid in attaching the cable to other protuberant conductors such as another cable. They fail to disclose any device or method for connecting a cable into a cavity. Moreover, the fusible materials disclosed fail to provide the structural strength of a rigid cable attachment portion. Patent No. 5,281,167 (Le et al.) discloses a connecting device which utilizes solder that is held in position by a flange. Such a flange restricts the opening of the connector thereby limiting the diameter size of the cable to be attached.
Pre-placed solder is used for attaching multi-strand automotive-type cable to a battery terminal connector. The motion for engaging and disengaging this type of connector with respect to a terminal stud is transverse to the axial cable-to-connector junction; thus, engagement and disengagement of the connector with respect to the
terminal does not involve axial stress. Moreover, the cables of this type are short in relation to the cable diameter, fixed at both ends, and contained within a compartment, whereby they are not subject to the intentional or inadvertent axial stress of other types of connectors. There is a need for improvements in axial-type connectors of the prior art, which will provide significantly greater axial strength to better accommodate the particular stresses unique to such connectors.
OBJECTS OF THE INVENTION It is the object of the invention to provide an improved axial-type electrical connector and method for permanent attachment of a multi-strand cable thereto that overcomes some of the shortcomings of the prior art.
It is another object of the invention to provide an improved axial-type electrical connector and method of permanently attaching a connector to a multi-strand cable that maximizes the axial strength of the cable-to-connector junction to withstand pulling along the cable.
It is still another object of this invention to maximize the electrical conductivity and reduce the electrical resistance at the cable-to-connector junction of axial-type connectors. It is still another object of this invention to allow for the creation of proper, consistent cable-to-connector solder joints for an improved axial-type electrical connectors, with minimal skill of the operator.
It is another object of the invention to provide an improved axial-type electrical connector and method of permanently attaching a connector to a multi-strand cable that allows the flux to be protected from contact with any impurities.
Still another object of the invention is to provide an improved axial-type electrical connector and method of permanently attaching a connector to a multi- strand cable where the solder body is formed in situ in the cavity.
Still another object of the invention is to provide an improved axial-type electrical connector and method of permanently attaching a connector to a multi-strand cable that eliminates air pockets between the solder and the cylindrical wall thereby
reducing the possibility of contamination and corrosion and increasing electrical contact and conductivity.
Yet another object of the invention is to provide an improved axial-type electrical connector and method of permanently attaching a connector to a multi-strand cable where the flux is hermetically sealed with the connecting cavity.
How these and other objects are accomplished will become apparent from the following descriptions and from the drawings.
SUMMARY OF THE INVENTION The invention involves an axial-type connector for electrically connecting a multi-strand cable to a terminal where the axial-type connector is comprised of a connecting portion for engagement with a terminal and a rigid cable-attachment portion that includes a non-deformable neck that extends from the connecting portion and defines a cavity having a depth, a closed inner end, an open outer end and a cross- sectional area that is substantially equal along the entire depth between the inner end and the outer end as well as substantially equal to the diameter of the cable. Solder is secured within the cavity, and flux is secured within the cavity in contact with the solder. The solder and flux are both of amounts suitable for soldering engagement of the cable to the cable-attachment portion, thereby facilitating soldering of cable to the axial-type connector. The connecting portion is configured and arranged such that the longitudinal axis of the cavity is aligned with the direction of insertion of the connecting portion into the complementary receptor terminal.
By aligning the cavity axis with the direction of insertion of the connecting portion into the complementary receptor terminal, the cable-to-connector junction will be subject to the maximum axial stress through inadvertent and intentional acts along the axis of the cable. These could include the stress encountered as the connecting portion is being pushed into or pulled out of, a tight receptor terminal. Axial stress can also be placed on the cable-to-connector junction by a transverse force across the cable, such as from a person tripping over the cable. It is thus of significant benefit to provide the maximum mechanical strength at the cable-to-connector junction that this invention readily supplies through soldering.
The pre-positioning of the solder and flux within the cavity removes the need to add molten solder to the axial-type connector once the cable is inserted thereby reducing the possibility that one may burn oneself while connecting the multi-strand cable to the axial-type connector. By pre-positioning an appropriate amount of solder that bathes the inner end and all sides of the axial-type connector cavity, a solid connection is achieved that eliminates the need to crimp the neck of the axial-type connector. This allows for the use of a rigid neck that offers greater protection to the cable strands secured within the cavity.
In one embodiment of the invention, the multi-strand cable is surrounded by insulation and includes a length free of insulation that is equal to or greater than the depth of the cavity.
In still another embodiment of the invention, the amount of the solder used is such that at least about one-half of the depth of the cavity is filled with solder thereby allowing for a stronger connection with the cable as the melted solder is displaced along the sides of the cavity and between the portions of the cable strands outside of and adjacent to the cavity.
In another embodiment of the invention, the cavity has a cylindrical lateral wall and the solder conforms to and is joined with the lateral wall. Such an embodiment eliminates air pockets between the solder and the cylindrical wall thereby reducing the possibility of the sidewalls becoming contaminated with impurities, thus preventing corrosion and subsequent degradation of the connection. In a more specific version of such embodiment, the solder is a solder body formed in situ in the cavity. Such an embodiment eliminates any air pockets or open space that would weaken the strength of the connection. In still another embodiment of the invention, the flux is a mass in contact with the inner end of the cavity. In a specific version of the preferred embodiment, the flux is sealed within the cavity. In yet a more specific embodiment, the flux is sealed within the cavity by the solder.
Another aspect of the invention involves a method for permanently attaching a multi-strand electric cable to an axial-type connector comprising: (1) providing an axial-type connector having (a ) a rigid cable-attachment portion that has a non-
deformable neck that extends from the connecting portion where the neck defines a cavity with a closed inner end, an open outer end and a cross-sectional area that is substantially equal along substantially the entire depth between the inner end and the outer end as well as substantially equal to the diameter of the cable, (b) solder secured within the cavity, (c) flux secured within the cavity in contact with the solder, and (d) a connecting portion for mechanical engagement into a complementary receptor terminal such that the cavity is aligned with the direction of insertion of the axial-type connector into the receptor terminal ; (2) inserting the multi-strand electric cable into the cavity; (3) applying heat to the neck to melt the flux and the solder; (4) further inserting the cable into the cavity to facilitate movement of the solder and flux along the strands and the surface of the cavity; and (5) removing the heat to allow solidification of the solder. In another embodiment of the method, the multi-strand cable has an insulation- free section of sufficient length such that the further inserting step allows the end of the cable to contact the inner end of the cavity. In yet another embodiment of the method, the further inserting of the cable displaces the melted flux and solder thereby causing the flux and solder to wick-up beyond the cavity and amongst the cable strands.
In still another embodiment of the method, heat is applied to the neck to melt the flux and the solder prior to inserting the cable into the cavity. The invention also involves a combination axial-type connector and multi- strand cable made by the process comprising the steps of (1) providing an axial-type connector having (a) a connecting portion for engagement with the terminal, (b) a rigid cable-attachment portion with a non-deformable neck extending from the connecting portion, the neck defining a cavity with a closed inner end, an open outer end and a cross-sectional area that is substantially equal along substantially the entire depth between the inner end and the outer end as well as substantially equal to the diameter of the cable, (c) solder secured within the cavity and (d) flux secured within the cavity in contact with the solder; (2) inserting the multi-strand electric cable into the cavity; (3) applying heat to the neck to melt the flux and the solder; (4) further inserting the cable into the cavity to facilitate movement of the solder and flux along the strands and
the surface of the cavity and beyond the cavity and between the strands; and (5) removing the heat to allow solidification of the solder.
Another embodiment of the invention involves an axial-type connector for electrically connecting a multi-strand cable having a diameter to a terminal, the axial- type connector comprising a connecting portion for engagement with a terminal and, a rigid cable-attachment portion including a non-deformable neck extending from the connecting portion and defining a cavity having a depth, a closed inner end, an open outer end and a cross-sectional area that is substantially equal along substantially the entire depth between the inner end and the outer end as well as substantially equal to the diameter of the cable, solder secured within the cavity, and flux secured within the cavity in contact with the solder, the solder and flux being of amounts suitable for soldering engagement of the cable to the cable-attachment portion, thereby facilitating soldering of the multi-strand cable to the axial-type connector.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate preferred embodiments which include the above-noted characteristics and features of the invention. The invention will be readily understood from the descriptions and drawings. In the drawings:
FIGURE 1 is a perspective view of an axial-type connector with a cut-away portion showing the solder body and flux positioned in the neck of the axial-type connector.
FIGURE 2 is a perspective view of an axial-type connector and a multi-strand cable such as the type commonly used with a axial-type connector where the axial- type connector has a cut-away portion showing the solder body and flux positioned in the neck of the axial-type connector.
FIGURE 3 A is a sectional side view of the axial-type connector and multi- strand cable showing a view of the neck of the axial-type connector with flux and solder bodies positioned at the inner end of the neck cavity.
FIGURE 3B is a sectional side view of the axial-type connector and multi- strand cable showing heat being applied to the axial-type connector and a view of the
neck of the axial-type connector with flux and solder bodies positioned at the inner end of the neck cavity.
FIGURE 3C is a sectional side view of the axial-type connector and multi- strand cable showing heat being applied to the axial-type connector, the cable fully inserted into the neck cavity, and a view of the neck with molten solder and flux along the cavity walls and between the strands of the cable.
FIGURE 3D is a sectional side view of the axial-type connector and multi- strand cable showing the cable fully inserted into the neck cavity and a view of the neck with molten solder and flux along the cavity walls and extending between the strands of the cable under the insulation.
FIGURE 4 A is a is a perspective view of a male DIN socket axial-type connector with a cut-away portion showing the solder body and flux positioned in the neck of the axial-type connector.
FIGURE 4B is a perspective view of a male DIN socket axial-type connector and a multi-strand cable such as the type commonly used with a axial-type connector where the axial-type connector has a cut-away portion showing the solder body and flux positioned in the neck of the axial-type connector.
FIGURE 5 A is a perspective view of a female DIN socket axial-type connector with a cut-away portion showing the solder body and flux positioned in the neck of the axial-type connector.
FIGURE 5B is a perspective view of a female DIN socket axial-type connector and a multi-strand cable such as the type commonly used with a axial-type connector where the axial-type connector has a cut-away portion showing the solder body and flux positioned in the neck of the axial-type connector.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGURE 1 shows the invention which involves an axial-type connector 10 for electrically connecting a multi-strand cable 12 to a terminal (not shown) where the axial-type connector 10 is comprised of a connecting portion 14 for engagement with a terminal and a rigid cable-attachment portion 16 that includes a non-deformable neck
18 (shown in FIGURE 3A) that extends from the connecting portion 14 and defines a cavity 20 having a depth 22, a closed inner end 24, an open outer end 26 and a cross- sectional area that is substantially equal along the entire depth 22 between the inner end 24 (shown in FIGURE 3 A) and the outer end 26 as well as substantially equal to the diameter of the cable 12, thereby facilitating a "snug" fit with the cable 12 (i.e., without substantial play between the cable 12 and cable-attachment portion 16). Solder 28 is secured within the cavity 20, and flux 30 is secured within the cavity 20 in contact with the solder 28. The solder 28 and flux 30 are both of amounts suitable for soldering engagement of the cable 12 to the cable-attachment portion 16, thereby facilitating soldering of the multi-strand cable 12 to the axial-type connector 10.
In one embodiment of the invention, as shown in FIGURES 2 and 3 A-D, the multi-strand cable 12 is surrounded by insulation 32 and includes a length free of insulation 32 that is equal to or greater than the depth 22 of the cavity 20, thereby allowing the insulation-free portion of the cable 12 to completely fill the cavity 20. This ensures a more thorough connection between the cable 12 and the axial-type connector 10 as the melted solder 28 and flux 30 is displaced by the cable 12 and forced along the sidewalls 34 of the cavity 20. Furthermore, the displacement of the melted solder 28 and flux 30 also causes the solder 28 to "wick-up" between the strands 36 of the cable 12 in the cavity 20 and beyond thereby creating a natural strain relief and strengthening of the cable 12 that prevents the cable 12 from flexing along the portion of its length closest to the cable-attachment portion 16 of the axial-type connector 10. This strengthening prevents the cable 12 from being broken as a result of repeated flexing in the vicinity of the axial-type connector 10.
Because the diameter of the cable 12 is substantially equal to the cross- sectional area of the cavity 20, little or no free space exists within the cavity 20 once the cable 12 is inserted. This lack of free space causes the molten solder 28 and flux 30 to seep between all of the strands 36 of the cable 12.
In another embodiment of the invention, at least about one-half of the depth 22 of the cavity 20 is filled with solder 28 thereby increasing the strength of the connection. Such filing of the cavity 20 facilitates the aforementioned wicking-up of the melted solder 28 and flux 30.
In another embodiment of the invention, the cavity 20 has a cylindrical lateral wall 34 and the solder 28 conforms to and is joined with the lateral wall 34. Such an embodiment eliminates air pockets between the solder 28 and the cylindrical wall 34 thereby reducing the possibility of the sidewalls 34 becoming contaminated, thus preventing corrosion and subsequent degradation of the connection. In a more specific version of such embodiment, the solder 28 is a solder body formed in situ in the cavity 20. Such an embodiment eliminates any air pockets or open space that would weaken the strength of the connection.
FIGURES 1, 2 and 3A-B show still another embodiment of the invention where the flux 30 is a mass in contact with the inner end 24 of the cavity 20. In a specific version of the preferred embodiment, the flux 30 is sealed within the cavity 20. In yet a more specific embodiment, the flux 30 is sealed within the cavity 20 by the solder 28 where it is protected from contamination thus ensuring a stronger connection. In a more preferred embodiment of the invention, the flux 30 is a coating that is sealed within the cavity 20, and more preferredly, the flux 30 is sealed within the cavity 20 by the solder 28.
FIGURES 4A, 4B, 5 A, and 5B demonstrate that the preferred embodiments are useful in any suitable axial-type connector 10 without regard to the connecting portion 14 as long as a rigid cable-attachment portion 16 is present to contain the solder 28 and the flux 30, and receive the cable 12. Here illustrated are DIN style male and female socket connectors.
FIGURES 3A-D depict another aspect of the invention which involves a method for permanently attaching a multi-strand electric cable 12 to a axial-type connector 10 comprising: (1) providing an axial-type connector 10 having (a) a connecting portion 14 that is suitable for engagement with a terminal, (b) a rigid cable- attachment portion 16 that has a non-deformable neck 18 that extends from the connecting portion 14 where the neck 18 defines a cavity 20 with a closed inner end 24, an open outer end 26 and a cross-sectional area that is substantially equal along substantially the entire depth 22 between the inner end 24 and the outer end 26 as well as substantially equal to the diameter of the cable 12, (c) solder 28 secured within the
cavity 20 and (d) flux 30 secured within the cavity 20 in contact with the solder 28; (2) inserting the multi-strand cable 12 into the cavity 20; (3) applying heat 38 to the neck 18 to melt the flux 30 and the solder 28; (4) further inserting the cable 12 into the cavity 20 to facilitate movement of the solder 28 and flux 30 along the strands 36 and the surface of the cavity 20; and (5) removing the heat 38 to allow solidification of the solder 28.
Inserting the cable 12 into the cavity 20 prior to heating the neck 18 not only prevents the molten solder 28 from spilling out of the cavity 20, it also prevents the formation of a "cold solder" between the cable 12 and the axial-type connector 10. Such a connection can occur when the molten solder 28 does not wick-up amongst the strands 36 of the cable 12. In such an instance, the cable 12 can eventually be pulled out of the axial-type connector 10 as only the tips of the strands 36 are secured to the solder 28.
In another embodiment of the method, the multi-strand cable 12 has an insulation-free section of sufficient length such that the further inserting step allows the end of the cable 12 to contact the inner end 24 of the cavity 20. Such a connection ensures that the solder 28 will be displaced amongst the strands 36 of the cable 12 thereby resulting in a solid connection.
In yet another embodiment of the method, the further inserting of the cable 12 results in a more secure connection as solder 28 is displaced by the cable 12 and forced along the sidewalls 34 of the cavity 20 and between the various strands 36 of wire.
In still another embodiment of the method, heat 38 is applied to the neck 18 to melt the flux 30 and the solder 28 prior to inserting the cable 12 into the cavity 20.
The invention, as shown in FIGURE 3D, also involves a combination axial-type connector 10 and attachment cable 12 made by the process comprising the steps of (1) providing a axial-type connector 10 having (a) a connecting portion 14 for engagement with the terminal, (b) a rigid cable-attachment portion 16 with a non- deformable neck 18 extending from the connecting portion 14, the neck 18 defining a cavity 20 with a closed inner end 24, an open outer end 26 and a cross-sectional area that is substantially equal along substantially the entire depth 22 between the inner end 24 and the outer end 26 as well as substantially equal to the diameter of the cable 12,
(c) solder 28 secured within the cavity 20 and (d) flux 30 secured within the cavity 20 in contact with the solder 28; (2) inserting the multi-strand electric cable 12 into the cavity 20; (3) applying heat 38 to the neck 18 to melt the flux 30 and the solder 28; (4) further inserting the cable 12 into the cavity 20 to facilitate movement of the solder 28 and flux 30 along the strands 36 and the surface 34 of the cavity 20 and beyond the cavity 20 and between the strands 36; and (5) removing the heat 38 to allow solidification of the solder 28.
Another embodiment of the invention involves a axial-type connector 10 for electrically connecting a multi-strand cable 12 having a diameter to a terminal, the axial-type connector 10 comprising a connecting portion 14 for engagement with a terminal and, a rigid cable-attachment portion 16 including a non-deformable neck 18 extending from the connecting portion 14 and defining a cavity 20 having a depth 22, a closed inner end 24, an open outer end 26 and a cross-sectional area that is substantially equal along substantially the entire depth 22 between the inner end 24 and the outer end 26 as well as substantially equal to the diameter of the cable 12, solder 28 secured within the cavity 20, and flux 30 secured within the cavity 20 in contact with the solder 28, the solder 28 and flux 30 being of amounts suitable for soldering engagement of the cable 12 to the cable-attachment portion 16, thereby facilitating soldering of the multi-strand cable 12 to the axial-type connector 10. While the principles of the invention have been shown and described in connection with but a few embodiments, it is to be understood clearly that such embodiments are by way of example and are not limiting.
Claims
1. An axial-type electrical connector for electrically connecting a multi-strand cable to a terminal, the electrical connector comprising: -a rigid cable-attachment portion including:
-a non-deformable neck extending from the connecting portion and defining a cavity having a depth, a closed inner end, an open outer end and a cross-sectional area that is substantially equal along substantially the entire depth between the inner end and the outer end as well as substantially equal to the diameter of the cable;
-solder secured within the cavity; and
-flux secured within the cavity in contact with the solder, the solder and flux being of amounts suitable for soldering engagement of the cable to the cable-attachment portion, -a connecting portion for mechanical engagement into a complementary receptor terminal, configured and arranged such that the longitudinal axis of the cavity is aligned with the direction of insertion of the connecting portion into the complementary receptor terminal, whereby the axial strength of the assembled cable and connection is enhanced and maintained despite axial stress applied by pulling on the cable.
2. The connector of claim 1 wherein:
-the multi-strand cable is surrounded by insulation and includes a length free of insulation; and -the depth of the cavity is no greater than the length free of insulation.
3. The connector of claim 1 wherein at least about one-half of the depth of the cavity is filled with solder.
4. The connector of claim 1 wherein the cavity has a cylindrical lateral wall and the solder conforms to and is joined with the lateral wall.
5. The connector of claim 4 wherein the solder is a solder body formed in situ in the cavity.
6. The connector of claim 1 wherein the flux is a mass in contact with the inner end of the cavity.
7. The connector of claim 6 wherein the flux is sealed within the cavity.
8. The connector of claim 7 wherein the flux is sealed within the cavity by the solder.
9. The connector of claim 1 wherein the flux is sealed within the cavity.
10. The connector of claim 9 wherein the flux is sealed within the cavity by the solder.
11. A method for attaching a multi-strand cable to a terminal comprising: -providing an axial-type connector having (1) a rigid cable-attachment portion with a non-deformable neck extending from the connecting portion, the neck defining a cavity with a closed inner end, an open outer end and a cross- sectional area that is substantially equal along substantially the entire depth between the inner end and the outer end as well as substantially equal to the diameter of the cable, ( 2) solder secured within the cavity, (3) flux secured within the cavity in contact with the solder, and (4) a connecting portion for mechanical engagement into a complementary receptor terminal, configured and arranged such that the longitudinal axis of the cavity is aligned with the direction of insertion of the connecting portion into the complementary receptor terminal;
-inserting the multi-strand cable into the cavity; -applying heat to the neck to melt the flux and the solder; -further inserting the cable into the cavity to facilitate movement of the solder and flux along the strands and the surface of the cavity; and -removing the heat to allow solidification of the solder.
12. The method of claim 11 wherein the multi-strand cable has an insulation- free section of sufficient length such that the further inserting step allows the end of the cable to contact the end of the cavity.
13. The method of claim 11 wherein the further inserting of the cable displaces the melted flux and solder thereby causing the flux and solder to wick-up beyond the cavity amongst the cable strands.
14. A method for permanently attaching a multi-strand cable having a diameter ial-type connector comprising:
-providing a connector having (1) a rigid cable-attachment portion with a non- deformable neck extending from the connecting portion, the neck defining a cavity with a closed inner end, an open outer end and a cross-sectional area that is substantially equal along substantially the entire depth between the inner end and the outer end as well as substantially equal to the diameter of the cable, ( 2) solder secured within the cavity, (3) flux secured within the cavity in contact with the solder, and (4) a connecting portion for mechanical engagement into a complementary receptor terminal, configured and arranged such that the longitudinal axis of the cavity is aligned with the direction of insertion of the connecting portion into the complementary receptor terminal; -applying heat to the neck to melt the flux and the solder; -inserting the cable into the cavity to facilitate movement of the solder and flux along the strands and the surface of the cavity; and
-removing the heat to allow solidification of the solder.
15. A combination axial-type connector and attached multi-strand cable made by the process comprising the steps of:
-providing a connector having (1) a rigid cable-attachment portion with a non- deformable neck extending from the connecting portion, the neck defining a cavity with a closed inner end, an open outer end and a cross-sectional area that is substantially equal along substantially the entire depth between the inner end and the outer end as well as substantially equal to the diameter of the cable, (2) solder secured within the cavity, (3) flux secured within the cavity in contact with the solder, and (4) a connecting portion for mechanical engagement into a complementary receptor terminal, configured and arranged such that the longitudinal axis of the cavity is aligned with the direction of insertion of the connecting portion into the complementary receptor terminal; -inserting the multi-strand cable into the cavity; -applying heat to the neck to melt the flux and the solder; -further inserting the cable into the cavity to facilitate movement of the solder and flux along the strands and the surface of the cavity and beyond the cavity between the strands; and -removing the heat to allow solidification of the solder.
16. The combination of claim 15 wherein at least about one-half of the depth of the cavity is filled with solder whereby the strength of the cable is enhanced beyond the cavity.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/US2000/023131 WO2002017436A1 (en) | 2000-08-23 | 2000-08-23 | Solder-in-place axial-type connector |
| AU2000267992A AU2000267992A1 (en) | 2000-08-23 | 2000-08-23 | Solder-in-place axial-type connector |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/US2000/023131 WO2002017436A1 (en) | 2000-08-23 | 2000-08-23 | Solder-in-place axial-type connector |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2002017436A1 true WO2002017436A1 (en) | 2002-02-28 |
Family
ID=21741705
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2000/023131 WO2002017436A1 (en) | 2000-08-23 | 2000-08-23 | Solder-in-place axial-type connector |
Country Status (2)
| Country | Link |
|---|---|
| AU (1) | AU2000267992A1 (en) |
| WO (1) | WO2002017436A1 (en) |
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005004291A1 (en) * | 2003-06-13 | 2005-01-13 | Molex Incorporated | Electrical connector solder terminal |
| CN101867098A (en) * | 2009-04-14 | 2010-10-20 | 株式会社电装 | Aluminium conductor terminal device and manufacture method thereof |
| EP2908382A1 (en) * | 2014-02-13 | 2015-08-19 | Sumitomo Wiring Systems, Ltd. | Terminal fitting, wire with terminal fitting and method of connecting a wire with a terminal fitting |
| US20150255885A1 (en) * | 2012-09-20 | 2015-09-10 | Jong-il Choi | Connection terminal core for cable connector and method for connecting said connection terminal core for cable connector and said cable with each other |
| CN109638489A (en) * | 2018-12-14 | 2019-04-16 | 湖州格雷电力电缆有限公司 | A kind of minor diameter cable connecting terminal |
| WO2020185216A1 (en) * | 2019-03-08 | 2020-09-17 | Onanon, Inc. | Preformed solder-in-pin system |
| CN114312389A (en) * | 2022-01-30 | 2022-04-12 | 郑州恒天铜业有限公司 | New energy automobile fills electric pile with cable and jointing equipment that have waterproof function |
| US12034263B2 (en) | 2022-07-26 | 2024-07-09 | Onanon, Inc. | Preformed solder-in-pin system |
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2000
- 2000-08-23 AU AU2000267992A patent/AU2000267992A1/en not_active Abandoned
- 2000-08-23 WO PCT/US2000/023131 patent/WO2002017436A1/en active Application Filing
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US1188055A (en) * | 1914-09-16 | 1916-06-20 | Edward Hall Faile | Connector for electric conductors. |
| US3243211A (en) * | 1962-07-23 | 1966-03-29 | Raychem Corp | Connector with fusible material |
| US3316343A (en) * | 1966-01-03 | 1967-04-25 | Raychem Corp | Heat shrinkable connector with preplaced solder therein |
| US3519982A (en) * | 1968-11-06 | 1970-07-07 | Gerome R White Jr | Method and means of forming electrical connections with conductors |
| US3852517A (en) * | 1972-06-12 | 1974-12-03 | Raychem Corp | Conductive insert for heat recoverable electrical connector |
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| US4858310A (en) * | 1988-04-12 | 1989-08-22 | W. L. Gore & Associates, Inc. | Method for soldering a metal ferrule to a flexible coaxial electrical cable |
| US5025554A (en) * | 1988-07-08 | 1991-06-25 | Yazalci Corporation | Method of connecting a crimp-style terminal to electrical conductors of an electrical wire |
| US5046957A (en) * | 1990-06-25 | 1991-09-10 | Amp Incorporated | Solder plate assembly and method |
| US5281167A (en) * | 1993-05-28 | 1994-01-25 | The Whitaker Corporation | Coaxial connector for soldering to semirigid cable |
| US5772454A (en) * | 1995-11-03 | 1998-06-30 | The Whitaker Corporation | Wire to board contact terminal |
| US6099365A (en) * | 1995-11-03 | 2000-08-08 | North American Specialties Corporation | Solder-holding clips for applying solder to connectors or the like |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005004291A1 (en) * | 2003-06-13 | 2005-01-13 | Molex Incorporated | Electrical connector solder terminal |
| US8328564B2 (en) | 2003-06-13 | 2012-12-11 | Molex Incoporated | Electrical connector solder terminal |
| CN101867098A (en) * | 2009-04-14 | 2010-10-20 | 株式会社电装 | Aluminium conductor terminal device and manufacture method thereof |
| US20150255885A1 (en) * | 2012-09-20 | 2015-09-10 | Jong-il Choi | Connection terminal core for cable connector and method for connecting said connection terminal core for cable connector and said cable with each other |
| EP2908382A1 (en) * | 2014-02-13 | 2015-08-19 | Sumitomo Wiring Systems, Ltd. | Terminal fitting, wire with terminal fitting and method of connecting a wire with a terminal fitting |
| CN104852162A (en) * | 2014-02-13 | 2015-08-19 | 住友电装株式会社 | Terminal fitting and wire with terminal fitting |
| CN104852162B (en) * | 2014-02-13 | 2018-06-29 | 住友电装株式会社 | The electric wire of terminal fittings and subsidiary terminal fittings |
| CN109638489A (en) * | 2018-12-14 | 2019-04-16 | 湖州格雷电力电缆有限公司 | A kind of minor diameter cable connecting terminal |
| WO2020185216A1 (en) * | 2019-03-08 | 2020-09-17 | Onanon, Inc. | Preformed solder-in-pin system |
| US10886685B2 (en) | 2019-03-08 | 2021-01-05 | Onanon, Inc. | Preformed solder-in-pin system |
| US11050206B2 (en) | 2019-03-08 | 2021-06-29 | Onanon, Inc. | Preformed solder-in-pin system |
| US11404838B2 (en) | 2019-03-08 | 2022-08-02 | Onanon, Inc. | Preformed solder-in-pin system |
| US11695244B2 (en) | 2019-03-08 | 2023-07-04 | Onanon, Inc. | Preformed solder-in-pin system |
| CN114312389A (en) * | 2022-01-30 | 2022-04-12 | 郑州恒天铜业有限公司 | New energy automobile fills electric pile with cable and jointing equipment that have waterproof function |
| CN114312389B (en) * | 2022-01-30 | 2024-01-30 | 郑州恒天铜业有限公司 | New energy automobile fills electric pile with cable and coupling equipment that have waterproof function |
| US12034263B2 (en) | 2022-07-26 | 2024-07-09 | Onanon, Inc. | Preformed solder-in-pin system |
Also Published As
| Publication number | Publication date |
|---|---|
| AU2000267992A1 (en) | 2002-03-04 |
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