WO2015031236A1 - Borne/connecteur à brise-oxyde intégral - Google Patents

Borne/connecteur à brise-oxyde intégral Download PDF

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Publication number
WO2015031236A1
WO2015031236A1 PCT/US2014/052482 US2014052482W WO2015031236A1 WO 2015031236 A1 WO2015031236 A1 WO 2015031236A1 US 2014052482 W US2014052482 W US 2014052482W WO 2015031236 A1 WO2015031236 A1 WO 2015031236A1
Authority
WO
WIPO (PCT)
Prior art keywords
wire
receiving portion
wire receiving
electrical
crimped
Prior art date
Application number
PCT/US2014/052482
Other languages
English (en)
Inventor
Kenneth J. Peters
William L. Arenburg
Original Assignee
Carlisle Interconnect Technologies, 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
Priority claimed from US14/010,073 external-priority patent/US9385449B2/en
Application filed by Carlisle Interconnect Technologies, Inc. filed Critical Carlisle Interconnect Technologies, Inc.
Priority to EP14759428.7A priority Critical patent/EP3039747B1/fr
Publication of WO2015031236A1 publication Critical patent/WO2015031236A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—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
    • H01R4/203—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 having an uneven wire-receiving surface to improve the contact
    • H01R4/206—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 having an uneven wire-receiving surface to improve the contact with transversal grooves or threads
    • 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
    • H01R4/26—Connections in which at least one of the connecting parts has projections which bite into or engage the other connecting part in order to improve the contact
    • 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
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5219—Sealing means between coupling parts, e.g. interfacial seal
    • 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
    • H01R4/188—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 having an uneven wire-receiving surface to improve the contact
    • 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

Definitions

  • This present invention relates generally to electrical connectors, and particularly to improving the performance, construction and ease of use of connectors on aluminum wire.
  • Electrical wires are most often made with copper or aluminum conductors. These may be of one solid piece, or stranded. For ease of
  • a lug or terminal is often attached to the end of the wire.
  • the terms lug, terminal lug, and terminal will be used interchangeably in this application.
  • a wire with a terminal is also referred to as a "cable" herein.
  • a cable might also incorporate multiple electrical conductors or wires that are connected or spliced together end-to-end. The cable, including the interface between the terminal and the conductor or between adjacent conductors, must efficiently conduct the electricity that the cable is meant to carry. If the conductance at the interface is not efficient (if resistance is high), the cable may not perform the function for which it is intended, or it may overheat. Usually, the terminal mechanically fastens to the aluminum or copper conductor.
  • Another consideration in cable manufacture is how to create a cable that resists moisture and air infiltration between the terminal and the conductor or at the transition between two spliced wires. In many cases this means making an airtight connection between the terminal or transition and the exterior of the wire insulation.
  • Still another consideration in cable manufacture is how to provide a terminal/cable combination that has a consistent and strong geometry. Preferably the terminal and cable are straight and smooth to avoid stress concentrations. With stranded wire, severing one or more strands during the terminal attachment process should also be avoided.
  • a tin plated copper terminal 10 includes a ring tongue (RT) style connector portion 1 1 , a cylindrical wire barrel 12, a perforated liner 14, and an annular ring 16 with an inclined wall 18. Terminal 10 is shown in exploded view with stranded aluminum wire 20 having conductor strands 22, an insulating sheath 24, and an abrasion sheath 26.
  • RT ring tongue
  • Figures 2 and 3 show the wire 20 installed in the terminal 10, before and after crimping by die set 27.
  • the deformation, known as terminal skew, of the terminal 10 is extensive, with the upper mounting surface 28 and lower mounting surface 30 no longer parallel to the axis 32 of the wire 20.
  • several conductor strands 22 might be severed as shown at 34 in the area of annular ring 16.
  • the pre-crimp geometry of Figure 2 is represented with phantom lines in Figure 3.
  • the extensive extrusion and crimping of the conductor strands 22 and barrel 12 changes the length 36 and the angle 38 an amount that is significant and not precisely predictable.
  • An electrical component for use with wires might be in the form of a terminal or connector.
  • the terminal has a mount portion, for connecting to a part of an electric circuit, and a wire receiving portion.
  • the connector implements adjacent wire receiving portions to receive the ends of wires that are connected together.
  • the wire receiving portions have an interior with a contact portion that has an oxide breaker element.
  • the wire receiving portion may also have a sealing portion that has at least one integral seal ring for sealing with the insulator of a wire.
  • the integral oxide breaker element may have tapered protrusions with a coating.
  • the coating is nickel, but may be other suitable materials.
  • the wire receiving portion accepts a wire, such as aluminum or copper wire to make a cable, and upon crimping of the receiving portion the oxide breaker element makes electrical contact with conductor(s) of the wire.
  • Figure 1 is an exploded view of a terminal of the prior art, with a wire.
  • Figure 2 is an assembled view of Figure 1 prior to crimping, and is also prior art.
  • Figure 3 is an assembled view of Figure 1 after crimping, and is also prior art.
  • Figure 4 illustrates one embodiment of the current invention with a stranded wire prior to installation.
  • Figure 5 is a partial cross-section of the embodiment, as indicated in Figure 4.
  • Figure 5A is a detail view of the embodiment, as indicated in Figure 5.
  • Figure 5B is a detail view of the embodiment, as indicated in Figure 5.
  • Figure 6 illustrates a not cross-sectioned wire slid into a cross- sectioned embodiment of Figure 4 for illustrative purposes.
  • Figure 7 illustrates an assembled and crimped embodiment of Figure 4.
  • Figure 8 is a cross-section of the embodiment, as indicated in Figure 7.
  • Figure 9 is another cross-section of the embodiment, as indicated in Figure 7.
  • Figure 10 is a partial cross-section illustrating an alternative
  • Figure 1 1 is a perspective view of a die set used for crimping.
  • Figure 12 is a perspective view of another alternative embodiment of the invention.
  • Figure 13 is a cross-sectional view of the embodiment of Figure 12.
  • Figure 14 is a perspective view of another alternative embodiment of the invention.
  • Figure 15 is a cross-sectional view of the embodiment of Figure 14.
  • Figure 16 illustrates a cross-sectional view of an embodiment of the connector of Figure 12 showing two wires connected together.
  • Figure 17 is a perspective view of another alternative embodiment of the invention.
  • Figure 18 is a perspective view of another alternative embodiment of the invention.
  • an integral electrical terminal 100 includes a body made from a solid piece of 1 100 Aluminum per ASTM B221 , and has a wire receiving portion 102 and a mount portion 104, and is shown with a stranded aluminum wire 20 having a conductor with conductor strands 22, an insulating sheath 24.
  • aluminum wire might be used in one embodiment of the invention, the conductor of the wire might be made of other suitable electrically conducting material, such as copper.
  • the wire connected with the terminal may also include an abrasion sheath 26.
  • the receiving portion 102 of the terminal body has a front face 106 surrounding an aperture 108, a back face 1 10, and an outer wall 1 12 between the front face 106 and the back face 1 10.
  • the receiving portion 102 is cylindrical, consistent with the usual cylindrical shape of wire, although the receiving portion 102 may be a variety of shapes.
  • Between the back face 1 10 and the mount portion 104 is a transition radius 1 14.
  • the mount portion has a parallel leg 1 16 and a
  • This terminal 100 is in the shape of what is known in the industry as a CRN terminal, however the mount portion 104 may be a variety of shapes. If the mount portion 104 had only the parallel leg 1 16, it would be an RT (Ring Tongue) configuration.
  • a top face 120 and a bottom face 122 are
  • the receiving portion 102 has a top 130 and a bottom 132, as determined by the orientation of the top face 120 and bottom face 122.
  • the wire receiving portion 102 is configured to be crimped, and has continuous annular interior wall 133 comprising a crimp portion 134 ( Figure 8) that comprises a seal portion or sealing portion 136 and a contact portion 138.
  • the sealing portion 136 is adjacent to, and spaced from, the contact portion 138 toward aperture 108.
  • a chamfer or radius 140 at the front face 106 connects with a seal zone surface 142.
  • the seal zone surface 142 is broken into four areas 144a, b, c, d by three integral seal rings 146a, b, c protruding radially inward from the seal zone surface 142.
  • each seal ring 146 has a face 148 ( Figure 5B) of a particular width, with a front angled wall 150 and a back angled wall 152 leading to the adjacent one of the four areas 144. In this embodiment, all the angled walls 150, 152 are the same angle, however, in other embodiments the angles may be different, or may be a positive or a negative radius.
  • An integral funnel 154 is between the seal or sealing portion 136 and the contact portion 138.
  • the integral funnel 154 guides the conductor strands 22 from the larger seal portion 136 into the contact portion 138, while the wire 20 is being inserted into the terminal 100.
  • the contact portion 138 has a continuous cylindrical wall 155 with a major diameter 156 and an integral oxide breaker or oxide breaker element 158, the term this application will use for the macro object that breaks through the oxide layer on the conductor or conductor strands 22 when the wire receiving portion is crimped.
  • the integral oxide breaker element 158 comprises a plurality of protrusions, such as tapered protrusions 162, extending radially inward from the major diameter 156 of the contact portion 138.
  • the protrusions are configured to engage the conductor of a wire positioned in the contact portion, and to protrude into the wire when the wire receiving portion is crimped.
  • These tapered protrusions 162 may be separate from each other, but in other embodiments, for ease of manufacture, these tapered protrusions 162 are in the form of a helical thread 164 ( Figure 5A) that is conveniently manufactured on metal cutting or forming
  • the thread 164 has a sixty degree included angle 166 and a pitch 167 of eighty, and is .008/.010 inch deep. A pitch 167 of sixty has also worked successfully. It is contemplated that other included angles 166 and pitch 167 combinations as well as depths would also work. A minor diameter 168 of the threads equal to .481 +/- .002 inch has been used for wire gauge 2/0.
  • the oxide breaker 158 further comprises a coating 170 on the protrusions 162. In various embodiments, the oxide breaker and the structures forming same might be coated with a material layer or left uncoated. In one particular embodiment, the coating 170 is an electroless nickel plate of .0005 +/- .002 per ASTM B733 Type III.
  • blind refers to a hole with only one aperture 108
  • coating process In addition to nickel, other coatings might be utilized and include electro nickel, gold, silver, tin and tin-lead, and alkaline- bismouth-tin.
  • the structure of the oxide breaker element provides not only the ability to break through the oxide layer on the conductor strand, but also improves the electrical and mechanical features of the invention.
  • the construction of the oxide breaker element increases the surface area of the crimp, and the contact with the conductor, to improve the overall electrical properties of the connection in the transition from the wire to the terminal.
  • the oxide breaker element 158 increases the grip function at the contact portion 138, and increases the pull force necessary to remove the wire 20 from terminal 100.
  • FIG. 10 illustrates an alternative embodiment of a contemplated terminal 500 in which the protrusions 162 of the oxide breaker 502 are axial ridges 504. The orientation of the axial ridges 504 are parallel to the direction of pull-out.
  • the protrusions 162 improve upon the prior art and provide improved electrical properties for current conductance purposes, they might be slightly less effective in improving pull-out requirements as those illustrated in Figure 5.
  • these protrusions 162 comprise peaks 172, angular faces 174, and bottoms 176, and may have no coating, or may be covered by coating 170 as seen in detail Figure 5A.
  • Other embodiments of protrusions 162 are contemplated but not shown, for example, a plurality of spikes rising from the major diameter 156 might also be implemented.
  • the wire 20 is inserted in the terminal so that the conductor or conductor strands 22 are guided by the integral funnel 154 into the contact portion 138.
  • the three seal rings 146a,b,c surround the insulation sheath 24, and the integral oxide breaker 158 surrounds the conductor of the wire, including the conductor strands 22.
  • the assembly 178 is placed in a suitable crimping die, such as a modified hex crimping die 182 ( Figure 1 1 ), and crimped to make a cable 184 with a crimp 186.
  • a suitable crimping die such as a modified hex crimping die 182 ( Figure 1 1 ), and crimped to make a cable 184 with a crimp 186.
  • the crimp 186 comprises 2 opposing concave facets 188 and four straight facets 190. Between the facets are six corners 192.
  • On one of the concave facets 188 is an indicator button 194.
  • the indicator button 194 will be properly formed if the wire 20 was properly inserted and crimped. If the wire 20 was improperly inserted or crimped the indicator button 194 will be shaped improperly, indicating to a person or a visual inspection system that the particular cable 184 should be rejected.
  • the indicator button 194 is formed by a recess (not shown) in crimping die 182. If the conductor strands 22 are not present in the proper position in the terminal 100, the receiving portion 102 will not extrude into the recess, and the indicator button 194 will not be formed.
  • the conductor strands 20 are squeezed together tightly at 195 as compared to the visibly individual strands at 196 outside of the terminal 100.
  • the sealing rings 146a,b,c are squeezed into the insulating sheath 24 to make a hydrostatic seal 198.
  • the integral oxide breaker 158 is squeezed into the aluminum conductor strands 22 to give the assembly 178 a conductive electrical path 202 between the receiving portion 102 and the stranded aluminum wire 20.
  • Oxide Breaker testing A smooth bore design was compared with a machined oxide breaker by testing. Results showed that the smooth bore did not meet the low initial 6.0 millivolt requirement whereas the machined oxide breaker barrel met the requirement with very good margin. Further testing after Thermal Shock and Current Cycling proved that the machined oxide breaker feature continued to perform well.
  • Thermal Shock testing After the initial millivolt drop testing, a modified 100 cycle Thermal Shock test was run on the same set of 2/0 AWG Single -Hole Tensolite Aluminum Terminal samples. The temperature was cycled between -65°C and +175°C but no current flow was included in the testing. Millivolt drop results were tested at the end of the 100 cycles. The millivolt results after 100 cycles show that the terminals met the millivolt requirement of BPS-T-217 and the more stringent millivolt requirement of BPS-T-233.
  • Hydrostatic seal testing The hydrostatic test used aluminum terminals crimped to wire and installed into a water filled chamber. The chamber was cycled 25 times from 0 to 80 PSI and held at pressure for 15 minutes each cycle. All samples passed.
  • FIG. 12-16 illustrate further alternative embodiments of the invention in the form of a connector that might be implemented to connect together or splice together two conductors or wires.
  • the connector may act as a splice connector to splice together two wires of the same size, or could be in the form of a transition connector to splice together two different size wires.
  • Figures 12 and 13 illustrate a connector device or element wherein the two wires that are connected together or spliced together are generally of the same size or gauge, such as 1/0 to 1/0 size wires.
  • Figures 14 and 15 illustrate the transition connector for connecting together wires having different gauges, such as a 1/0 to 2/0 size wire transition.
  • the connecters of Figures 12-16 may be used to connect wires of the same material, such as two aluminum or two copper wires, or may be used to connect together two different wires, such as an aluminum wire and a copper wire.
  • the connector 300 of Figures 12 and 13 has a body formed of a suitable electrically conductive material, such as aluminum or copper.
  • Connector 300 has two adjacent wire receiving portions 302 that are positioned at opposing ends of the body, and configured to receive the exposed end of a wire, such as an aluminum wire or a copper wire.
  • Each receiving portion 302 forms a corresponding aperture 304 in the end of the connector like with the terminal embodiment.
  • the receiving portion 302 might also be cylindrical, consistent with other embodiments, and the usual cylindrical shape of a wire, but the receiving portion might also be a variety of other shapes.
  • each receiving portion 302 includes an interior wall 306 that forms a suitable portion to be crimped that includes a sealing portion 308 and a contact portion 310.
  • a chamfer 312 transitions to surface 314 that forms the sealing portion 308.
  • the seal zone of the sealing portion might be considered to be broken into a number of different areas 316a-316d by integral seal rings 318a-318c that protrude radially inwardly from surface 314.
  • a greater or lesser number of areas 316 or seal rings 318 might be implemented in the embodiment of the invention than the three rings 318 and four areas 316 illustrated in the figures.
  • Each seal ring 318a- 318c will be constructed or configured as illustrated in Figure 5b having suitable faces and angled walls, as noted herein.
  • An integral transition area or funnel 320 feeds between the sealing portion 308 and the contact portion 310 to guide the conductor of a wire, as illustrated in Figure 16, from a larger diameter sealed portion 308 to the smaller diameter contact portion.
  • the contact portion also has a continuous inner surface 322, which has an oxide breaker element 324 formed thereon for breaking up the oxide layer on a conductor of a wire inserted into the connector 300.
  • the integral oxide breaker element 324 may have a plurality of protrusions, such as tapered protrusions, such as those illustrated and discussed with respect to Figure 5.
  • the protrusions extend radially inwardly from the surface 322 in the contact position, and they include individually tapered protrusions or a helical thread, as illustrated in Figures 5-5A, or might take the form as illustrated in Figure 10.
  • the oxide breaker element 324 is suitably configured to engage a wire positioned in the contact portion, and the protrusion protrude into or penetrate into a conductor 22 of a wire when the receiving portion 302 is crimped.
  • the oxide breaker element breaks up any oxide on the conductor, and also electrically engages the conductor for the purposes of conducting electrical current through the connector 300. While embodiments of the invention in the form of a terminal might conduct electricity to a particular point of a circuit, the embodiment of connector 300 is directed to form a suitable electrical connection, splice, or transition between the ends of two wires that are connected end-to-end, as illustrated in Figure 16.
  • the oxide breaker element might be a bare structure essentially presenting the metal of the connector 300 to the wire
  • the oxide breaker element, and particularly the protrusions and structures of the oxide breaker element 324 might be coated with a suitable coating, similar to the coatings discussed herein above with respect to the terminal embodiment.
  • Both of the oxide breaker elements of the connectors 300, 301 might be coated with a coating, or only one might be coated with the other one left uncoated.
  • Figures 12 and 13 illustrate a connector 300 for use with wires that are essentially the same size, diameter, or gauge, such as 1/0.
  • Figures 14 and 15 illustrate an embodiment wherein the wires have a different gauge, such as a 1/0 to 2/0 transition. That is, connector 301 , as illustrated in Figures 14 and 15, has one receiving portion 303 that is smaller than another receiving portion 305. To that end, the connector 301 provides a suitable splice and transition between differently-sized wires.
  • the inner surface 322a of the contact portion 310 has a smaller inner diameter than the corresponding surface 322b in the adjacent wire receiving portion 305.
  • connector 301 All of the other elements of connector 301 are similar to those of connector 300, and thus, are set forth with similar reference numerals.
  • transition connector 301 an angled outer surface 307 indicates the transition between the different sizes.
  • a structure having a uniform outside diameter, such as that shown by connector 300 might also be implemented with only the inner surface 322a being accordingly sized to its smaller size.
  • suitable wire stop structures 309, 31 1 are formed.
  • an appropriate connector 300, 301 might be utilized to connect together or splice together the ends of two wires similar to the way that the terminal 100 is connected to the end of a wire.
  • the ends of the wire 20 are inserted into the terminal, and the conductor 22 is guided into the appropriate contact portion 310.
  • the seal rings surround the insulation sheath 24 of the wire, while the oxide breaker 324 surrounds the conductor 22.
  • the entire assembly can then be placed in a suitable crimping die and crimped so that the seal rings seal around the insulation sheath 24, and the oxide breaker element 324 presses into and engages the conductor 22.
  • the connectors 300, 301 are otherwise similar in operation and performance to the terminal 100 discussed herein.
  • the wires connected may be of the same material or of different materials.
  • both of the oxide breaker elements of a connector might be coated with a coating such as Nickel, or only one might be coated.
  • a coating such as Nickel
  • only one might be coated if an aluminum wire is spliced to a copper wire, only the receiving portion and oxide breaker element that engages the aluminum wire might be coated.
  • both oxide breaker elements might be coated, for example.
  • Figure 17 illustrates another alternative embodiment of the invention incorporating a lubricant layer for the purposes of improved crimping of a connector or terminal of the invention. While a terminal embodiment is illustrated in Figure 17, the features of the lubricant layer are equally applicable to the connector
  • the terminal 350 includes a mount portion 352, which may be mounted to an appropriate surface, such as a grounding surface, when a wire or cable implementing terminal 350 is implemented.
  • Terminal 350 also includes a wire receiving portion 354 constructed as discussed herein.
  • the wire receiving portion will have an appropriate sealing portion 308 and contact portion 310.
  • Each wire receiving portion 308 will include an aperture 304 with other appropriate structures positioned on an interior surface, including integral seal rings 318a-318c.
  • the terminal 350 of Figure 17 is similar to other terminals or connectors discussed herein in most of its construction, but also has a lubricant layer.
  • the crimping process can be affected, sometimes detrimentally.
  • the interior surfaces such as the oxide breaker element
  • the exterior surfaces of the device are also coated.
  • a majority percentage of the wire receiving portion 354 will be crimped as shown herein for capturing a wire conductor, and breaking up any oxide on the outer surface of the wire conductor. While certain coating materials flow over the outer surface of wire receiving portion 354 during the crimping process, other coating materials are harder and more brittle.
  • the coating material may extrude or flow into various crimp points of the die, such as the seams 183, as illustrated in Figure 1 1 .
  • a coating of tin will sufficiently flow around the outside surface of the wire receiving portion 354 when it is crimped, a coating material layer of nickel, will not.
  • a hard material like nickel extrudes into the crimp seams 183 of the die during the crimping process, it will create flashing in the form of fins or wings at certain areas of the crimp. Such flashing may then pull away from the crimped terminal or connector, thus exposing the aluminum of the terminal or connector to corrosion.
  • such a situation with flashing formed may be considered a failed crimp process.
  • the outside surface of the wire receiving portion is coated with a lubricant layer 360.
  • the lubricant layer 360 is made of a suitable lubricant material, such as PTFE, such as FluoroPlate®- XK3-654-LT, available from Orion Industries of Chicago, Illinois.
  • the lubricant layer 360 is applied generally to the wire receiving portion 354, but only on the outside surface thereof.
  • Other areas, such as the internal surfaces of the wire receiving portion 354, as well as the mount portion 352 are appropriately masked to prevent any overspray.
  • the wire receiving portion 354 outside or external surface may be appropriately degreased while certain of the conductive areas are masked to be kept free from overspray.
  • the lubricant material is applied on the outside surface of at least part of the wire receiving portion, such as in a thickness in the range of 0.0003 - 0.001 inches.
  • the thickness of the applied lubricant layer 360 may be 0.0006 +/- 0.0002 inches.
  • the applied lubricant layer 360 may also be cured at around 160° +/- 5° Fahrenheit, for around twenty minutes.
  • the lubricant layer 360 provides lubrication to a harder coating material, such as nickel, so that, during the crimp, the coating materials flow more easily in the die, and prevents undesirable flashing. In that way, the overall terminal or connector is improved, and failed crimps are minimized.
  • Figure 18 illustrates another alternative embodiment, which has features which may be implemented in either a terminal or connector, as disclosed herein.
  • Figure 18 illustrates a terminal embodiment, but the features are equally applicable to a connector embodiment as well.
  • the terminal 362 has an appropriate wire receiving portion 364, which is constructed as disclosed herein, including a sealing portion 308 and contact portion 310, with appropriate structures as shown.
  • flexible seal rings may be implemented along with the seal rings 318a - 318c.
  • one or more flexible seal rings 370a, 370b might be implemented in one or more of the areas 316a - 316d that are provided between the seal rings 318 of the sealing portion 208.
  • flexible seal ring 370a is positioned between and adjacent to rings 318a and 318b, while flexible seal ring 370b is positioned between and adjacent to rings 318b and 318c.
  • the flexible seal rings 370 are formed of a suitably flexible material, such as an RTV Silicone.
  • One suitable material is Heat Resistant Sealant 736, available from Dow Corning.
  • the flexible seal rings 370 are deposited in the appropriate spaces 316, and would generally take up less than the space or volume between the seal rings 318.
  • Each of the flexible seal rings 370 is preferably formed continuously for 360° around the air surface of the sealing portion 308. An exact shape for the flexible seal rings 370 is not critical.
  • the flexible seal rings 370a are flexed when the wire receiving portion 364 is crimped, as noted herein for forming a complete wire assembly or cable using an appropriate wire.
  • the flexible seal rings 370 provide additional sealing to the overall seal that is provided by the crimping of the rings 318. In that way, an overall sealed environment within contact portion 310 is created and maintained.
  • a solvent wash might be utilized to wash the interior surfaces of the wire receiving portion 364.
  • a high pressure dispenser with volumetric control one or more 360° rings of sealant are applied.
  • the flexible seal rings 370 in one embodiment, may be 50% higher than the height of the adjacent rigid seal rings 318.
  • the flexible seal rings 370 might be applied by hand, with a suitable tool to deposit material in the various areas 316, such as up to a level with the rings 316. The material applied is appropriately viscous, and can flow, but then hardens.
  • Material may then be allowed to cure at room temperature, such as for a minimum of twenty-four hours, to provide the seal features of embodiments of the invention.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

L'invention concerne une borne électrique intégrale (100) d'une seule pièce qui présente une partie montage (104) et une partie recevant un fil (102). La partie recevant un fil (102) comporte une paroi intérieure annulaire continue (133) présentant une partie contact munie d'un brise-oxyde intégral (158) spécialement conçu pour briser la couche d'oxyde sur le fil en aluminium. La partie recevant le fil (102) comporte également une partie d'étanchéité (136) avec au moins une bague d'étanchéité intégrale (146). Un câble électrique est fabriqué par sertissage de la borne électrique (100) à un fil en aluminium en utilisant un sertissage hexagonal modifié.
PCT/US2014/052482 2013-08-26 2014-08-25 Borne/connecteur à brise-oxyde intégral WO2015031236A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP14759428.7A EP3039747B1 (fr) 2013-08-26 2014-08-25 Borne/connecteur à brise-oxyde intégral

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US14/010,073 US9385449B2 (en) 2009-02-16 2013-08-26 Terminal/connector having integral oxide breaker element
US14/010,073 2013-08-26

Publications (1)

Publication Number Publication Date
WO2015031236A1 true WO2015031236A1 (fr) 2015-03-05

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PCT/US2014/052482 WO2015031236A1 (fr) 2013-08-26 2014-08-25 Borne/connecteur à brise-oxyde intégral

Country Status (2)

Country Link
EP (1) EP3039747B1 (fr)
WO (1) WO2015031236A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021160394A1 (fr) * 2020-02-14 2021-08-19 Phoenix Contact E-Mobility Gmbh Ensemble élément de contact pour partie fiche de connexion
EP3611800B1 (fr) * 2018-08-13 2022-02-16 Hitachi Metals, Ltd. Fil électrique équipé de bornes

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US2974400A (en) * 1952-03-11 1961-03-14 Frank J Sowa Method of making an insulated electrical connector
US3955044A (en) 1970-12-03 1976-05-04 Amp Incorporated Corrosion proof terminal for aluminum wire
US5422438A (en) * 1991-02-07 1995-06-06 Raychem Sa Electrical crimp connector
US20020050385A1 (en) * 2000-10-13 2002-05-02 Kazuhiro Murakami Structure of mounting terminal to covered electric wire and method thereof
US20080217055A1 (en) * 2006-07-27 2008-09-11 Markus Gumley Electrical Wire Connector with Temporary Grip
US20100206631A1 (en) * 2009-02-16 2010-08-19 Peters Kenneth J Terminal having integral oxide breaker
US20110097948A1 (en) * 2008-02-21 2011-04-28 Melni Mark L Electrical connectors and methods of manufacturing and using same

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GB2387280B (en) * 2001-01-19 2004-10-13 Yazaki Corp Method of waterproofing terminal-wire connecting portion
JP2002216862A (ja) * 2001-01-19 2002-08-02 Yazaki Corp 端子と電線の接続部の防水構造及び防水方法
CN201797061U (zh) * 2010-04-14 2011-04-13 方军 10-35kV高压电缆头KFD接线装置

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US2974400A (en) * 1952-03-11 1961-03-14 Frank J Sowa Method of making an insulated electrical connector
US3955044A (en) 1970-12-03 1976-05-04 Amp Incorporated Corrosion proof terminal for aluminum wire
US5422438A (en) * 1991-02-07 1995-06-06 Raychem Sa Electrical crimp connector
US20020050385A1 (en) * 2000-10-13 2002-05-02 Kazuhiro Murakami Structure of mounting terminal to covered electric wire and method thereof
US20080217055A1 (en) * 2006-07-27 2008-09-11 Markus Gumley Electrical Wire Connector with Temporary Grip
US20110097948A1 (en) * 2008-02-21 2011-04-28 Melni Mark L Electrical connectors and methods of manufacturing and using same
US20100206631A1 (en) * 2009-02-16 2010-08-19 Peters Kenneth J Terminal having integral oxide breaker

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See also references of EP3039747A1 *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3611800B1 (fr) * 2018-08-13 2022-02-16 Hitachi Metals, Ltd. Fil électrique équipé de bornes
WO2021160394A1 (fr) * 2020-02-14 2021-08-19 Phoenix Contact E-Mobility Gmbh Ensemble élément de contact pour partie fiche de connexion

Also Published As

Publication number Publication date
EP3039747A1 (fr) 2016-07-06
EP3039747B1 (fr) 2021-09-15

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