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US3633153A - Terminal for aluminum wire - Google Patents

Terminal for aluminum wire Download PDF

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Publication number
US3633153A
US3633153A US37643A US3633153DA US3633153A US 3633153 A US3633153 A US 3633153A US 37643 A US37643 A US 37643A US 3633153D A US3633153D A US 3633153DA US 3633153 A US3633153 A US 3633153A
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US
United States
Prior art keywords
wire
aluminum
tines
terminal
cutting edges
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US37643A
Inventor
Kamal Ahmed
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TE Connectivity Corp
Original Assignee
AMP Inc
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Filing date
Publication date
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Application granted granted Critical
Publication of US3633153A publication Critical patent/US3633153A/en
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Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
    • H01R4/2495—Insulation penetration combined with permanent deformation of the contact member, e.g. crimping

Definitions

  • This invention relates to a terminal for aluminum wire and to a connection comprising such a terminal crimped to aluminum wire.
  • Aluminum and its alloys tend to form an insulating oxide coating and have a low mechanical strength. Stripping an insulating sheath from an aluminum conductor requires considerable skill if the aluminum is not to be nicked; such skill is at a premium. Nicking or otherwise marring the aluminum core is especially bad in the case of low-current single-strand wire because the mechanical strength is affected.
  • a terminal comprises a barrel portion and a contact portion, tines directed inwardly of the barrel portion adjacent one end adapted mechanically to grip an insulated electrical wire having an aluminum core receiva ble in the barrel, at least two inwardly extending cutting edges spaced apart longitudinally and extending transversely of the barrel portion between the tines and the contact portion adapted to penetrate the insulation and electrically contact the aluminum core on crimping the terminal and the wire.
  • FIG. 1 is a plan view of a blank for making a terminal
  • FIG. 2 is a longitudinal median sectional view of a terminal made from the blank of FIG. 1;
  • FIG. 3 is an end view of another terminal.
  • FIG. 4 is a partial longitudinal sectional view of the terminal of FIG. 3 crimped to aluminum wire.
  • the blank of FIG. 1 is a flat brass-stamping having a generally oblong portion 1, the precursor of the barrel portion, and a ring-tongue contact portion 2, these portions being joined by an integral neck portion 3.
  • Two rows of tines 4 are formed from the oblong portion at a location remote from the contact portion 2, conveniently by punching holes and using the upstanding burrs as the tines 4.
  • Two generally sigmoidshaped cuts 5, arranged back-to-back, are made between the neck 3 and the tines 4 generally parallel to each other and the shorter side of the oblong portion 1.
  • the opposed outer walls of the cuts 5 are raised generally normal to the oblong portion 1 to form cutting edges 6 which are then inclined slightly apart to the condition shown in FIG. 2.
  • the longer edges of the oblong portion 1 are then rolled towards each other to direct the tines 4 and the cutting edges 6 inwardly of the barrel portion so formed.
  • An end portion of an aluminum wire is passed into the barrel portion 1 forwardly of the tines 4, the free end of the wire stopping adjacent the neck portion 3.
  • the assembly so made is then crimped, so forcing the wire onto the cutting edges 6 which penetrate through the wire insulation electrically to contact the aluminum core.
  • the cutting edges 6 are spaced apart sufficiently to ensure that, on crimping, the
  • the neck 3 may be folded up to form a flap to protect the free end of the wire, coated with inhibitor.
  • the two cutting edges 7 of the terminal of FIG. 3 are bifurcated longitudinally of the barrel portion to define a wirereceiving gap 8, and the floor between them is cut away, FIG. 4.
  • the tines 4 are the same as those of the terminal of FIGS. 1 and 2, and the contact portion comprises an end extension having a bent-up portion 9 terminating in a tab receptacle 10 standing above the level of the barrel portion 1 and at an acute angle to the major axis of the barrel portion.
  • the barrel portion has an outer insulating sheath 13, FIG. 4.
  • the terminal of FIG. 3 is crimped to a wire comprising a sheath II about an aluminum core 12, to the condition shown in FIG. 4 where the two cutting edges 7 are bent apart by the crimping and the walls of each gap 8 cut through the insulating sheath 11 to contact the core I2.
  • the contact portion may be of taper pm form for use in junction boxes.
  • the insulation may be of natural or synthetic resin, and is preferably polyethylene.
  • the number of cutting edges may be increased, dependent on the current density of the wire to be terminated.
  • the invention is of special value in terminating telephone wires having polyethylene sheathed single strand aluminum cores, each of which carries a current of about 1 l milliamps at 50 volts DC.
  • An electrical terminal for aluminum wire comprising a barrel portion and a contact portion, tines directed inwardly of the barrel portion adjacent one end adapted mechanically to grip an insulated wire having an aluminum core receivable in the barrel, at least two inwardly extending cutting edges spaced apart longitudinally and extending transversely of the barrel portion between the tines and the contact portion adapted to penetrate the insulation electrically to contact the aluminum core on crimping the terminal and the wire, the cutting edges being inclined apart longitudinally of the barrel portion.
  • An electrical terminal for insulating aluminum wire including a wire-receiving portion, tines directed inwardly of the wire-receiving portion adjacent one end thereof, the tines being adapted mechanically to grip an insulated wire having an aluminum core receivable in the wire-receiving portion, at least two inwardly extending cutting edges spaced apart longitudinally and extending transversely of the wire-receiving portion to penetrate the insulation electrically to contact the aluminum core on crimping, the cutting edges being formed from the floor of the wire-receiving portion and being inclined apart longitudinally of the wire-receiving portion.

Landscapes

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

Abstract

An electrical terminal for use with aluminum wire and having tines for gripping the wire insulation, and inwardly extending cutting edges for penetrating the insulation to contact the wire core.

Description

United States Patent Inventor Appl. No.
Filed Patented Assignee Priority Kama] Ahmed Stanmorc, England 37,643
May 15, 1970 Jan. 4, 1972 A.M.P. Incorporated Harrisburg, Pa. May 30, 1970 Great Britain TERMINAL FOR ALUMINUM WIRE 2 Claims, 4 Drawing Figs.
US. Cl
Int. Cl Field of Search seed Primary Examiner-Joseph H. McGlynn Attorneys-Curtis, Morris and Safford, William J. Keating,
William Hintze, Frederick W. Rating, John R. Hopkins, Adrian J. La Rue and Jay L. Seitchik ABSTRACT: An electrical terminal for use with aluminum wire and having tines for gripping the wire insulation, and inwardly extending cutting edges for penetrating the insulation to contact the wire core.
- PATENTED JAN 4 I972 2 l/l/l TERMINAL FOR ALUMINUM WIRE This invention relates to a terminal for aluminum wire and to a connection comprising such a terminal crimped to aluminum wire.
Aluminum and its alloys tend to form an insulating oxide coating and have a low mechanical strength. Stripping an insulating sheath from an aluminum conductor requires considerable skill if the aluminum is not to be nicked; such skill is at a premium. Nicking or otherwise marring the aluminum core is especially bad in the case of low-current single-strand wire because the mechanical strength is affected.
SUMMARY A terminal according to this invention comprises a barrel portion and a contact portion, tines directed inwardly of the barrel portion adjacent one end adapted mechanically to grip an insulated electrical wire having an aluminum core receiva ble in the barrel, at least two inwardly extending cutting edges spaced apart longitudinally and extending transversely of the barrel portion between the tines and the contact portion adapted to penetrate the insulation and electrically contact the aluminum core on crimping the terminal and the wire.
This invention is described, by way of example, with reference to the accompanying drawing, in which:
FIG. 1 is a plan view of a blank for making a terminal;
FIG. 2 is a longitudinal median sectional view of a terminal made from the blank of FIG. 1;
FIG. 3 is an end view of another terminal; and
FIG. 4 is a partial longitudinal sectional view of the terminal of FIG. 3 crimped to aluminum wire.
The blank of FIG. 1 is a flat brass-stamping having a generally oblong portion 1, the precursor of the barrel portion, and a ring-tongue contact portion 2, these portions being joined by an integral neck portion 3. Two rows of tines 4 are formed from the oblong portion at a location remote from the contact portion 2, conveniently by punching holes and using the upstanding burrs as the tines 4. Two generally sigmoidshaped cuts 5, arranged back-to-back, are made between the neck 3 and the tines 4 generally parallel to each other and the shorter side of the oblong portion 1. The opposed outer walls of the cuts 5 are raised generally normal to the oblong portion 1 to form cutting edges 6 which are then inclined slightly apart to the condition shown in FIG. 2. The longer edges of the oblong portion 1 are then rolled towards each other to direct the tines 4 and the cutting edges 6 inwardly of the barrel portion so formed.
An end portion of an aluminum wire, not shown, is passed into the barrel portion 1 forwardly of the tines 4, the free end of the wire stopping adjacent the neck portion 3. The assembly so made is then crimped, so forcing the wire onto the cutting edges 6 which penetrate through the wire insulation electrically to contact the aluminum core. The cutting edges 6 are spaced apart sufficiently to ensure that, on crimping, the
portion of wire between them is held sufficiently taut for the edges to penetrate the insulation and contact the core. The crimping also causes the tines 4 to grip but not penetrate the wire to prevent rearward axial withdrawal of the wire from the terminal. Optionally, the neck 3 may be folded up to form a flap to protect the free end of the wire, coated with inhibitor.
The two cutting edges 7 of the terminal of FIG. 3 are bifurcated longitudinally of the barrel portion to define a wirereceiving gap 8, and the floor between them is cut away, FIG. 4. The tines 4 are the same as those of the terminal of FIGS. 1 and 2, and the contact portion comprises an end extension having a bent-up portion 9 terminating in a tab receptacle 10 standing above the level of the barrel portion 1 and at an acute angle to the major axis of the barrel portion. The barrel portion has an outer insulating sheath 13, FIG. 4. The terminal of FIG. 3 is crimped to a wire comprising a sheath II about an aluminum core 12, to the condition shown in FIG. 4 where the two cutting edges 7 are bent apart by the crimping and the walls of each gap 8 cut through the insulating sheath 11 to contact the core I2. I
The contact portion may be of taper pm form for use in junction boxes. The insulation may be of natural or synthetic resin, and is preferably polyethylene. The number of cutting edges may be increased, dependent on the current density of the wire to be terminated.
The invention is of special value in terminating telephone wires having polyethylene sheathed single strand aluminum cores, each of which carries a current of about 1 l milliamps at 50 volts DC.
What is claimed is:
1. An electrical terminal for aluminum wire, comprising a barrel portion and a contact portion, tines directed inwardly of the barrel portion adjacent one end adapted mechanically to grip an insulated wire having an aluminum core receivable in the barrel, at least two inwardly extending cutting edges spaced apart longitudinally and extending transversely of the barrel portion between the tines and the contact portion adapted to penetrate the insulation electrically to contact the aluminum core on crimping the terminal and the wire, the cutting edges being inclined apart longitudinally of the barrel portion.
2. An electrical terminal for insulating aluminum wire, including a wire-receiving portion, tines directed inwardly of the wire-receiving portion adjacent one end thereof, the tines being adapted mechanically to grip an insulated wire having an aluminum core receivable in the wire-receiving portion, at least two inwardly extending cutting edges spaced apart longitudinally and extending transversely of the wire-receiving portion to penetrate the insulation electrically to contact the aluminum core on crimping, the cutting edges being formed from the floor of the wire-receiving portion and being inclined apart longitudinally of the wire-receiving portion.
and the neck may be 1 $3253? 1 TED STATES PATENT @EHCIE @E'HMQATE m CE'MN January 4, 19 72 Pacenf No 3 6 3 3 1 5 3 Dated Invention-(s) KAMAL AHMED It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:
Claim 2, line 1, column 2, "insulating" should be insulated Signed and sealed this 2nd day of May B972,
(SEAL) i ittsskfiz EDWARD ZF'ZJLEICHER, JR. ROBERT GOTTSGHALK Y Commissioner" of Patents Attssting Officer AMP 2684

Claims (2)

1. An electrical terminal for aluminum wire, comprising a barrel portion and a contact portion, tines directed inwardly of the barrel portion adjacent one end adapted mechanically to grip an insulated wire having an aluminum core receivable in the barrel, at least two inwardly extending cutting edges spaced apart longitudinally and extending transversely of the barrel portion between the tines and the contact portion adapted to penetrate the insulation electrically to contact the aluminum core on crimping the terminal and the wire, the cutting edges being inclined apart longitudinally of the barrel portion.
2. An electrical terminal for installed aluminum wire, including a wire-receiving portion, tines directed inwardly of the wire-receiving portion adjacent one end thereof, the tines being adapted mechanically to grip an insulated wire having an aluminum core receivable in the wire-receiving portion, at least two inwardly extending cutting edges spaced apart longitudinally and extending transversely of the wire-receiving portion to penetrate the insulation electrically to contact the aluminum core on crimping, the cutting edges being formed from the floor of the wire-receiving portion and being inclined apart longitudinally of the wire-receiving portion.
US37643A 1969-05-30 1970-05-15 Terminal for aluminum wire Expired - Lifetime US3633153A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB2754069 1969-05-30

Publications (1)

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US3633153A true US3633153A (en) 1972-01-04

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US37643A Expired - Lifetime US3633153A (en) 1969-05-30 1970-05-15 Terminal for aluminum wire

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Country Link
US (1) US3633153A (en)
JP (1) JPS4926793B1 (en)
AT (1) AT303858B (en)
BE (1) BE751043A (en)
CH (1) CH513526A (en)
DE (1) DE2024364C3 (en)
DK (1) DK130267B (en)
ES (1) ES380162A1 (en)
FR (1) FR2048905A5 (en)
GB (1) GB1257502A (en)
IL (1) IL34517A (en)
NL (1) NL7007509A (en)
NO (1) NO129371B (en)
ZA (1) ZA703131B (en)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3903896A (en) * 1974-04-01 1975-09-09 Dietrich Harmjanz Catheter for the electrical stimulation of the heart
EP0055543A2 (en) * 1980-12-12 1982-07-07 Raychem Pontoise S.A. Wire stripping and penetrating arrangement
US20100206631A1 (en) * 2009-02-16 2010-08-19 Peters Kenneth J Terminal having integral oxide breaker
US9142902B2 (en) 2013-08-01 2015-09-22 Lear Corporation Electrical terminal assembly
US9190756B2 (en) 2013-08-01 2015-11-17 Lear Corporation Electrical terminal assembly
US9385449B2 (en) 2009-02-16 2016-07-05 Carlisle Interconnect Technologies, Inc. Terminal/connector having integral oxide breaker element
US9711926B2 (en) 2013-11-19 2017-07-18 Lear Corporation Method of forming an interface for an electrical terminal
US9985362B2 (en) 2015-10-22 2018-05-29 Carlisle Interconnect Technologies, Inc. Arc resistant power terminal
US10844895B2 (en) 2015-04-10 2020-11-24 Knorr-Bremse Systeme Fuer Nutzfahrzeuge Gmbh Clamping sleeve and a method for producing a clamping sleeve

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2524347C2 (en) * 1975-06-02 1985-01-10 Grote & Hartmann Gmbh & Co Kg, 5600 Wuppertal Push-in sleeve with conductor claw, in particular enamelled wire claw
DE29716767U1 (en) * 1997-09-18 1997-11-06 Stocko Metallwarenfab Henkels Flat receptacle for electrically connecting a stripped cable or the like. with a flat plug
JP2013182727A (en) * 2012-02-29 2013-09-12 Yazaki Corp Terminal fitting

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2873434A (en) * 1954-12-31 1959-02-10 Ibm Insulation piercing terminal
GB1008995A (en) * 1958-10-15 1965-11-03 Amp Inc Improvements in or relating to electrical connectors
US3335392A (en) * 1965-07-19 1967-08-08 Essex Wire Corp Terminal construction
US3410950A (en) * 1966-06-01 1968-11-12 Amp Inc Insulated moisture-proof connecting device
US3510827A (en) * 1967-11-14 1970-05-05 Etc Inc T-tap connectors

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2873434A (en) * 1954-12-31 1959-02-10 Ibm Insulation piercing terminal
GB1008995A (en) * 1958-10-15 1965-11-03 Amp Inc Improvements in or relating to electrical connectors
US3335392A (en) * 1965-07-19 1967-08-08 Essex Wire Corp Terminal construction
US3410950A (en) * 1966-06-01 1968-11-12 Amp Inc Insulated moisture-proof connecting device
US3510827A (en) * 1967-11-14 1970-05-05 Etc Inc T-tap connectors

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3903896A (en) * 1974-04-01 1975-09-09 Dietrich Harmjanz Catheter for the electrical stimulation of the heart
EP0055543A2 (en) * 1980-12-12 1982-07-07 Raychem Pontoise S.A. Wire stripping and penetrating arrangement
EP0055543A3 (en) * 1980-12-12 1982-08-04 Raychem Pontoise S.A. Wire stripping arrangement
US4781606A (en) * 1980-12-12 1988-11-01 Raychem Corporation Wire stripping arrangement
US9385449B2 (en) 2009-02-16 2016-07-05 Carlisle Interconnect Technologies, Inc. Terminal/connector having integral oxide breaker element
US20100206631A1 (en) * 2009-02-16 2010-08-19 Peters Kenneth J Terminal having integral oxide breaker
US8519267B2 (en) * 2009-02-16 2013-08-27 Carlisle Interconnect Technologies, Inc. Terminal having integral oxide breaker
US10164348B2 (en) 2009-02-16 2018-12-25 Carlisle Interconnect Technologies, Inc. Terminal/connector having integral oxide breaker element
US9142902B2 (en) 2013-08-01 2015-09-22 Lear Corporation Electrical terminal assembly
US9190756B2 (en) 2013-08-01 2015-11-17 Lear Corporation Electrical terminal assembly
US9711926B2 (en) 2013-11-19 2017-07-18 Lear Corporation Method of forming an interface for an electrical terminal
US10844895B2 (en) 2015-04-10 2020-11-24 Knorr-Bremse Systeme Fuer Nutzfahrzeuge Gmbh Clamping sleeve and a method for producing a clamping sleeve
US9985362B2 (en) 2015-10-22 2018-05-29 Carlisle Interconnect Technologies, Inc. Arc resistant power terminal

Also Published As

Publication number Publication date
DE2024364B2 (en) 1973-07-19
ZA703131B (en) 1971-01-27
CH513526A (en) 1971-09-30
FR2048905A5 (en) 1971-03-19
NO129371B (en) 1974-04-01
NL7007509A (en) 1970-12-02
GB1257502A (en) 1971-12-22
DK130267C (en) 1975-06-23
ES380162A1 (en) 1972-08-16
DE2024364C3 (en) 1974-02-07
DE2024364A1 (en) 1970-12-03
BE751043A (en) 1970-11-03
DK130267B (en) 1975-01-27
IL34517A0 (en) 1970-07-19
IL34517A (en) 1972-12-29
JPS4926793B1 (en) 1974-07-11
AT303858B (en) 1972-12-11

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