Patent Grant
9343820
The subject matter described and/or illustrated herein relates generally to crimp contacts that are deformed to grip one or more exposed wire conductors of an electrical wire.
A crimp contact is a type of electrical contact that is deformed (i.e., crimped) to grip wire conductors that are exposed at a terminating end of an electrical wire. The wire conductors are inserted into a cavity defined by the crimp contact, and the crimp contact is then deformed (e.g., crushed) so that the interior surfaces of the crimp contact compress and securely engage the wire conductors. Crimp contacts may facilitate connecting the electrical wire to other electrical connectors or devices. Crimp contacts may also be used to join terminating ends from two electrical wires in which the wire conductors from each terminating end are inserted into the cavity of the crimp contact prior to deforming.
Known crimp contacts are sized according to a total cross-sectional area of the wire conductors that the crimp contacts will engage. However, these known crimp contacts are typically only suitable for a limited number of cross-sectional areas. For instance, one contact configuration may only be suitable for the wire conductors of electrical wires that have wire gauges 18-20 American Wire Gauge (AWG). AWG is a frequently used standard in the industry. The tools used to deform the crimp contacts are typically configured for one type of crimp contact. As such, a manufacturer or individual working with electrical wires of different wire gauges may require a number of different crimp contacts and a number of different crimping tools.
Accordingly, there is a need for crimp contacts that are capable of gripping a greater range of wire gauges than known crimp contacts.
In one embodiment, a cable assembly is provided that includes an electrical wire having a terminal end that includes at least one exposed wire conductor. The cable assembly also includes a crimp contact having a centerline and first and second sidewalls that extend from the centerline in opposite directions. The centerline extends parallel to a longitudinal axis of the crimp contact. Each of the first and second sidewalls has a base section and a leg section. The leg section extends a lateral distance from the centerline to a longitudinal edge of the leg section. The base section extends a lateral distance from the centerline to a longitudinal edge of the base section. The lateral distance of the leg section is greater than the lateral distance of the base section for each of the first and second sidewalls. The leg section of the first sidewall is located opposite the base section of the second sidewall. The leg section of the second sidewall is located opposite the base section of the first sidewall. The first and second sidewalls surround and engage the at least one wire conductor.
In another embodiment, a crimp contact is provided that includes a contact body having a centerline and first and second sidewalls that extend from the centerline in opposite directions away. The centerline extends parallel to a longitudinal axis of the crimp contact. Each of the first and second sidewalls has a base section and a leg section. The leg section extends a lateral distance from the centerline to a longitudinal edge of the leg section. The base section extends a lateral distance from the centerline to a longitudinal edge of the base section. The lateral distance of the leg section is greater than the lateral distance of the base section for each of the first and second sidewalls. The leg section of the first sidewall is located opposite the base section of the second sidewall. The leg section of the second sidewall is located opposite the base section of the first sidewall.
In some embodiments, the leg section of the first sidewall interfaces with the base section of the second sidewall and/or the leg section of the second sidewall interfaces with the base section of the first sidewall. For example, the leg section of one of the sidewalls may be folded under the base section of the opposite sidewall. As another example, the longitudinal edge of the leg section of one of the sidewalls may interface with the longitudinal edge of the base section of the opposite sidewall.
In some embodiments, the crimp contact is dimensioned to surround and engage at least one wire conductor that has a total cross-sectional area of X and, separately, to surround and engage at least one wire conductor that has a total cross-sectional area of at least about 3X.
In some embodiments, each of the leg sections of the first and second sidewalls surrounds a plurality of the wire conductors. Furthermore, in some embodiments, each of the leg sections of the first and second sidewalls may surround a different arrangement of the wire conductors. The wire conductors may also have a varying conductor density or distribution within the crimp contact as the crimp contact extends from a leading edge of the crimp contact to the electrical wire. For example, the wire conductors may laterally shift within a contact cavity of the crimp contact. In some cases, each of the leg sections of the first and second sidewalls may surround at least one common wire conductor (e.g., the same wire conductor).
In
The crimp contact 105 may be stamped and formed from conductive sheet material (e.g., metal). As described herein, the crimp contact 105 may be dimensioned to grip a plurality of different wire gauges within a designated range. For example, the crimp contact 105 may be dimensioned to grip cables or electrical wires having an American Wire Gauge (AWG) between 10-22 AWG. In particular embodiments, the crimp contact 105 may be dimensioned to surround and grip wire conductors having a total cross-sectional area of X and, separately, to surround and grip wire conductors having a total cross-sectional area of at least about 3X or 5X or, more particularly, at least about 8X. As one non-limiting example, a first type of electrical wire may have wire conductors with a total (e.g., collective) cross-sectional area of about 0.75 mm2 and a second type of electrical wire may have wire conductors with a total cross-sectional area of at least about 5.00 mm2. Embodiments described herein may be configured to grip either of the first and second types. As another non-limiting example, a first type of electrical wire may have wire conductors with a total cross-sectional area of about 1.00 mm2 and a second type of electrical wire may have wire conductors with a total cross-sectional area of at least about 3.00 mm2. In the case of multiple wire conductors, each strand may have, by way of example only, radiuses of about 0.125 mm. However, the wire conductors may have other dimensions in alternative embodiments.
The contact body 114 includes a center portion 122 and opposite first and second sidewalls 124, 126, that are joined by the center portion 122. As shown in
The first and second sidewalls 124, 126 are configured to be deformed around and pressed against the wire conductors 110. The first and second sidewalls 124, 126 may have similar structural features. For example, the first sidewall 124 has a base section 132 and a leg section 134, and the second sidewall 126 may also have a base section 142 and a leg section 144. The base and leg sections 132, 134 have longitudinal edges 162, 164, respectively, and the base and leg sections 142, 144 have longitudinal edges 172, 174. The longitudinal edges 162, 164, 172, 174 extend parallel to the longitudinal axis 190 in the illustrated embodiment.
As shown, the leg section 134 and the base section 142 are located along the leading edge 116, and the leg section 144 and the base section 132 are located along the trailing edge 118. The leg section 134 is defined between a portion of the leading edge 116 and an interior edge 180. The leading and interior edges 116, 180 may face in opposite directions along the longitudinal axis 190. The interior edge 180 extends between the longitudinal edges 162, 164. The leg section 144 is defined between a portion of the trailing edge 118 and an interior edge 182. The leading and interior edges 118, 182 may face in opposite directions along the longitudinal axis 190. The interior edge 182 extends between the longitudinal edges 172, 174. As shown, the interior edges 180, 182 extend in directions that are substantially transverse (or perpendicular) to the longitudinal axis 190. The interior edges 180, 182 may also be characterized as extending along planes that are substantially orthogonal to the longitudinal axis 190. As shown in
With respect to
In the illustrated embodiment, the lateral distances 135 and 145 are substantially equal and the lateral distances 133 and 143 are substantially equal. In other embodiments, however, the lateral distances 135, 145 may not be equal and/or the lateral distances 133, 143 may not be equal. Also, in the illustrated embodiment, the contact body 114 includes only two leg sections and only two base sections. In other embodiments, there may be more leg sections and/or base sections. For example, a third leg section may extend along the trailing edge 118 such that the base section 132 is located between the third leg section and the leg section 134. A third base section may extend along the trailing edge 118 such that the leg section 144 is located between the third base section and the base section 142. However, the contact body is not required to have opposing leg and base sections throughout. For example, in another alternative embodiment, third and fourth base sections may oppose each other along the trailing edge 118 with the centerline 160 therebetween.
As shown in
With respect to
The crimping applicator 202 defines opposing first and second contoured walls 220, 222. The first contoured wall 220 is configured to initially engage the first sidewall 124 (
The leading and trailing portions 208, 210 may have wall-bending features 224, 226, respectively. The wall-bending features 224, 226 are sections of the leading and trailing portions 208, 210, respectively, that have predetermined shapes for forming the crimp contact 105. The wall-bending features 224, 226 are shaped differently than each other. As will be shown and described with reference to
As shown in
Accordingly, the leg section 134 of the first sidewall 124 may interface with the opposite base section 142 of the second sidewall 126, and the leg section 144 of the second sidewall 126 may interface with the opposite base section 132 of the first sidewall 124. A leg section may interface with a base section when the longitudinal edge of the leg section or the exterior surface of the leg section is located proximate to the longitudinal edge of the opposite base section. For example, as shown in
In some embodiments, the configurations of the first and second sidewalls 124, 126 cause a varying conductor density or distribution within the contact cavity 254 when the crimp contact 105 is deformed. For instance, by comparing the cross-sections C1, C2, and C3, it is shown that the leg sections 134, 144 may surround different arrangements of the wire conductors 110. A first arrangement of wire conductors is different from a second arrangement if at least one of the wire conductors in the first arrangement is not within the second arrangement or vice versa. For example, as shown in the cross-section C1, the wire conductors 110A, 110B, 110C, and 110D are surrounded by the leg section 144. In the cross-section C3, the wire conductors 110A, 110E, 110F, 110G and 110H are surrounded by the leg section 134. For illustration, the wire conductors 110B, 110C, and 110D are also shown in C3. In the cross-section C2, the wire conductors 110A-110H have different locations with the contact cavity 254 than in the cross-sections C1 and C3. Thus, the leg sections 134, 144 surround different arrangements of the wire conductors 110. In
This varying conductor distribution may cause multiple different contact points where the interior surface 150 of the crimp contact 105 engages the wire conductors 110 thereby increasing the friction between the wire conductors 110 and the interior surface 150. As such, a greater tensile force to remove the wire conductors 110 from the crimp contact 105 may be required. Moreover, the changing orientation or position of individual wire conductors 110 may cause a greater frictional force than other known crimp contacts and, as such, would require a greater tensile force to remove the wire conductors. For example, in an exemplary embodiment, the common wire conductor 110A wraps between the interior edges 180, 182. If the electrical wire 106 was inadvertently pulled away from the crimp contact 105 after the crimp contact 105 was deformed, the configuration of the wire conductor 110A and the interior edge 182 may cause a greater frictional force that would prevent the withdrawal. Accordingly, the crimp contact 105 may provide greater resistance to inadvertent removal of the wire conductors 110 than other known crimp contacts.
In
In
In
Accordingly, the crimp contacts described herein may be configured to grip the wire conductors of electrical wires having a greater range of wire gauges than known crimp contacts. In addition, the crimp contacts may enable a greater gripping or compressive force caused by an increase in friction between the interior surface of the crimp contact and the wire conductors within the contact cavity of the crimp contact. In order to remove the wire conductors, a greater withdrawal force may be required to overcome the gripping force.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the subject matter described and/or illustrated herein should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
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