Solderless connection to Litz wire

Patent metadata

Field	Value
Publication number	US-10957992-B2
Application number	US-201916449577-A
Country	US
Kind code	B2
Filing date	Jun 24, 2019
Priority date	Aug 29, 2018
Publication date	Mar 23, 2021
Grant date	Mar 23, 2021

Abstract

An electrical contact assembly having a braided Litz wire and an electrical contact. The electrical contact has a contact portion and a Litz wire termination portion. The contact portion is configured to make an electrical connection with a mating contact. The Litz wire termination portion has serrations which engage the braided Litz wire. The Litz wire termination portion has a length to allow the Litz wire termination portion to make an electrical connection with each individual wire of the Litz wire.

First claim

The invention claimed is:

1. An electrical contact assembly comprising:
a braided Litz wire having multiple wire strands which are individually insulated;
an electrical contact having a contact portion and a Litz wire termination portion, the contact portion is configured to make an electrical connection with a mating contact;
the Litz wire termination portion having serrations which penetrate the individually insulated multiple wire strands of the braided Litz wire, the Litz wire termination portion having a length to allow the Litz wire termination portion to make an electrical and mechanical connection with each individual wire strand of the multiple wire strands of the Litz wire.

2. The electrical contact assembly as recited in claim 1 , wherein the serrations of the Litz wire termination portion extend in a direction with is perpendicular to a longitudinal axis of the Litz wire termination portion.

3. The electrical contact assembly as recited in claim 1 , wherein each serration has a top wall with tapered sidewalls which extend therefrom.

4. The electrical contact assembly as recited in claim 1 , wherein each serration has a top wall with a flat surface.

5. The electrical contact assembly as recited in claim 1 , wherein the serrations have a depth of between 0.002 inches and 0.008 inches.

6. The electrical contact assembly as recited in claim 1 , wherein the serrations have a centerline to centerline spacing of 0.02 inches.

7. The electrical contact assembly as recited in claim 1 , wherein the Litz wire termination portion has a length which is at least two times a length of a braided section of the braided Litz wire.

8. The electrical contact assembly as recited in claim 1 , wherein the contact portion is a tab.

9. The electrical contact assembly as recited in claim 1 , wherein the Litz wire termination portion is crimped to the Litz wire.

10. The electrical contact assembly as recited in claim 9 , wherein the Litz wire termination portion has a bottom wall crimped in the shape of a w-crimp.

11. The electrical contact assembly as recited in claim 10 , wherein the Litz wire termination portion has a top wall crimped in the shape of an inverted w-crimp.

12. An electrical contact assembly comprising:
a braided Litz wire having multiple wire strands which are individually insulated;
an electrical contact having a contact portion and a Litz wire termination portion, the contact portion is configured to make an electrical connection with a mating contact;
the Litz wire termination portion having serrations which engage the individually insulated multiple wire strands of the braided Litz wire, the Litz wire termination portion having a length which is at least two times a length of a braided section of the braided Litz wire to allow the Litz wire termination portion to make an electrical and mechanical connection with each individual wire strand of the multiple wire strands of the Litz wire.

13. The electrical contact assembly as recited in claim 12 , wherein the serrations of the Litz wire termination portion extend in a direction with is perpendicular to a longitudinal axis of the Litz wire termination portion.

14. The electrical contact assembly as recited in claim 13 , wherein the Litz wire termination portion is crimped to the Litz wire.

15. The electrical contact assembly as recited in claim 14 , wherein the Litz wire termination portion has a bottom wall crimped in the shape of a w-crimp.

16. The electrical contact assembly as recited in claim 15 , wherein the Litz wire termination portion has a top wall crimped in the shape of an inverted w-crimp.

17. The electrical contact assembly as recited in claim 12 , wherein the contact portion is a tab.

18. The electrical contact assembly as recited in claim 12 , wherein each serration has a top wall with tapered sidewalls which extend therefrom.

19. The electrical contact assembly as recited in claim 18 , wherein the top wall has a flat surface.

20. The electrical contact assembly as recited in claim 19 , wherein the serrations have a centerline to centerline spacing of 0.02 inches.

Assignees

• Te Connectivity Corp
• TE Connectivity Services Gmbh

Inventors

• Randolph Kurt Allan
• Ruth Jeffrey Richard
• Mcdowell Paul Walter

Classifications

• H01B7/30

  with arrangements for reducing conductor losses when carrying alternating current, e.g. due to skin effect · CPC title

• H01R4/2495

  Insulation penetration combined with permanent deformation of the contact member, e.g. crimping · CPC title

• H01R4/18 Primary

  by crimping {(H01R4/01, H01R4/2495 take precedence; for coaxial cables H01R9/0518)} · CPC title

• H01R4/188 Primary

  having an uneven wire-receiving surface to improve the contact · CPC title