Electrical terminal for terminating a wire

Patent metadata

Field	Value
Publication number	US-9502785-B2
Application number	US-201514643406-A
Country	US
Kind code	B2
Filing date	Mar 10, 2015
Priority date	Mar 10, 2014
Publication date	Nov 22, 2016
Grant date	Nov 22, 2016

Abstract

An electrical terminal is disclosed having a crimp barrel. The crimp barrel has a base; and opposing side walls extending from the base and each has an opposing end region. The opposing side walls have a conductor receiving region in which the sidewalls have an F-crimp when crimped to stripped conductors of a wire; a wire insulation receiving region for receiving an insulation covered portion of the wire; and a transition region positioned between the conductor receiving region, and the wire insulation receiving region. The opposing end regions in the transition region are overlapped in the circumferential direction when crimped to surround the wire.

First claim

What is claimed is:

1. An electrical terminal, comprising a crimp barrel having:
a base;
opposing side walls extending from the base and each having an opposing end region, the opposing side walls having a conductor receiving region in which the sidewalls have an F-crimp when crimped to a conductor of a wire, one of the sidewalls in the conductor receiving region extending a first distance along a length of the base that is greater than a second distance of the opposing sidewall along the length of the base, a wire insulation receiving region for receiving an insulation covered portion of the wire, and a transition region positioned between the conductor receiving region and the wire insulation receiving region, the opposing end regions in the transition region being overlapped in the circumferential direction when crimped to surround the wire; and
one or more bendable front cover ends positioned at a first end of the conductor receiving region and crimped to overlap and close the first end, the first end opposite to a second end of the conductor receiving region adjacent to the transition region.

2. The electrical terminal of claim 1 , wherein the base, the side walls of the conductor receiving region, and the side walls of the transition region define a tunnel having a confined volume when crimped.

3. The electrical terminal of claim 1 , wherein, when crimped, the base and the sidewalls of the wire insulation receiving region have a non-overlapping open or closed ring shape.

4. The electrical terminal of claim 3 , wherein, when crimped, the side walls of the wire insulation receiving region also form a tunnel at least partially adjacent the transition region.

5. The electrical terminal of claim 1 , wherein, when crimped, the transition region has a funnel shape.

6. The electrical terminal of claim 1 , wherein the first distance is approximately equal to a thickness of the front cover end.

7. The electrical terminal of claim 1 , wherein an intersection between the sidewalls of the conductor receiving region and the sidewalls of the transition region has a cut in an edge region.

8. The electrical terminal of claim 1 , wherein an intersection between the sidewalls of the transition region and the sidewalls of the wire insulation receiving region has a cut in an edge region.

9. An electrical connector comprising:
an electrical terminal having a crimp barrel with a base, opposing side walls extending from the base and each having an opposing end region, the opposing side walls having a conductor receiving region in which the sidewalls have an F-crimp when crimped to a conductor of a wire, one of the sidewalls in the conductor receiving region extending a first distance along a length of the base that is greater than a second distance of the opposing sidewall along the length of the base, a wire insulation receiving region for receiving an insulation covered portion of the wire, and a transition region positioned between the conductor receiving region and the wire insulation receiving region, the opposing end regions in the transition region being overlapped in the circumferential direction when crimped to surround the wire, and one or more bendable front cover ends positioned at a first end of the conductor receiving region and crimped to overlap and close the first end, the first end opposite to a second end of the conductor receiving region adjacent to the transition region; and
a wire crimped in the crimp barrel.

10. The electrical connector of claim 9 , further comprising a corrosion prevention material filling voids inside at least the conductor receiving region and the transition region of the crimp barrel.

11. The electrical connector of claim 9 , wherein the wire is made of aluminum and the crimp barrel is made of copper.

12. A method for preparing an electrical connector, comprising the steps of introducing a wire in a crimp barrel having a base such that bare conductors of the wire are positioned in a conductor receiving region and an insulation covered portion of the wire is positioned in a wire insulation receiving region with the transition between the bare conductors and insulation being in a transition region;
folding the sidewalls of the conductor receiving region to form an F-crimp over the bare conductors, one of the sidewalls in the conductor receiving region extending a first distance along a length of the base that is greater than a second distance of the opposing sidewall along the length of the base;
folding the sidewalls of the transition region to form an overlapping crimp along a circumferential direction of the wire; and
folding the sidewalls of the wire insulation receiving region to form a closed or open non-overlapping ring shape.

13. The method according to claim 12 , further comprising the step of:
folding front cover ends of the sidewalls of the conductor receiving region to seal the conductor inside a tunnel formed by the sidewalls of the conductor receiving region and the transition region.

Assignees

• Tyco Electronics Amp Gmbh
• Te Connectivity Germany Gmbh
• Tyco Electronics France Sas

Inventors

• Schmidt Helge
• Rosi Alexandre
• Rouillard Xavier
• Picaud Jean Pierre
• Salgado Carlos
• Chin Tehuai
• Bluemmel Uwe

Classifications

• H01R4/188

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

• H01R43/005

  for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing · CPC title

• H01R13/5216

  characterised by the sealing material, e.g. gels or resins · CPC title

• H01R4/185 Primary

  combined with a U-shaped insulation-receiving portion · CPC title

• H01R4/62

  Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors (H01R4/68 takes precedence) · CPC title