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Патент USA US2405111

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Aug- 6, 1946.
Filed Sept. 25, 1942
C. F
Patented Aug. 6, 1946
2,405,111 '
Vernon E. Carlson, Short Hills, and Thomas 0.
Freedom, Scotch Plains, N. J., assignors to Air
craft Marine Products, Inc., Elizabeth, N. J., a
corporation of New Jersey
Application September 25, 1942, Serial No. 459,624
(01. 173-269)
This invention relates to a terminal for elec~
trical wiring. More particularly the invention re
lates to a terminal having means for supporting
an insulated portion of the wire as well as for
engaging and electrically contacting the central
conductive portion of the wire. In my divisional
be made of any thin, high strength material hav
ing appreciable resiliency and preferably is made
of a ductile material such as sheet metal which
can be formed into shape by drawing and press
ing by means of suitable dies.
In the accompanying drawing, we have shown
application Serial No. 592,784, ?led May 9, 1945,
a preferred embodiment of our invention as ap
I have claimed certain methods of making a ter
plied to a connector terminal of a type commonly
used in low tension electrical wiring.
minal embodying the present invention.
Electrical connectors for use in connection with 10
In the drawing,
conductor wires are commonly made with a fer
Figure 1 is a view in longitudinal section show
rule adapted to receive and engage and electri
ing an insulated wire with a connector terminal
cally contact the conductive portion of the wire.
attached thereto and the insulation supporting
When these are applied to an insulated wire, the
sleeve secured in operative relation on the con
insulation is commonly stripped away from the 15 nector and insulated portion of the wire.
end which is inserted into the ferrule so that the
Figure 2 is a view in similar longitudinal sec
central conductive wire is supported near its end
by the ferrule and beyond the end by the insu
tion and partly broken away showing a connector
lation, but for a short distance between the ends
of the insulation and the ferrule the wire remains
unsupported; and, if it is subjected to bending
tion of a supporting sleeve according to my inven
tion by a suitable process and apparatus.
Figure 4 shows an alternative to the hird stage
of the formation as illustrated in Figure 3.
Figure 5 shows another alternative to the fifth
stage of the forming operations as illustrated in
stresses, the strains tend to concentrate at this
point. To overcome this in situations where seri
ous bending stresses are encountered, it has been
common practice to provide an extension on the
ferrule with ears to wrap around and support the
insulated portion of the wire, or to provide over
the ferrule a longer ferrule of more or less rigid
insulation material. The former construction is
unsatisfactory in a number of respects, among
which not the least important is that the cut edge
of the metal ears gives a sharp concentration of
and supporting sleeve ready for application to the
Figure 3 shows successive stages in the forma
Figure 3; and Figure 6 shows in longitudinal
section an alternative form in which the sleeve is
fitted to the inside instead of the outside of the
Referring to the drawing, the terminal con
nector I0 is shown of a type now widely used in
stresses which may eventually out the insulation.
The latter is often precluded by expense of
which a ferrule H is formed with an internal
manufacture or by space considerations.
It is an object of our present invention to pro
vide a simple and inexpensive structure for sup
porting the insulated portion of a wire in its rela
tion to a connector. More particularly, it is an
l2 and an extended portion I3 of suitable form is
adapted to engage a binding post or other elec
object of our invention to provide strong support
and secure engagement between the insulated
portion of the wire and a connector with neg~
ligible increase in dimension and at slight addi
tional cost. A further object of the invention is
to provide an inexpensive method for the manu
f acture of such supporting structure.
With these objects in view, we have, according
to our present invention, provided for the sup
port of the insulated portion of the wire by means
of a sleeve ?tted to the ferrule portion of the con
nector with its outer end projecting beyond the
ferrule and having the material thereof folded
diameter adapted to receive the conductor wire
trical connecting device, Tightly ?tted over the
opposite side of this ferrule l l is sleeve l5 which
is positioned thereon at the outer end by radially
indented or crimped portions l6. These indenta
tions are preferably substantially circumferential
and of sufficient depth so that, as shown in Fig
ures l and 2, they constitute a “funnel” portion
over the ends of the ferrule H and thus serve to
‘ guide the wires of the electrical conductor 12 into
the mouth of the ferrule. It is desirable also to
indent or crimp the end of the sleeve at the oppo
site end of the ferrule as shown at I 1 so that the
sleeve is held securely in both directions, but this
is not essential since the insulation I 8 0n the wire
will itself engage the indented portion I6 when
the connector is pressed onto the wire and thus
hold the sleeve in the proper position and rela
ing ?ngers or serrations which assist in holding
. tion.
Moreover, if as indicated in Figure 1, the
the insulated portion of the wire. This sleeve may .55 connector is of the solderless type which is se
back within itself and slit so as to form engag
cured to the wire by crimping of the ferrule II,
this crimping itself will serve to interlock and
completely secure the sleeve 15 and the ferrule
II. To facilitate such crimping and a perfect
connection in the crimped area, the ferrule and
wire are advantageously of soft aluminum or cop
per with or Without tinning. The sleeve may be
of the same material or, being relatively thin, may
be of a more resilient material such as brass or
the course of the stretching of this rim into the
cylindrical form, the scored lines are torn open,
or if already out, are stretched apart, as indi
cated in the drawing, leaving serrations or ?n
gers inwardly directed and spaced from the end
of the ferrule. The ?nal operation is the for
mation of the crimp or circumferential groove
H by means of suitable dies pressed against the
ferrule from opposite sides. This step may also
aluminum alloy or a harder copper, e. g., about 10 be combined with step c, the crimping dies then
“quarter hard.” The parts may be tinned, or
silvered or otherwise treated to reduce corrosion
without impairing conductivity.
Beyond the indentation It, the sleeve I5 is of
serving to support the ferrule during the inser~
tion of the ?nal forming punch.
The above series of operations with tools as
illustrated in Figure 3 results in a sleeve for use
a diameter ?tted to that of the insulated portion 15 where the ferrule of the connector is of approxi
mately the same thickness as the insulation on
iii of the wire and due to the formation of the
the wire. If the ferrule is larger than the wire,
outer end of the sleeve with its reentrant fold
it is necessary to use in the preliminary draw
slit at intervals as shown so as to form ?ngers
ing operation a stepped die in which the upper
2i] projecting slightly into the interior bore of
the sleeve, the insulation is locked by the sharp 20 portion has a larger diameter than the lower
portion. If, on the other hand, the insulated
serrated edge of this fold or ?ngers whereas the
wire is to be of larger diameter than the ferrule,
outer edge of the sleeve against which the flex
then it is necessary to use in step e, a die of larger
ing of the wire must occur is smoothly rounded
diameter than that used in the drawing of the
and slightly flared due to its formation by fold
ing inward of a portion of the material at Hi. 25 initial cup, with the result that the lower portion of the sleeve is stretched to a diameter larger
This folding protects the wire against cha?ng
than that of the initially formed cup. If the
or cutting and also assists in threading the in
difference in diameter is substantial this may
sulation into the bore of the sleeve. This latter
require several dies of progressively larger diam
function is served by folding back the edge either
inwardly or externally, but as will be apparent 30 eter used in a series of drawing operations.
In Figure 6 is shown a modi?ed form of the
from the drawing, the locking of the insulation
invention wherein the smaller end of the sleeve
by the folded-back portion can be had only if it
that, instead of being ?tted to the outside of the
is folded inwardly.
ferrule of the connector terminal, is ?tted to the
The outer portion of this sleeve may also be
crimped and/or advantageously compressed, e. g. 35 conductor wire and adapted to be inserted into
the bore of the ferrule as shown, whereupon the
as set forth in the copending application of
assembly will be secured together by crimping
Vernon E. Carlson, Serial No. 455,033, ?led
as in the case already described above. In this
August 17, 1.942, so that the serrated edge is
pressed into the insulation for secure engage
ment and, if desired, a perfect seal secured.
As will be clearly evident from the above de
scription, the structure described provides ample
support and a secure holding of the insulated
wire with protection against injury with a mini
mum of increase in weight and dimensions and
at a low cost. Because of the cylindrical form
and the fact that the cylinder is tightly packed
within by the insulated wire at one end and
the heavier ferrule at the other, the metal or
other material of this sleeve i5 need be of only
case, since the smaller end of the sleeve remains
40 closed, it will not be possible to form the sleeve
in the manner shown in Figure 3 and described
above, but the outer edge may be turned inwardly
by drawing or other suitable technique. It will
be understood, however, that the end of the sleeve
need not be left closed, but may be punched
out as in the other embodiments, and, if de
sired, the end may be turned or expanded over
the end of the ferrule, so that, in effect, the
sleeve is rivetted in place.
The use of an insulation supporting sleeve
broadly, as well as the use of such a sleeve to
very light material.
hold closed a ferrule which is rolled up from
Figure 3 shows, by the series of diagrammatic
flat stock, are described and claimed in a prior
?gures representing successive steps of the metal
application of Stephen N. Buchanan, Serial No.
drawing operation, one way in which the sleeve
421,408, ?led December 3, 1941.
above described may be made in accordance with
The use of a thimble to seal the wire, as shown
my present invention. As indicated ‘n step a, the
for example in Figure 6, is the invention of one
sleeve is drawn from flat sheet or strip stock.
of us, described and claimed in the co-pending
The ?rst step, in one of several operations, is
application of Vernon E. Carlson, Serial No.
to draw this stock into the desired ferrule form;
an intermediate stage in this drawing is indicated 60 455,034, ?led August 17, 1942, issued as Patent
2,385,792 on October 2, 1945.
at b. When the drawing is completed to the
We claim:
desired form, the edge is trimmed, which may be,
1. In an electrical connector of the class where
as indicated at c in Figure 3, combined with a
in a conducting member terminates in a ferrule
?nal drawing operation, or it may, if desired,
for reception of a conductor wire, the combina
be combined with the following step illustrated
tion with. said ferrule of a sleeve ?tted to said
at d. The step illustrated at d in Figure 3 is the
ferrule and extending therebeyond to support an
piercing and scoring by which the center of the
insulated portion of said wire, the outer end of
bottom of the drawn cup or ferrule is punched
said sleeve having the material thereof folded
out and a series of radial cuts or deep scorings
formed at the same time by a suitable die 70 back into the sleeve and terminating in a serrated
edge, and said sleeve being indented circumfer
at the base of the punch. In the step illustrated
entially at the outer end of the ferrule, whereby
at e, a punci'i inserted in the opposite direction
to ?x its position thereon and forming a funnel
turns inwardly and stretches to cylindrical form,
over the end of the ferrule.
what had previously been the rim of the bot
2. An electrical terminal having a conducting
tom of the cup remaining after the step d. In 75
member terminating in a ferrule for reception of
a conductor wire, a sleeve ?tted to said ferrule
and extending therebeyond to support an in
sulated portion of said wire, the outer end of said
sleeve having the material thereof folded back
into the sleeve and terminating in a serrated edge,
and said sleeve being indented at the ends of the
ferrule, whereby to fix its position thereon.
like portion to assist in guiding the conductor
wire into the bore of the ferrule.
5. An electrical terminal having a conducting
member terminating in a ferrule for reception of
a bared conductor ‘wire and a sleeve ?tted to vsaid
ferrule and extending therebeyond with a diam
eter adapted to receive and support an insulated
portion of said conductor wire, and said sleeve
being radially indented along a circumferential
line close beyond the end of the ferrule, whereby
3. An electrical terminal having a conducting
member terminating in a ferrule for reception of
a conductor wire, a sleeve ?tted to said ferrule
said indentation forms a funnel-like portion to
and extending therebeyond to support an in
assist in guiding the bared wire into the bore of
sulated portion of said Wire, the outer end of
the ferrule.
6. An electrical terminal having a conducting
said sleeve ?tted over and extending beyond said
ferrule having a smoothly rounded edge at its 15 member terminating in a ferrule for reception of
mouth, and a sloping circumferential shoulder
a conductor wire, a sleeve ?tted to said ferrule
and extending therebeyond to support an in
on the interior of said sleeve at a distance from
its end serving as a funnel to assist in guiding a
sulated portion of said wire, the outer end of
said sleeve having the material thereof folded
wire into the ferrule from the end of the sleeve.
back into the sleeve and terminating in a ser“
4. An electrical terminal as de?ned in claim 3
rated edge.
in which the sleeve is radially indented along a
circumferential line close beyond the end of the
ferrule, whereby said indentation forms a funnel
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