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Патент USA US3074160

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Jan. 22, 1963
Original Filed Sept. 9, 1955
2 Sheets-Sheet 1
Quamm BERG
Jan. 22, 1963
Original Filed Sept. 9, 1955
2 Sheéis-Sheet 2
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United States Patent O?ice
Quentin Berg, New Cumberland, Pa, assignor to Al“?
Incorporated, a corporation of New Jersey
Original application Sept. 9, 1955, Ser. No. 536,893, now
Patent No. 2,929,946, dated Mar. 15, 1960. Divided
Patented Jan. 22, 1963
The importance of this is evident when it is remembered
that the applicator machines must be located where the
terminals are being applied, and in the possession of
persons unfamiliar with their manufacture and proper
maintenance. Sharpened cutting blades heretofore used
on these structures required frequent adjustment, sharp
ening and/or replacement expensive in itself as well as
limiting the time the machine was in operation, without
having to be shut down for such servicing. Further
10 more, such cutting means frequently left small burrs
This invention is related to electrical connectors of
extending from the cut edge of the connectors, and it
the type which are used, in the form of a continuous
has been found distinctly advantageous to avoid such
strip of connectors, in machines which pressure-crimp the
burrs in many applications, particularly in precision elec
connectors individually onto wire conductors or the like.
trical resistors and radio frequency chokes.
In preferred form, the subject connector is adapted to 15
The invention is applicable generally to the connecting
connect a lead wire to electrical elements with precision
of wires to circuit component elements, e.g., the resist
to embody them as useful components for electrical cir- .
ance elements, choke coils etc., mentioned above. Such
cuits (e.g., resistors, reactors, and capacitors). This
elements are commonly made in the ‘form of wire helically
application is a division of my copending application,
wound onto a core of insulating material. This wire
Serial No. 536,893, ?led September 9, 1955, now Patent
wound insulation or other circuit element which is to
No. 2,929,046.
be subsequently connected into a circuit as a component
‘Connectors in strip form have recently come into wide
thereof is referred to herein as “electrical element.” With
use as a consequence of inventions of V. E. Carlson
lead wire connections made at each end of lengths of
(Patent No. 2,396,913) and W. S. Watts (application .
such elements, they become useful circuit components.
No. 514,214, ?led December 14,1943) and successive 25 The electrical values, e.g., resistance or reactance, of such
developments of their associates F. L. Pierce, I. C.
components and consequently their performance in a
Macy, and myself. In those cases Where the connectors
given circuit are dependent on the active length of the
are to be used for permanently joining two or more con~
element, that is, its length between the closest opposite—
and this application Apr. 30, 1959, Ser. No. 816,355
3 Claims. (Cl. 29-15555)
ducting members, such strip generally comprises pairs of
end contacts with the connectors or the lead-in wires.
rolled-up laterally-opposed portions of sheet metal which 30 In the broader aspects of this invention, it is concerned
form either cylindrical ferrules or channels, with an inte
with the making of connections on circuit component
elements other than resistance or reactance coils, e.g.,
next connector in the strip.
paper-foil capacitors and even simple conductors.
In such strip as known before the present invention,
My new connector-strips are used to make permanent
portions of the stock were stricken away to leave such 35 lead-wire connections to such electrical elements, and
joining portions of substantially lesser transverse extent
this with speed, economy, precision, accuracy and elec
than the adjoining parts of the connectors. In a copend
trical and mechanical security. It has been found to
ing application of F. L. Pierce there is shown a strip
be distinctly advantageous, however, to avoid the tear
having successive terminals partially sheared from one
ing out or extrusion of burrs, during cutting of the end
another without waste and the joining portions weakened 40 connector from the strip, as such burrs could, under
to facilitate ?nal severing by tearing or shearing in auto
certain conditions, damage a fragile circuit component
matic applicator machines with greatly increased life of
element, or reduce the spacing from other circuit ele
shear blades and thus reducing cost of servicing such
ments or otherwise be detrimental to the excellence of
machines. This also avoided the necessity for precision
the connection.
die structures such as had been used to stamp out con
It is, therefore, a general object of this invention to
necting portions of the strip prior to or during the
provide a continuous strip of electrical connectors which
pressure-crimping operation.
will hold together under the handling to which it must
In my copending application, Serial No. 119,220, ?led
be subjected in manufacture, transit and use but from
October 3, 1949, I disclose and claim continuous strips
which individual connectors can be severed without need
of electrical connector structures which can be indexed
for sharp edged tools and with production of a connector,
or moved by strip-feeding members although there are
well adapted to join two conducting members with great
substantially no gaps between the connectors. These
precision accuracy, .and electrical and mechanical sta
structures include turning outwardly one edge at the
bility, even where one conducting member to be joined
sides of the U-shaped portions so that this edge projects
is a fragile electrical element.
to form an abutment for indexing or driving means and 55
Beyond this, it is an object to the invention to make
generally consist of deforming the side walls of such
connections with such precision and stability.
U-shaped portions in various fashions to produce such
With these and other objects, which will be apparent,
abutments. With these novel indexing abutments, the
my invention provides a continuous strip of electrical
ral connection from the base of each channel to the
cost of the connectors is reduced, as none of the sheet
connectors Which are in full edge contact with one an
metal stock is wasted in the connector joining portions 60 other in the strip to maintain their parallelism while
which would be cut out during use and discarded. Sub
they are being subsequently severed, and which are joined
stantially all of the stock is incorporated into the con
in the strip by a thin section of metal spaced from the
nectors themselves. The present connector likewise
inner and outer faces of the strip, whereby each con
achieves the advantages of full utilization of the entire
nector can be accurately severed from the strip without
strip stock, and the avoidance of the necessity of main
the use of sharp cutting members with greater precision
taining sharp shear edges in the applicator machines;
than was known in the prior art, and this merely by the
but according to this invention, I have now discovered
imposition of opposed, laterally o?F-set forces to the end
that the terminals can be made to provide their own
connector and the adjacent connector of the strip to
shear within themselves and to avoid leaving of substan-v 70 which it is attached.
tial projections from torn edges even though no sharp
It is also an important object to apply connectors from
shear edges are maintained in the machine.
strip without the protrusion of any burrs, such as may
be acquired during the severing of connectors from the
structures which comprise, individually, electrical con
stri .
nectors 48.
Referring to FIGURES l and 2, the lance 38, in form
ing the dihedral 44, severs it at its trailing edge 56 from
the flat stock 42, but for the vertex 52 of the dihedral 44
which is offset from said ?at stock 42 and partially severed
sion, and, laterally, they are substantially thinner than
therefrom. This particular forming operation thus serves
the sheet metal which comprises the connectors. In
the functions of forming the individual connector blanks
combination with this small joining area, this invention
43, bending them generally into the form of a dihedral 4!:
in preferred form utilizes a recessed area in the inner
surface of the connector strip adjacent each such joining 10 as an intermediate step in their slitting from the continu
ous strip, leaving a joining area 54- of small cross-section,
area. Other novel features in combination particularly
and, by virtue of ?rst providing an offset 55 in the strip
adapt my invention to certain speci?c applications.
IPaccomplish these as well as other objects through the
use of novel joining areas between the connectors in
the strip. These areas are longitudinally of small dimen
The aforesaid, and other objects will in part be pointed
and then re-aligning the connector blanks 43 as they are
out in and will in part become apparent from the fol
further shaped to form connectors 48, providing a recessed
lowing speci?cation and claims, taken in conjunction
with the accompanying drawings.
area ‘56 in the strip 46 adjacent the joining areas 54.
The nature of this recess 56 and joining area 54
is best seen in FIGURE 2 taken in conjunction with
In the drawings:
FIGURE 5 and with FIGURES 3, 4 and 6, which lat
ter ?gures present this area 54 after subsequent shear
a continuous strip of connectors by such die structures, 20 ing. It is to be noted that the joining area is of
FIGURE 1 is an isometric view of upper die struc
tures, a strip of sheet metal stock as it is formed into
and lower die structures as are used in conjunction with
the upper structures;
FIGURE ,2 is an axial longitudinal sectional view
taken on the line 2-2 of FIGURE 1, with the die
structures brought together'against the strip;
FIGURE 3 is an isometric view of a strip of con
relatively small cross-section, and, preferably, does not
extend laterally into contact with either surface of
the strip. Among the advantages accruing from this
latter feature is the fact that the dimensions of each in
25 dividual connector are well pro-established by the place
ment of said joining area 54; these connectors 48 are
thereby adapted to be accurately severed from the strip
nectors embodying this invention;
FIGURE 4 is an isometric View of a single connector
as might be severed from a strip as'shown in FIGURE 4;
FIGURE 5 is a side elevational view of a strip as is
shown in FIGURE 2, partially broken away to present
without the use of sharp cutting means, but rather with
the mere imposition of a lateral force between the end
connector 48a and the strip 46 (FIGURES 3 and 5).
This shearing process is best seen in FIGURE 7, where
in the strip 46a, here in an inverted position, is seen dis
an axial cross-section of this strip;
FIGURE 6 is an end elevation of a connector as is
posed between an upper guiding and supporting member
shown in FIGURE 3;
FIGURE 7 is a side view of the strip of connectors,
58 and a lower supporting member 60. A third member,
in practice one of two cooperating die structures, referred
to herein as the upper crimping die 62, is abutted against
the bottom (here turned upward) of the end connector
480 of the strip 46a, and the upper crimping die 62 and
FIGURE 8 is a right end elevational view of certain
the strip supporting members 58 and 60' are driven trans
elements in FIGURE 6',
'FIGURE 9 is a cross-section taken at the line 9-9 40 versely (vertically) relative to one another, and the end
connector is thus slid or wiped ed the supported strip 46a.
in FIGURE 7;
electrical element, lead wire, and their assembly appara
tus, the latter shown partially in cross-section;
FIGURE 10 is a side elevation of a precision elec
In effect, the supported strip provides the “shearing edge”
trical circuit component, partially broken away and pre
for this severing action—i.e., the connectors shear against
sented in axial cross section;
one another.
FIGURE 11 is an isometric view of an end connection
of the component shown in FIGURE 10;
In the lateral movement of the end con
nector 480 relative to the strip 46a the vertical end edges
67 of the side walls 68 of the end connector 480 slide
FIGURE 12 is a cross section taken at the line 12—-12
along those 67:; of adjacent connector in the strip 46a,
in FIGURE 11.
Referring to FIGURE 1, a strip of sheet metal 20 is
shown disposed between an upper set of die structures
22 and a lower set of die structures 24, this strip 20
edly reformed at various stages in the opposed die
thus advantageously limiting the motion of the end con~
hector to a laterally shearing one and causing joining area
54 to be cleanly sheared rather than partially bent and
torn off. The recessed area 56 previously described pro
vides further assurance in that if by any chance this shear~
ing should produce any burr it would be within this recess
structures 22 and 24.
and within the thickness of the connector 480 as well as
The lower die structures 24 include a generally ?at
surfaced anvil 26, a lancing block 28 having a dihedral
surface 29, and a “U-ing” or bending block 30 having
a. curved cylindriform surface 32. For forming the
of that in the adjacent connector in the strip 46a.
Subsequent application of the end connector 480 to a
being successively worked, cut, and otherwise repeat
fragile electrical element 64 and a lead wire 66 is seen in
FIGURES 7 and 8 taken together. Referring to FIGURE
7, after being severed from the strip 46a the end connec
preferred connector strip 46, two small peening forms
33 are on opposite sides of the surface 36 of the anvil 26. 60 tor 48c is held between the upper crimping die 62 and
a lower crimping die 74, by virtue of sliding frictional
The lancing block surface 29 at its ridge 34, is offset
engagement of the side walls 72 of this lower die '74 with
beneath the plane of the anvil surface 36 a distance
the longitudinal end edges 70 of the connector 48c.
less than the thickness of the sheet-metal strip 20 to
In application to an electrical element and a lead wire,
be formed.
65 as is shown in FIGURE 8, the severed end connector 48d
Cooperating with these surfaces are upper die struc
is disposed between the crimping dies 62 and '72, with a
tures 22 which include a lance 38 and a “U-ing” or
fragile electrical circuit element 64 and a lead wire dis
curving punch 4%. A strip of sheet metal 26 indexed
posed opposite the end edges 70 of the connector d?b.
intermittently (from right to left in the drawings) be
Subsequent bringing together of the dies 62 and 72 en
tween the repeatedly closed sets of die structures 22
closes and compressively engages the electrical element 64
and 24 is cut and bent from its originally flat stock
in the connector 48b and securely grips the lead wire be
form 42 into partially folded portion, comprised of
tween the end edges 76 of the connector.
The previously discussed recessed areas 56 in the strip
two surfaces joining at an angle, which will be referred
46, or 46a, provide recessed end edges 76 in the severed
to as a dihedral 4d, and then bent further to form a
continuous strip 46 of generally cylindriform, U-shaped
connector 480. In the connection 30 (FIGURE 9), seen
partially in cross-section in the opposite-end connection
80a, these recessed edges '76 accommodate any burr which
might conceivably be produced during the shearing of the
connector from its strip, and thus preclude the cutting of
the fragile wires 82 of the electrical element 64a.
The formation of the recessed edges 76 also serves to
avoid sharp corners, which even though free from burrs
might impose damaging shear stresses on the fragile wires
sive gripping of the lead wire can be acquired while the
enclosed element is held with adequate but not destruc
tive pressure; and that such adequate gripping pressure
is reached after the lead wire has been gripped between
the edges 70 but before it has been weakened beyond the
requirements of its use. When the crimping dies are at
the end of their movement, the wire 66 should be sub
stantially deformed between the edges 70 so that it is
82 when the connections 8d are crimped thereon.
keyed against rotation and against axial pull-out. (Note
Referring again to FIGURE 7, it is seen that the con 10 FIGURES l1 and 12.) In order that the element 64 will
nector 480 has a longitudinal dimension (length from left
not be scratched by the connector as it is being forced
to right in FIGURE 7) great enough to permit the con
around the element during assembly (which could result
nector to grip a substantial length of the electrical ele
in breakage of the fragile wires when the connector there
ment 64a. This entire area is substantially uniformly
after is peripherally compressed and worked or ?owed
compressed onto the element 64a so that the element is 15 beyond its yield point and thus given a permanent “set”
securely gripped with a good electrical contact but with
to secure the lead wire and element) this peripheral
out excessive pressure of the connector 430 on the fragile
dimension plus the diameter of the lead wire should be
wires 82 (because of distribution of the gripping force
considerably greater than the compressed circumference
over an area su?icient to preclude the damaging of these
of the electrical element used.
With the dimensional
wires). Further, it is distinctly advantageous to have this 20 relationships of connector, electrical element, and lead
longitudinal dimension great enough to provide a secure
wire as shown in the accompanying drawings, this inner
grip on a lead ‘wire 66:: between the end edges 7d of the
periphery is approximately four times the lateral Width
connector 4311.’ even though this lead wire 66a. does not
extend to the inner edge 84 of the connector (note the
of the rounded bottom portion of the inner surface of the
connector measured at an altitude equal to one half said
connection 80a, FIGURE 10, also FZGURE 11). The
width above the bottom of the interior.
inner edge 84 is thus relieved from great compression, and
In crimping, the element 64 is initially of diameter‘
this produces a longitudinal gradient of pressure on the
slightly greater than the said lateral width of the bottom
electrical element 64a which helps to protect it against
portion of the connector and hence does not immediately
damage, and this also avoids any danger of driving the cut
bottom therein; but as the end edges 7t? of the connector
end of the lead Wire into the electrical element 64a in 30 are bent around in the die the Width is slightly increased
the critical area which determines its active length. The
and the element is pushed in toward the bottom. The
length of the connector 48 also determines the leverage
lead wire is then gripped between the longitudinal end
which the lead wire 66 can exert tending to pry open the
edges of the connector as the electrical element is en
connection, although ordinarily the rigidity of the con
closed thereby; and the connector is then ?nally com
nection is so much greater than the bending strength of 35 pressed against the Wire until, ?nally, inelastic radial ex
the wire that this leverage is not a controlling factor.
trusion and compression of the connector sets walls there
Yet another function served by the length of the con
of in a form to maintain a strong but well distributed
nector 43 is the strengthening against ?exure of the con
gripping pressure on the enclosed element. A general
nections 80, 88a, which in turn enhances the electrical and
expression for the width of the strip of sheet metal stock
40 from which these preferred forms of connectors are made
mechanical stability of these connections.
It is to be noted that, in the preferred embodiment
has been found to be pi times the sum of the outside dia~
shown in the drawings, the strip of connectors 46 pre
meter of the electrical element plus the thickness of the
sents the general appearance of a channel and, more par
sheet metal stock minus the lead wire diameter, and 3 to
ticularly, One with a rounded bottom. In certain appli
25 percent of the remainder added thereto to allow for
cations, such as that described herein, this rounded con— 45 compressive “setting.”
tour of the bottom of the connectors is distinctly ad
Although the 25% addition will ordinarily be more
vantageous in onder that the connectors can receive and
than necessary (and even larger excess can be used in ex
snugly ?t round fragile electrical elements without dam
treme cases) it is permissible in my invention by reason
aging them during crimping. The radius of curvature
of the crimping die set shown in FIGURE 7. As the pres
of the bottom inner surface of the connectors, or of the 50 sure on the ferrule increases in the dies its frictional re
channel comprising a strip of connectors, is in present
sistance against the die face increases so that instead of
practice, slightly less than the outer radius of curvature
pinching off the wire, the compression tends to be relieved
of a round electrical element to be gripped therein. The
by thickening and extrusion of the metal in the Zone
reason for this is that the forces on the connector as it
where the surfaces of the male and female dies meet.
is driven along the side walls 72 and into the lower 55 Unless lead wires in the form of wider more or less ?at,
crimping die 74 tend to spread its bottom as said con
strips of metal were used, the connector itself would have
nector is driven around and about said element. It is to
an inner lateral periphery greater than three times the
be understood, of course, that strips with other than
Width of the curved bottom inner surface thereof, said
rounded bottoms can be successfully used, with appro
width being taken at a point one-half this width above
priate male and female crimping means, but it unneces 60 the bottom of said inner surface.
sarily complicates the problem, when the element to be
engaged is round. If the electrical elements to be used
in the manufacture of circuit components were of a shape
other than round, or if they were not fragile but were
Various advantages accrue from having the side edges
of the connectors face-to-face in the strip and lying in the
same plane. As previously discussed, this construction
gives sliding support to the end connector as it is moved
themselves sturdy structures, the cross-sectional shape of
laterally across the strip for shearing and holds the align_
the connectors could be varied within broad limits pro
ment of the connector so that it is properly oriented in the
viding that the generally channel-like form is adhered to.
With the round, fragile, electrical element to be con
nected in an embodiment of this invention and a lead
were gripped between the longitudinal end edges (i.e.,
the longitudinally directed, laterally extreme end edges)
of the connector or channel, the lateral inner peripheral
dimension (i.e., from one such edge transversely around
the inner surface to the other end edge along a section
normal to the axis) must be such that secure compres 75
crimping die. Of great interest is the fact that this align
ment of the side walls of the connectors, in the strip, en
ables the size of the crimping die surfaces to be reduced
and permits crimping of the connectors onto fragile electri
cal elements with much less danger of damage by reducing
the necessary clearance between said elements and the die
surfaces. Advantageously this clearance is only slightly
greater than the thickness of the connector metal, but suffi
cient so that it does not bind on the core.
This small
clearance of the side of the element can be ?lled in by
thickening of the connector by compression during crimp
ing. These features permit much greater accuracy and
precision of the crimping operation. Furthermore, this
essentially cylindriform shape of the connectors obviates
the risk of having relatively inwardly disposed portions
of the side walls making contact, with high unit pressure,
with the electrical element as it is enclosed by the con
nector during crimping.
cure retention of the lead wire gripped between their
longitudinal end edges. In order to insure that this wire
is correctly engaged by these edges during the crimping
operation (see FIGURES 7 and 8), as well as to subse
' quently strengthen the assembly, they are provided with
thin ?anges extending from the outer surface of the side
wall of the connector. Referring again to FIGURE 1, the
small peening forms 33 are conveniently used to form
these ?anges 90; a peening punch 92 can be included
A yet further advantage gained in the use of strips com 10 among the upper die structures 22 so that the side edges
of the ?at strip 42 are extruded by compression between
prised of such aligned cylindriform connectors is the fact
this punch 92 and the forms 33 to form the ?anges 90.
that the strip can bend in only one direction. The joining
After this portion of the strip has been cut and formed
areas between connectors are strong enough to permit the
into a connector, the flanges 93 are seen to be disposed at
strip being handled, that is, loaded onto applicator ma
chines in the form of rolls of strip and the end of the strip 15 the center of the longitudinal end edges 70 of the con
nector, and is in part an extension of the outer surface of
fed through guiding and indexing mechanisms in the ma
the connector. Although other types of wire-gripping end
chines, the abutting relationship of the connectors in the
edge deformations may be used to enhance the security
strip enables them to behave as if they were rigid members
of the retention of the lead wire between the end edges
when subjected to columnar loading, greatly facilitating
their being accurately fed in an automatic applicator. 20 of the connector, these ?anges are particularly ‘advan
tageous as they tend to “gather” the lead wire into the
Furthermore, this strip is wound onto reels with easily
achieved neatness, as it bends in only one direction and
resists twisting. In order to gain these and other advan
tages a new means of providing an abutment for index
ing members to engage in feeding the strip in the machine,
is herein provided.
In my previously referred to copending application
proper position between the end edges during crimping.
Furthermore, the edge recesses 91, left by the metal being
peened outward to form the ?anges 90, receive extruded
portions of the lead wire during the ?nal high-compression
stage of the crimping operation, thus serving to “key” the
wire into place (note FIGURES l0 and ll). The ?anges
themselves, in combination with extrusion of the lead
Serial No. 119,220 I disclose and claim various embodi
wire, also serve to “key” the wire against subsequent ro
ments of lateral deformations in the side walls of strip
form connectors. -A speci?c embodiment of this broad 30 tation, as is shown in FIGURE 12. This gripping of the
wire is thus made independent of the enclosed element,
idea is claimed herein because its novel advantages closely
and enables the pressure on the wire and on the element
relate to the other features of the present invention. This
to be varied independently, as previously discussed.
novel indexing abutment in the embodiment shown is
If thinner and harder material, e.g., steel, is used in the
comprised of a lateral deformation of the side Wall of the
connector in the form of an indentation extending into 35 manufacture of connectors which are to be used as de
the side wall from the outer surface thereof. Referring
scribed above, it would be distinctly advantageous to so
to FIGURE 1, the upper set of die structures is seen to
include a pair of notchjng punches 88 which are so dis
form the longitudinal end edges that they-are e?ectively
posed, in this case, that they strike the strip of sheet metal
20 while it is still in ?at stock form 42 and produce in-,
dentations 94) which, after subsequent formation of the
connectors 48, reside in the side walls thereof. These in
edges, for instance, would not only be/Uifectively thick
thick enough to grip and retain the lead
e. Corrugated
enough, but would enhance a “keying? of the wire by
permitting extrusion thereof between the corrugations.
The minimization of burrs at the severed ends of the
connectors, the minimization of the maximum radial di
mens'ion of the connections formed therewith by gripping
An alternative structure preferable for some applications 45 the lead wire in an opening in the wall of the connector,
and the secure “keying” or rigid gripping of the lead
would be the placing of this indent on the inner bottom
wire——these and other features enhance the subsequent
surface of the strip of connectors so that, although index
molding of plastic insulating material over the electrical
ing must then be done from the inner side of the strip, the
components so formed. For instance, the lead wire is
indent could also serve the functions of partially pre-shear
used, advantageously, as a support for the component
ing the connectors one from another and recessing the
dentations 90 are so formed that a laterally disposed abut
ment 91 is available for engagement by indexing means.
area to be sheared.
The thickness of the sheet metal stock out of which the
connectors are to be made is, of course, dependent on
such things as the diameter of the lead wire to be subse
during such molding-if it is not properly disposed, and
securely held, in the component, it may preclude the com
ponent being adequately covered with insulation.
I claim:
1. The method of electrically coupling a conductor wire
quently gripped between the longitudinal end edges of the 55
to an elongated electrical component body having a con
connector, the hardness, elastic limit, and other charac—
teristics of this sheet metal stock, the nature of the elec
trical element, or, possibly, electrical conductor to be
ductive surface by a U-shaped channel including the steps
of disposing the conductor wire coaxially along the chan
nel; laying the component body in and along the channel;
gripped therein as well as other variables, such as the
size and shape of the crimping dies, which could be 60 closing the channel tightly against and in pressure engage
ment with the conductive surface of the component body;
adapted to meet speci?c connector-stock thickness require
and forcing the longitudinally extending faces, as de?ned
ments. With quarter or half-hard brass as stock, an elec
by the stock thickness of the channel, at the ends of the
trical element whose circumference is .380 inch, a stock
arms of the channel toward abutting relation and against
thickness of .023 to .029 inch has been found to be quite
the conductor Wire from opposite sides to grip the con
satisfactory for use with a soft copper lead wire whose
ductor wire in electrical engagement.
diameter is slightly greater than this thickness. Such
2. The method of electrically coupling a conductor
brass connectors have a yield point low enough to permit
wire to an elongated electrical component body having a
compressive ?ow of the metal therein during crimping
conductive surface by a U-shaped channel including the
and to thus allow a permanent “set” to be given to the
compressed connectors, and yet are strong enough to se 70 steps of disposing the conductor wire coaxially along the
channel; laying the component in and along the channel;
curely grip the lead wire and electrical element gripped
closing the channel tightly against and in pressure en
therein. If the sheet metal used is harder, it could be, ac
gagement with the conductive surface of the component
cordingly, of less thickness.
body; forcing the longitudinally extending faces, as de
Related ot the thickness of the sheet metal used in
making the connectors is the problem of insuring the se 75 ?ned by the stock thickness of the channel, at the ends of
the arms of the channel toward abutting relation and
against the conductor wire from opposite sides to grip
the conductor wire in electrical engagement; and, while
from opposite sides to grip the conductor wire in electrical
engagement; and, While circumferentialiy con?ning the
channel and conductor wire, compressing the channel be
yond its yield point.
circumferentially con?ning the channel and conductor
wire, compressing the channel beyond its yield point.
3. The method of electrically connecting a conductor
wire to a U-shaped channel to be applied on a component
body including the steps of laying the component body in
and along the channel; disposing the conductor wire co
axially along the channel; bending the arms of the channel 10
inwardly in a direction to form a ferrule embracing the
component body and to force the longitudinally extending
faces, as de?ned by the stock thickness of the channel, to
ward abutting relation and against the conductor wire
References Cited in the ?le of this patent
Rollefson ____________ __ May 31,
Offner ______________ __,__ May 2,
Sipe _________________ __ Dec. 12,
Freedom ____________ __ Dec. 19,
Berg _______________ __'__ Nov. 17, 1953
Berg ________________ .._ Jan. 22, 1957
Watts ___________ __n__ Feb. 26, 1957
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