Metal deforming – By tool-couple embodying nonplanar tool-face – Similar tool-faces
Reexamination Certificate
1999-12-17
2001-05-08
Crane, Daniel C. (Department: 3725)
Metal deforming
By tool-couple embodying nonplanar tool-face
Similar tool-faces
C072S409140, C072S453060, C029S751000
Reexamination Certificate
active
06227030
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electrical connectors and, more particularly, to a die used to crimp an electrical connector onto an electrical conductor.
2. Prior Art
U.S. Pat. No. 5,291,772 discloses a compression tool ram with an electrical connector crimping surface having a pyramid shaped section and two flat sections on opposite sides of the pyramid shaped section. The flat sections are provided to prevent over-crimping of the electrical connector. FCI USA, Inc. sells electrical connector crimping dies known as “W” type dies. The “W” type dies form a general circumferential crimp around a barrel section of the electrical connector. The “W” type of dies are installed primarily in what is known as an industry “D3” die retaining groove.
The D3 groove is very common in mechanical hand held crimp tools such as the MD6 HYTOOL™ as well as hydraulic Tools such as the BAT500 BATOOL™ sold by FCI USA, Inc. The D3 groove can accommodate various “W” dies and hence can crimp a multitude of conductor/connector size combinations. The crimp range of the “W” die using a circumferential crimp profile is often limited to 500 kcmil Copper and 4/0 Aluminum for hydraulic tools. The need to expand the range for aluminum has become evident in the underground residential distribution market. More specifically, there is a desire to use tools which use “W” dies which are capable of crimping an electrical connector onto a relatively large 350 kcmil size aluminum conductor; which is not possible with conventional “W” dies.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention, an electrical connector crimping die is provided comprising a first section for removably connecting the die to an electrical connector compression tool; and a second section connected to the first section for contacting an electrical connector. The second section comprises a generally crescent shaped crimp projection forming a crimp surface and at least one secondary over-crimp prevention surface. The secondary surface is recessed relative to the crimp surface and has a general radius of curvature larger than a general radius of curvature of the crimp surface.
In accordance with another embodiment of the present invention, an electrical connector hydraulic crimping tool for crimping an electrical connector onto a conductor is provided comprising a hydraulic drive section generally adapted to provide a maximum hydraulic crimping force of between about 6 to 7 tons; and an electrical connector crimping die connected to the drive section for movement by the drive section towards a cooperating crimping die. The electrical connector crimping die comprises a crimping projection with a width of about 0.25 inch and a height of about 0.045 inch for crimping the electrical connector onto the conductor without piercing through the connector, and wherein the conductor has a size of about 350 kcmil.
In accordance with one method of the present invention, a method for crimping an electrical connector onto a 350 kcmil aluminum electrical conductor is provided comprising steps of providing a hydraulic compression tool with a crimping die, the tool having a maximum hydraulic crimping force of about 6 to 7 tons, and the crimping die having a crimping projection and secondary over-crimp prevention surfaces on opposite sides of the crimping projection, the over-crimp prevention surfaces having curved surfaces with a radius of curvature about the same as an outer dimension of a barrel section of the electrical connector; and compressing the crimping die against the electrical connector with the crimping projection deforming the electrical connector and the over-crimp prevention surfaces subsequently contacting the electrical connector to prevent the crimping projection from penetrating through the connector or causing the connector to crack. The crimping projection deforms the connector inward at least about 0.045 inch along a width of at least about 0.25 inch without overcrimping the electrical connector.
REFERENCES:
patent: 3267717 (1966-08-01), Reischer
patent: 3365927 (1968-01-01), Lynch
patent: 4019236 (1977-04-01), Osman
patent: 4292833 (1981-10-01), Lapp
patent: 5042285 (1991-08-01), Levy
patent: 5193379 (1993-03-01), Ferraro
patent: 5291772 (1994-03-01), Ferraro
patent: 5421186 (1995-06-01), Lefavour
patent: 5657417 (1997-08-01), Di Troia
patent: 6101862 (2000-08-01), Rzasa
Electrical Master Catalog, The Electrical Connector Selector, Framatome Connectors Burndy Electrical, 4 pages.
Ayer John W.
Lefavour John D.
Mack Clayton W.
Crane Daniel C.
FCI USA Inc.
Perman & Green LLP
LandOfFree
Electrical connector crimping die with over-crimp prevention... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Electrical connector crimping die with over-crimp prevention..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Electrical connector crimping die with over-crimp prevention... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2551989