Electrical connectors – Metallic connector or contact also having securing part... – Securing part crimped or bent onto looped end of wire conductor
Reexamination Certificate
2001-05-01
2003-05-06
Patel, Tulsidas (Department: 2839)
Electrical connectors
Metallic connector or contact also having securing part...
Securing part crimped or bent onto looped end of wire conductor
C439S852000
Reexamination Certificate
active
06558208
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to an electrical contact and a method for press-bonding [this] electrical contact to an electrical wire.
DESCRIPTION OF THE PRIOR ART
Electrical contacts having wire retaining barrels engage and maintain an electrical wire therein are generally known in the art. One example of such an electrical contact, which is disclosed in Japanese Utility Model Application Kokoku No. S45-33001, is shown in FIG.
7
. This electrical contact
100
has a contact part
102
that electrically contacts a mating electrical contact (not shown in the figures), and a wire retention part
104
that is connected by bending the barrel around the outer circumference of an electrical wire (not shown in the figures). The wire retention part
104
is constructed from a pair of conductor barrels
104
a
,
104
a
which are bent about the core of the wire and frictionally engage the core wire, i.e., the conductor of the electrical wire. A pair of insulator barrels
104
b
,
104
b
are also provided and are bent about the outer covering of the wire and frictionally engage the outer covering, i.e., the insulation of the electrical wire. The conductor barrels
104
a
,
104
a
are formed so that their positions are offset relative to each other in the axial direction of the electrical contact
100
. The insulator barrels
104
b
,
104
b
are also formed so that their positions are offset relative to each other in the axial direction of the electrical contact
100
. The barrels are bent or press-bonded so that they envelop and frictionally engage the electrical wire from both sides of the electrical wire, thus pressing and fastening the outer covering of the electrical wire in place with the broadest possible area.
Furthermore, an electrical contact in which beveled surfaces are formed on the tip ends of the insulator barrels that are press-bonded or frictionally engaged to the outer covering of the electrical wire is disclosed in Japanese Utility Model Application Kokai No. S56-119264.
The barrel parts
104
b
,
104
b
of the electrical contact
100
disclosed in the above-mentioned Japanese Utility Model Application Kokoku No. S45-33001 are separated from each other in the axial direction of the electrical contact
100
after the barrels have been bent; accordingly, these barrel parts
104
b
,
104
b
are wrapped around the circumference of the outer covering of the electrical wire without contacting each other. As a result, the electrical contact
100
can be used on wires of various diameters, and the total length of the electrical contact
100
can be made relatively short. However, the pair of barrel parts
104
b
,
104
b
have no structural integrity following bending or press-bonding; consequently, the barrel parts
104
b
,
104
b
tend to open, so that the frictional engagement with the wire is weak, thereby allowing the wire to be inadvertently removed causing electrical failure.
Furthermore, in the latter prior art example, there are limits on the diameter of the electrical wires that can be used. Moreover, there is a danger that the tip ends of the insulator barrel will strike each other and bite into the outer covering of the electrical wire creating the possibility of damage to the outer covering of the electrical wire.
SUMMARY OF THE INVENTION
The present invention was devised to solve the above referenced problems. Consequently, the invention provides a compact electrical contact which has a high press-bonding strength while facilitating a broad range of applicable electrical wire diameters.
The electrical contact of the present invention has an electrical contact part, a conductor barrel that is press-bonded to or in frictional engagement with the core wire of an electrical wire, and an insulator barrel that is press-bonded to or in frictional engagement with the insulating covering of the electrical wire. The insulator barrel is constructed from a pair of left and right press-bonding parts disposed in positions that are offset relative to each other in the axial direction of the electrical wire. The electrical contact is constructed so that when the press-bonding parts are press-bonded to the electrical wire, the facing edges of the press-bonding parts, which face each other in the axial direction, contact each other on the electrical wire.
Both surfaces of the facing edges of the press-bonding parts may be subjected to swage working. Alternatively, the entire circumferences of only the inside surfaces of the press-bonding parts may be subjected to swage working. Or the entire circumferences of the outside surfaces may be subjected to swage working in addition to the entire circumferences of the inside surfaces.
The term “both surfaces of the facing edges” refers to both the inside surfaces of the facing edge parts of the plate members that form the press-bonding parts, i.e., the surfaces that contact the outer covering of the electrical wire when press-bonding is performed, and the outside surfaces of the facing edge parts, i.e., the surfaces that can be seen from the outside following press-bonding.
The term “entire circumference” does not necessarily refer strictly to the entire circumference of each press-bonding part; this term also refers to cases in which the area in the vicinity of the fixed end of each press-bonding part is not included in this circumference.
The shapes of the tip end portions of the press-bonding parts and the shapes of the corresponding portions that face these tip end portions during the press-bonding of the press-bonding parts may be complementary shapes. In addition to cases in which the shapes of the entire tip end portions of the press-bonding parts and the shapes of the corresponding portions of the electrical contact are shapes that are complementary to each other, the term “complementary” also includes cases in which the shapes of only portions of the tip end portions and the shapes of the corresponding portions are shapes that are complementary to each other.
The electrical wire press-bonding method using the electrical contact of the present invention is also described. When the electrical contact is press-bonded to the electrical wire, the pair of press-bonding parts make sliding contact with each other at the facing edges of said press-bonding parts, so that the respective tip ends of the press-bonding parts move while describing portions of a spiral track along the outer circumference of the aforementioned electrical wire.
REFERENCES:
patent: 1703325 (1929-02-01), Smarr
patent: 3051773 (1962-08-01), Batcheller
patent: 3120990 (1964-02-01), Kinkaid
patent: 3656093 (1972-04-01), Kinkaid
patent: 4385794 (1983-05-01), Lucius
patent: 4405189 (1983-09-01), Douty et al.
patent: 4840578 (1989-06-01), Sato
patent: 5302146 (1994-04-01), Yamamoto
patent: 5599214 (1997-02-01), Sakai et al.
patent: 6099360 (2000-08-01), Broschard, III et al.
patent: 878154 (1961-09-01), None
patent: 1 281 198 (1972-07-01), None
Patel Tulsidas
Tyco Electronics Amp K.K.
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