US3717842A - Method of connecting aluminum wire to electrical terminals - Google Patents

Method of connecting aluminum wire to electrical terminals Download PDF

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Publication number
US3717842A
US3717842A US00119309A US3717842DA US3717842A US 3717842 A US3717842 A US 3717842A US 00119309 A US00119309 A US 00119309A US 3717842D A US3717842D A US 3717842DA US 3717842 A US3717842 A US 3717842A
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United States
Prior art keywords
wire
aluminum
terminal
terminals
channel portion
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Expired - Lifetime
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US00119309A
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R Douglas
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PERFECTION ELECTRICAL PROD Inc
PERFECTION ELECTRICAL PROD INC US
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PERFECTION ELECTRICAL PROD Inc
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49179—Assembling terminal to elongated conductor by metal fusion bonding

Definitions

  • Such conventional terminals have a channel portion with extending tabs so that the wire can be placed in the open channel and the tabs crimped to close the channel and hold the wire in electrical connection with the terminal.
  • the solid or stranded wire is then ultrasonically welded to the channel portion to remove the oxide already on the aluminum wire and preclude any further build-up of aluminum oxide.
  • the invention relates to a method of connecting conventional electrical terminals having at least non-aluminum portions to solid or stranded aluminum wire.
  • Aluminum wire has been used for many years in certain limited applications. Recently new alloys such as triple E aluminum made by the Southwire Corporation have been developed which retain many of the desirable characteristics of aluminum wire and at the same time have other physical qualities which are much superior to conventional EC grade aluminum and which make such wire acceptable for general use in housing, vehicles, appliances, etc.
  • One terminal which has been used widely for many years for copper wires has a channel portion into which the copper wire can be placed and tabs which can be crimped to close the channel portion and hold the wire firmly in electrical connection with the channel portion.
  • These terminals have conventionally been made of such materials, brass, tin-plated or silver-plated brass, cadmium-plated or nickel-plated steel, bronze and phosphorus bronze. Because of their widespread use, manufacturers of these types of terminals have very large investments in equipment to apply these terminals to wire and for producing these terminals cheaply and on a large scale.
  • the present invention relates to a method whereby coventional terminalsrcan be'used for aluminum wire, thus obviating the necessity for new and expensive toolingand other equipment to both produce and apply the terminals to the wire. This is accomplished as discussed below by ultrasonically welding the solid aluminum or strands-to the closed channel portion afterthe wire has been placed in the channel and conventionally crimped. Ultrasonic welding has been employed in the past for welding aluminum wire asdiscussed, for example, in I-Iaigler U.S. Pat. No. 3,314,582.
  • Such terminals may be nickel-plated steel or other conventional material.
  • an aluminum alloy terminal having a non-aluminum coating, such as nickel may beemployed.
  • An aluminum terminal with a non-aluminum coating may be particularly satisfactory because no galvanic action can occur between the aluminumwportion of theterminal which contacts the aluminum wire and the wire. Further, welding between the employed.
  • aluminum portion of the terminal and the wire may be more satisfactory than welding the aluminum wire to a non-aluminum terminal portion.
  • FIG. 1 shows a perspective view of a conventional terminal with an open channel and an aluminum wire to be placed in the channel portion.
  • FIG. 2 shows a perspective view of the terminal of FIG. 1 with the aluminum wire crimped in and ultrasonically welded to the channel portion.
  • FIG. 1 shows a perspective view of a non-aluminum terminal 20, for example, nickel-plated steel, and an aluminum or aluminum alloy wire 22 which may comprise a plurality of strands as shown which are about to be placed in the open channel portion 24 of terminal 20 or alternately a solid wire.
  • nickel-plated steel may be unsatisfactory for other reasons, it can be successfully welded to the aluminum wire.
  • Galvanic reaction may be a problem for many terminal materials.
  • an aluminum terminal with a nonaluminum coating may also be employed. As shown,
  • Terminal 20 also includes portions 26 which attach terminal 20 to a further electrical contact or wire and portions 26 may be of any desired configuration. Any number of wires can be connected to a single terminal and two wires are frequently so connected.
  • Channel portion 24 includes two tabs 30 and 32 which extend along the open side of portion 24 which receives a wire.
  • the wire is first placed in channel 24 and then the tabs 30 and 32 are conventionally bent or crimped down on the wire 34 to the position shown in FIG. 2 to hold the wire in channel portion 24. If nothing further is done, the aluminum oxide already on the surfaces of the 'strandsof aluminum or solid wire 34 and that which accumulates thereafter will electrically insulate the terminal from the wire and provide an unsatisfactory connection.
  • the aluminum wire 34 is ultrasonically welded to the non-aluminum channel portion 24, and this connection, it has been found, provides a continuing electrical connection which is satisfactory.

Abstract

A method of connecting conventional electrical terminals having at least non-aluminum portions, such as nickel-plated steel, to solid or stranded aluminum wire so that aluminum oxide on the surfaces of the strands does not prevent a satisfactory electrical contact. Such conventional terminals have a channel portion with extending tabs so that the wire can be placed in the open channel and the tabs crimped to close the channel and hold the wire in electrical connection with the terminal. According to this invention, after the aluminum wire is held by crimping, the solid or stranded wire is then ultrasonically welded to the channel portion to remove the oxide already on the aluminum wire and preclude any further build-up of aluminum oxide.

Description

[ 1 Feb. 20, 1973 [54] METHOD OF CONNECTING ALUMINUM WIRE TO ELECTRICAL TERMINALS [75] Inventor: Richard Douglas, Jr., Nashville,
Tenn.
[73] Assignee: Perfection Electrical Products, Inc., I
Nashville, Tenn.
[22] Filed: Feb. 26, 1971 [21] Appl. No.: 119,309
53 mi of Search.....339/275, 276, 27s; 174/84 R,
[56] References Cited UNITED STATES PATENTS 7/1954 Hipple ..339/275 T 7/1967 Pennings 9/ 1957 Redslob 9/1958 Martines ..339/275T 8/1969 Metzger, Jr. ..228/1 Primary Examiner.loseph H. McGlynn Attorney-Cushrnan, Darby & Cushman [57] ABSTRACT A method of connecting conventional electrical terminals having at least non-aluminum portions, such as nickel-plated steel, to solid or stranded aluminum wire so that aluminum oxide on the surfaces of the strands does not prevent a satisfactory electrical contact. Such conventional terminals have a channel portion with extending tabs so that the wire can be placed in the open channel and the tabs crimped to close the channel and hold the wire in electrical connection with the terminal. According to this invention, after the aluminum wire is held by crimping, the solid or stranded wire is then ultrasonically welded to the channel portion to remove the oxide already on the aluminum wire and preclude any further build-up of aluminum oxide.
1 Claim, 2 Drawing Figures BRIEF DESCRIPTION OF THE PRIOR ART AND SUMMARY OF THE INVENTION The invention relates to a method of connecting conventional electrical terminals having at least non-aluminum portions to solid or stranded aluminum wire.
Aluminum wire has been used for many years in certain limited applications. Recently new alloys such as triple E aluminum made by the Southwire Corporation have been developed which retain many of the desirable characteristics of aluminum wire and at the same time have other physical qualities which are much superior to conventional EC grade aluminum and which make such wire acceptable for general use in housing, vehicles, appliances, etc.
One terminal which has been used widely for many years for copper wires has a channel portion into which the copper wire can be placed and tabs which can be crimped to close the channel portion and hold the wire firmly in electrical connection with the channel portion. These terminals have conventionally been made of such materials, brass, tin-plated or silver-plated brass, cadmium-plated or nickel-plated steel, bronze and phosphorus bronze. Because of their widespread use, manufacturers of these types of terminals have very large investments in equipment to apply these terminals to wire and for producing these terminals cheaply and on a large scale.
Unfortunately, this conventional method of connecting strands of wire or solid wire to these types of terminals is not satisfactory for aluminum or aluminum alloy wires because aluminum oxide tends to build up on the surface of the aluminum before and after crimping and acts as an insulator rather than a conductor. In order to overcome this problem, special terminals have been developed. In one terminal a plurality of sharp prongs or pyramids'are formed on the interior of the channel so that, when the tabs are crimped to hold the strands in place, these prongs or pyramids penetrate through the oxide on the wire and into the aluminum below to provide a good electrical connection. While satisfactory as terminals, new and expensive machines must be developed to produce the special terminals required for aluminum wire and to apply them to the aluminum wire.
The present invention relates to a method whereby coventional terminalsrcan be'used for aluminum wire, thus obviating the necessity for new and expensive toolingand other equipment to both produce and apply the terminals to the wire. This is accomplished as discussed below by ultrasonically welding the solid aluminum or strands-to the closed channel portion afterthe wire has been placed in the channel and conventionally crimped. Ultrasonic welding has been employed in the past for welding aluminum wire asdiscussed, for example, in I-Iaigler U.S. Pat. No. 3,314,582.
. Such terminals may be nickel-plated steel or other conventional material. Alternatively, an aluminum alloy terminal having a non-aluminum coating, such as nickel, may beemployed. An aluminum terminal with a non-aluminum coatingmay be particularly satisfactory because no galvanic action can occur between the aluminumwportion of theterminal which contacts the aluminum wire and the wire. Further, welding between the employed.
aluminum portion of the terminal and the wire may be more satisfactory than welding the aluminum wire to a non-aluminum terminal portion.
Many other objects and purposes of the invention will be clear from the following detailed description of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a perspective view of a conventional terminal with an open channel and an aluminum wire to be placed in the channel portion.
FIG. 2 shows a perspective view of the terminal of FIG. 1 with the aluminum wire crimped in and ultrasonically welded to the channel portion.
DETAILED DESCRIPTION OF THE DRAWINGS FIG. 1 shows a perspective view of a non-aluminum terminal 20, for example, nickel-plated steel, and an aluminum or aluminum alloy wire 22 which may comprise a plurality of strands as shown which are about to be placed in the open channel portion 24 of terminal 20 or alternately a solid wire. While nickel-plated steel may be unsatisfactory for other reasons, it can be successfully welded to the aluminum wire. Galvanic reaction may be a problem for many terminal materials. As mentioned above, an aluminum terminal with a nonaluminum coating may also be employed. As shown,
the interior of channel portion 24 is substantially smooth. Terminal 20 also includes portions 26 which attach terminal 20 to a further electrical contact or wire and portions 26 may be of any desired configuration. Any number of wires can be connected to a single terminal and two wires are frequently so connected.
Channel portion 24 includes two tabs 30 and 32 which extend along the open side of portion 24 which receives a wire. To attach an aluminum wire to terminal 20, the wire is first placed in channel 24 and then the tabs 30 and 32 are conventionally bent or crimped down on the wire 34 to the position shown in FIG. 2 to hold the wire in channel portion 24. If nothing further is done, the aluminum oxide already on the surfaces of the 'strandsof aluminum or solid wire 34 and that which accumulates thereafter will electrically insulate the terminal from the wire and provide an unsatisfactory connection. However, after wire 34 is crimped in the channel portion 24, according to this invention the aluminum wire 34 is ultrasonically welded to the non-aluminum channel portion 24, and this connection, it has been found, provides a continuing electrical connection which is satisfactory. This welding tends to break down the oxide on the wire and prevent formation of further oxide between the terminal and wire. Any conventional ultrasonic welding apparatus and/or method can be .Many changes and modifications in the above embodiment of this invention can, of course, be made without departing from the'scope of the invention and accordingly that scope is intended to be limited only by without portions of the terminal extending into said wire and tabs forming part of said channel portion comprising the steps of:
placing said wire in said channel portion of said terminal without any part of said terminal extending 5 into said wire,
US00119309A 1971-02-26 1971-02-26 Method of connecting aluminum wire to electrical terminals Expired - Lifetime US3717842A (en)

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Cited By (55)

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FR2391575A1 (en) * 1977-05-18 1978-12-15 Daimler Benz Ag Conductor terminal fitting machine employing metal deformation - performs additional welding of joint and welded area is incorporated in pressure zone
DE3017364A1 (en) * 1980-05-07 1981-11-19 Niebuhr Mikroschweißtechnik GmbH, 8752 Goldbach Crimping and welding of cables to spade socket connectors - where ultrasonic welding appts. crimps socket tags and welds them to bared end of electric cable
EP0046636A1 (en) * 1980-08-25 1982-03-03 Texas Instruments Incorporated Ultrasonic bond energy monitor
FR2501923A1 (en) * 1981-03-13 1982-09-17 Pechiney Aluminium Ultrasonic vibration assisted crimp cable connector for stranded wires - compresses lug wings onto bared wire and onto wired insulation during or before application ultrasonic waves
DE3335848A1 (en) * 1982-10-04 1984-04-05 Hitachi, Ltd., Tokyo METHOD FOR CONNECTING AN ALUMINUM WIRE
US4596352A (en) * 1983-09-29 1986-06-24 Schunk Ultraschalltechnik Gmbh Apparatus for joining or, respectively compressing electric conductors
EP0261905A2 (en) * 1986-09-24 1988-03-30 Elco Corporation An electrical connector and a method for connecting wires thereto
US4799899A (en) * 1985-11-06 1989-01-24 Yazaki Corporation Connective structure for conductive wires and a method of manufacturing the same
US4817814A (en) * 1987-08-28 1989-04-04 American Technology, Inc. Ultrasonically welding a conductor wire to an electrical terminal
EP0310792A2 (en) * 1987-09-21 1989-04-12 Patent-Treuhand-Gesellschaft für elektrische Glühlampen mbH Signal lamp for mounting on circuit boards
US4913678A (en) * 1989-02-02 1990-04-03 Gte Products Corporation Electrical contact
US5134249A (en) * 1990-06-28 1992-07-28 Aue Institute Limited Electronic circuit connectors and method of manufacturing the same
EP0614247A2 (en) * 1993-03-04 1994-09-07 Sumitomo Wiring Systems, Ltd. Electric wire joining method
US5541365A (en) * 1993-03-15 1996-07-30 Yazaki Corporation Beam Welding Terminal Structure
US5935463A (en) * 1994-06-28 1999-08-10 Yazaki Corporation Wire welding method, and wire fixing jig
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Cited By (104)

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Publication number Priority date Publication date Assignee Title
FR2391575A1 (en) * 1977-05-18 1978-12-15 Daimler Benz Ag Conductor terminal fitting machine employing metal deformation - performs additional welding of joint and welded area is incorporated in pressure zone
DE3017364A1 (en) * 1980-05-07 1981-11-19 Niebuhr Mikroschweißtechnik GmbH, 8752 Goldbach Crimping and welding of cables to spade socket connectors - where ultrasonic welding appts. crimps socket tags and welds them to bared end of electric cable
EP0046636A1 (en) * 1980-08-25 1982-03-03 Texas Instruments Incorporated Ultrasonic bond energy monitor
FR2501923A1 (en) * 1981-03-13 1982-09-17 Pechiney Aluminium Ultrasonic vibration assisted crimp cable connector for stranded wires - compresses lug wings onto bared wire and onto wired insulation during or before application ultrasonic waves
DE3335848A1 (en) * 1982-10-04 1984-04-05 Hitachi, Ltd., Tokyo METHOD FOR CONNECTING AN ALUMINUM WIRE
US4580713A (en) * 1982-10-04 1986-04-08 Hitachi, Ltd. Method for bonding an aluminum wire
US4596352A (en) * 1983-09-29 1986-06-24 Schunk Ultraschalltechnik Gmbh Apparatus for joining or, respectively compressing electric conductors
US4799899A (en) * 1985-11-06 1989-01-24 Yazaki Corporation Connective structure for conductive wires and a method of manufacturing the same
EP0261905A2 (en) * 1986-09-24 1988-03-30 Elco Corporation An electrical connector and a method for connecting wires thereto
EP0261905A3 (en) * 1986-09-24 1989-02-22 Elco Corporation An electrical connector and a method for connecting wires thereto
US4817814A (en) * 1987-08-28 1989-04-04 American Technology, Inc. Ultrasonically welding a conductor wire to an electrical terminal
EP0310792A2 (en) * 1987-09-21 1989-04-12 Patent-Treuhand-Gesellschaft für elektrische Glühlampen mbH Signal lamp for mounting on circuit boards
EP0310792A3 (en) * 1987-09-21 1990-04-11 Patent-Treuhand-Gesellschaft Fur Elektrische Gluhlampen Mbh Signal lamp for mounting on circuit boards
US4913678A (en) * 1989-02-02 1990-04-03 Gte Products Corporation Electrical contact
US5134249A (en) * 1990-06-28 1992-07-28 Aue Institute Limited Electronic circuit connectors and method of manufacturing the same
EP0614247A2 (en) * 1993-03-04 1994-09-07 Sumitomo Wiring Systems, Ltd. Electric wire joining method
EP0614247A3 (en) * 1993-03-04 1996-02-14 Sumitomo Wiring Systems Electric wire joining method.
US5541365A (en) * 1993-03-15 1996-07-30 Yazaki Corporation Beam Welding Terminal Structure
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