APPARATUS AND METHODS FOR FILAMENT CRIMPING AND MANUFACTURING

• US 20110000577A1
• Filed: 07/01/2010
• Published: 01/06/2011
• Est. Priority Date: 06/22/2006
• Status: Active Grant

• Current Assignee: Craig Kennedy, Darrel Wood II, Leonid Foshansky, Mark Saunders, Robert Bogursky
• Original Assignee: Craig Kennedy, Darrel Wood II, Leonid Foshansky, Mark Saunders, Robert Bogursky
• Inventors: Foshansky, Leonid, Bogursky, Robert, Wood, Darrel II, Kennedy, Craig, Saunders, Mark
• Granted Patent: US 8,113,243 B2
• Time in Patent Office: Days
• US Class Current: 140/71.R
• CPC Class Codes: H01R 4/01 Connections using shape memory materials, e.g. shape memory metal
• CPC Class Codes: H01R 4/188 having an uneven wire-receiving surface to improve the contact
• CPC Class Codes: H01R 43/048 Crimping apparatus or processes H01R43/042 takes precedence
• CPC Class Codes: Y10T 29/49181 by deforming
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing
• CPC Class Codes: Y10T 29/5121 Wire working
• CPC Class Codes: Y10T 428/1241 Nonplanar uniform thickness or nonlinear uniform diameter [e.g., L-shape]

Abstract

Apparatus and methods for filament crimping. In one embodiment, the apparatus comprises a body and a filament crimp element. The filament crimp element comprises a first set of cavities disposed at a spacing which creates a first set of features and a second set of cavities disposed at a spacing which creates a second set of features. The first and second set cavities are substantially opposite one another. The first set of features are adapted to be placed at least partially within the second set of cavities and the second set of features are adapted to be placed at least partially within the first set of cavities. Methods and apparatus for the manufacture of the device are also disclosed. In addition, methods for automated placement and manufacture of assemblies using the crimp elements are also disclosed.

Claims

1-57. -57. (canceled)

58. A filament crimping element, said element comprising:

a first plurality of cavities, said first set of cavities disposed at a spacing which creates a first plurality of features; and

a second plurality of cavities, said second set of cavities disposed at a spacing which creates a second plurality of features;

wherein said first and second pluralities of cavities are substantially opposite one another when said crimping element is crimped, said first plurality of features adapted to be placed at least partially within said second plurality of cavities, and said second plurality of features adapted to be placed at least partially within said first plurality of cavities; and

wherein said first and second pluralities of features comprises substantially rounded edges, said substantially rounded edges mitigating deformation of at least a portion of said filament during crimping.

59. The crimping element of claim 58, wherein said first and second pluralities of cavities and features form a substantially serpentine channel therebetween for said filament when said crimping element is crimped.

60. The crimping element of claim 59, further comprising a body having at least one leg, said at least one leg being useful for a purpose other than crimping.

61. The crimping element of claim 60, further comprising at least one feature disposed proximate said body, said at least one feature having a substantially planar surface formed thereof adapted for pickup by a pick-and-place machine.

62. The crimping element of claim 58, wherein said crimping element is formed from a material which has a hardness less than that of said filament, said lesser hardness of said material at least mitigating deformation of said filament by said crimping element during crimping.

63. The crimping element of claim 58, wherein said filament is formed from a Titanium-containing metal, and said crimping element is formed at least in part from a copper-containing alloy.

64. A crimping element comprising a crimped filament, said element comprising:

a first plurality of pre-formed cavities, said first plurality of pre-formed cavities disposed so as to at least partly define a first plurality of crimp features; and

a second plurality of pre-formed cavities, said second plurality of pre-formed cavities so as to at least partly define a second plurality of crimp features;

wherein said first and second pluralities of cavities are substantially opposite to and substantially offset from one another when said crimping element is crimped; and

wherein said pre-forming of said pre-formed cavities mitigate over-compression of said crimped filament thereby preventing damage to said crimped filament.

65. The crimping element of claim 64, wherein when said crimping element is crimped around said filament, at least part of said first plurality of crimp features is received within said second plurality of pre-formed cavities, and at least part of said second plurality of crimp features is received within said first plurality of pre-formed cavities, thereby forming a substantially serpentine channel for said filament.

66. The crimping element of claim 64, wherein said first crimp features are substantially juxtaposed and coplanar with one another in a first plane, and said second crimp features are substantially juxtaposed and coplanar with one another in a second plane.

67. The crimping element of claim 64, wherein said first and second pluralities of crimp features each comprise substantially rounded edges, said substantially rounded edges mitigating detrimental material deformation of at least a portion of said filament during crimping.

68. The crimping element of claim 64, wherein said first and second pluralities of crimp features each comprise filament engagement surfaces having substantially rounded profiles, said substantially rounded profiles mitigating material deformation or cutting of at least a portion of said filament during crimping.

69. The crimping element of claim 64, wherein the crimped filament comprises a diameter of less then 0.010 inches (0.254 mm)

70. A method of manufacturing a crimping assembly comprising a crimping element and a crimped filament, comprising:

pre-forming said crimping element prior to crimping so as to provide a gap, said pre-formed crimping element comprised of;

a first plurality of cavities, said first plurality of cavities disposed so as to at least partly define a first plurality of features; and

a second plurality of cavities, said second plurality of cavities disposed so as to at least partly define a second plurality of features;

disposing a filament at least partly within said gap and adjacent at least a portion of said first and second plurality of cavities;

placing said filament under tension; and

crimping said crimping element so as to fixedly secure said filament to said crimping element.

71. The method of claim 70, further comprising:

feeding said crimping element into a crimping machine along a given feed direction;

wherein said given feed direction is substantially parallel with said disposed filament.

72. The method of claim 70, wherein said act of crimping causes said first and second pluralities of cavities and features to form a substantially serpentine channel therebetween for said filament.

73. The method of claim 72, wherein when said act of crimping causes a part of said first plurality of features to be received within said second plurality of cavities, and a part of said second plurality of features to be received within said first plurality of cavities, thereby forming said substantially serpentine channel.

74. The method of claim 70, wherein said crimping element is formed from a material which has a hardness less than that of said filament, said lesser hardness of said material at least mitigating deleterious material deformation of said filament by said crimping element during the act of crimping.

75. The method of claim 74, wherein said first features are substantially juxtaposed and coplanar with one another in a first plane, and said second features are substantially juxtaposed and coplanar with one another in a second plane.

76. The method of claim 75, wherein said first and second features each comprise substantially rounded edges, said substantially rounded edges mitigating deleterious material deformation of at least a portion of said filament during crimping.

77. The method of claim 75, wherein said first and second features each comprise filament engagement surfaces having substantially rounded profiles, said substantially rounded profiles mitigating cutting of said filament during crimping.

78. The method of claim 70, wherein said act of placing said filament under tension comprises placing said filament under 15-30 g of tension.