Electric wiring terminal and method of making same
First Claim
1. A method of connecting wire coated with a resin-type high temperature insulation to an electrical terminal of metallic material having a connector portion and a relatively large flag portion connected thereto by an essentially narrow neck portion and disposed in acute angular relation with respect to said connector portion, said method comprising the steps ofwrapping said wire around said neck portion with a portion of said wire extending from said neck portion and between said connector portion of said terminal and said flag portion, thenelectrically contacting a pair of spaced electrodes with said connector portion of said terminal and said flag portion and passing current therebetween so that resistance to passage of said current by said neck portion heats said neck portion and said wire wrapped therearound sufficiently to explode said insulation from said wire whereby establishing a good electrical connection between said wire and said terminal at said neck portion, andsimultaneously moving at least one of said electrodes toward the other to bend said neck portion and to press said flag portion against said connector portion of said terminal to clamp the extending portion of said wire therebetween.
1 Assignment
0 Petitions
Accused Products
Abstract
An electrical terminal having a wire clamping tab connected thereto by an essentially thin neck portion about which a wire coated with a resin-type, high temperature insulation is adapted to be wound so that, when the tab is bent back against the terminal by opposed, energized electrodes to clamp a portion of the wire extending from the neck portion therebetween, resistance of the latter to flow of current heats both the neck portion and the wire wrapped therearound sufficiently to explode the insulation from the wire to assure a good electrical connection. At the same time the relatively large area of the terminal and its clamping tab maintains the clamped portion of the wire below its annealing temperature so that it is resistant to breakage in use.
6 Citations
5 Claims
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1. A method of connecting wire coated with a resin-type high temperature insulation to an electrical terminal of metallic material having a connector portion and a relatively large flag portion connected thereto by an essentially narrow neck portion and disposed in acute angular relation with respect to said connector portion, said method comprising the steps of
wrapping said wire around said neck portion with a portion of said wire extending from said neck portion and between said connector portion of said terminal and said flag portion, then electrically contacting a pair of spaced electrodes with said connector portion of said terminal and said flag portion and passing current therebetween so that resistance to passage of said current by said neck portion heats said neck portion and said wire wrapped therearound sufficiently to explode said insulation from said wire whereby establishing a good electrical connection between said wire and said terminal at said neck portion, and simultaneously moving at least one of said electrodes toward the other to bend said neck portion and to press said flag portion against said connector portion of said terminal to clamp the extending portion of said wire therebetween.
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3. A method of connecting wire coated with a resin-type high temperature insulation to an electrical terminal of metallic material having a connector portion and a relatively large flag portion connected thereto by an essentially narrow neck portion and disposed in acute angular relation with respect to said connector portion, said method comprising the steps of
wrapping said wire around said neck portion with a portion thereof extending from said neck portion and between said connector portion of said terminal and said flag portion, and then squeezing said flag portion and said connector portion of said terminal between a pair of electrodes causing an electrical current to be passed through said flag, neck and connector portions, said current being sufficient to heat said neck portion by resistance thereof to passage of said current to a sufficiently high temperature to explode the insulation from the wire wrapped therearound and to anneal the metal in said neck portion, and the squeezing force applied by said electrodes being sufficient to bend said neck portion at least after annealing thereof so as to collapse said flag portion against said connector portion of said terminal to clamp the extending portion of said wire therebetween.
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5. A method of connecting wire coated with a high temperature insulation to an electrical terminal of a heat and electrically conductive material, said terminal having a connector portion and a relatively large flag portion connected thereto by a relatively small neck portion, said method comprising the steps of
wrapping said wire around said neck portion with a portion thereof extending from said neck portion and between said connector portion of said terminal and said flag portion, and then bending said neck portion to bring said flag portion into overlapping relation with said connector portion of said terminal to clamp the extending portion of said wire therebetween using a pair of electrodes which pass electrical current through said flag, neck and connector portions and maintaining current flow for a predetermined limited interval of time during which the relatively small cross-sectional dimensions of said neck portion and the resistance thereof to passage of said current heats both said neck portion and the portion of said wire wrapped around said neck portion to a temperature above the annealing temperature of said wire to explode the insulation from the wrapped portion of said wire while the relatively large mass of said flag connector and terminal portions maintains the portion of said wire clamped therebetween at a temperature below the annealing temperature of said wire, whereby the latter retains its strength and its ability to maintain its integrity when subjected to vibration and other adverse conditions in use.
Specification