Method for insulating wire terminations

• US 8,635,770 B2
• Filed: 11/16/2010
• Issued: 01/28/2014
• Est. Priority Date: 11/16/2010
• Status: Active Grant

• Current Assignee: Joyal Products Incorporated
• Original Assignee: Joyal Products Incorporated
• Inventors: Warner, Allan S.
• Primary Examiner(s): Nguyen, Donghai D
• Application Number:
  US12/947,231
• Publication Number:
  US 20120118633A1
• Time in Patent Office: 1,169 Days
• Field of Search: 295/17, 295/18, 298/57, 298/58, 29860-867, 298/76, 174/84.R, 174/94.R, 219/56, 219/56.22, 219/58, 219/91.21, 439/736, 439/874
• US Class Current: 29/858
• CPC Class Codes: H01B 19/00 Apparatus or processes specially adapted for manufacturing insulators or insulating bodies manufacture of porcelain for electric insulation C04B33/26
• CPC Class Codes: H01B 7/282 Preventing penetration of fluid , e.g. water or humidity, into conductor or cable
• CPC Class Codes: H01R 4/20 using a crimping sleeve H01R4/01 takes precedence
• CPC Class Codes: H01R 4/70 Insulation of connections end caps H01R4/22
• CPC Class Codes: H02G 1/14 for joining or terminating cables
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material
• CPC Class Codes: Y10T 29/49183 of ferrule about conductor and terminal
• CPC Class Codes: Y10T 29/49227 Insulator making
• CPC Class Codes: Y10T 29/49931 Joined to overlapping ends of plural rods

Abstract

A method for insulating wires is disclosed. A portion of the plurality of wires and an insulating material are placed in a tube having an open end. Pressure is applied to the tube. During the application of pressure, the tube, the plurality of wires, and the insulating material are heated to a temperature above a melting point of the insulating material. As a result, the insulating material is melted and driven toward the open end of the tube. Upon removal of the heat, the insulating material solidifies and forms a barrier proximal to the open end of the tube.

Claims

1. A method for insulating a plurality of wires, comprising the steps of:

placing a portion of the plurality of wires in a tube having an open end;

placing an insulating material within the tube and about an outer surface of the plurality of wires;

applying pressure to the tube; and

during the applying of pressure step, heating the tube, the plurality of wires, and the insulating material to a temperature above a melting point of the insulating material,

wherein the insulating material is melted and driven toward the open end of the tube.

2. The method of claim 1, wherein upon removal of the heat, the insulating material solidifies and forms a barrier proximal to the open end of the tube.

3. The method of claim 1, wherein the applied pressure and heat are sufficient to deform the tube and compress the wires, the insulating material, and the tube together such that the wires are pressed against other wires and the insulating material.

4. The method of claim 3, wherein the heat is sufficient to fuse the wires to each other but insufficient to melt the tube.

5. The method of claim 1, wherein the insulating material is a thermoplastic.

6. The method of claim 1, wherein the insulating material is wax.

7. The method of claim 1, wherein the insulating material is a solid tube.

8. The method of claim 1, wherein the insulating material maintains the same composition upon heating and re-solidifying.

9. The method of claim 1, wherein the insulating material is sprayed on the wires.

10. The method of claim 1, wherein the wires have been previously coated with insulating material.

11. The method of claim 1, wherein the insulating material is sprayed on an inner surface of the tube.

12. The method of claim 1, wherein the insulating material has a shape of a washer, and further comprising the step of orienting the washer shaped insulating material along a plane perpendicular to the wires and the tube proximal to the open end of the tube.

13. The method of claim 1, wherein the tube is open at both ends, the insulating material is driven toward the ends and forms an insulating barrier about the wires proximal to the ends.

14. The method of claim 1, wherein the tube is closed at one end.

15. The method of claim 1, wherein the tube is initially closed at one end and further comprising the step of forming an opening in the closed end to relieve pressure buildup of volatized materials.

16. The method of claim 2, wherein the barrier is substantially impermeable to fluids.

17. The method of claim 16, wherein the fluids are bodily fluids.

18. The method of claim 1, wherein the wires are insulated.

19. The method of claim 18, further comprising the step of applying to the tube fusing heat and current to remove the wire insulation from the metal wires.

20. The method of claim 19, wherein the metal of the insulated wires is copper based and the tube is tin-coated, the method further comprising wetting at least one of said wires with tin from the tin-coating during the step of applying the fusing heat and current.

21. The method of claim 19, wherein the metal of the insulated wires is copper based and the tube is tin-coated, the method further comprising causing the tin from the tin-coating to flow during the step of applying fusing heat and current to seal small spaces formed at least in part by the wires within the tube.