Delphi Technologies, Inc.

Lisa L Flauto

Kurt Paul Seifert

William J Palm

Bruce J Serbin

Jeffrey M Handel

Masahiro Yoshino

Kurt P Seifert

A method to electrically and mechanically connect at least one wire conductor to a terminal includes the steps of cutting and stripping a portion of an insulation outer layer along an end section of the at least one wire conductor to expose a lead of the at least one wire conductor. A further step includes applying a bonding process to the exposed lead to break down oxides disposed on the lead. A further step in the method is crimping the lead having the applied bonding process to the terminal to form a crimp connection connecting the at least one wire conductor to the terminal.

Crimp connection to aluminum cable

An electrical contact includes at least one grooved channel defined in an interior surface of the electrical contact along at least a portion the electrical contact disposed along a longitudinal axis. The portion is configured to axially receive a lead of a wire cable for attachment thereto and thereby allow the attached lead to at least engagingly make contact against a recessed surface of the grooved channel. The grooved channel has a depth and includes at a least one sidewall extending along the depth. The sidewall includes at least one section that angularly extends from the interior surface to a point recessed from the interior surface disposed on the sidewall along the depth.

Electrical contact having channel with angled sidewalls and romboid knurl pattern

An electrical contact includes a knurl pattern disposed along at least a portion of an interior surface of the electrical contact. The portion receives a lead of a wire cable along a longitudinal axis and is attached thereto to form a crimp connection. The knurl pattern includes a plurality of recessed elements and each recessed element has a rhombus shape that includes inner corners. An orientation of a first pair of opposing, generally axial inner corners define an axial minor distance therebetween and an orientation of a second pair of opposing, inner corners define a major distance therebetween. The axial minor distance is less than the major distance. The recessed elements of the knurl pattern are especially suitable for engagement with an aluminum wire cable to form the crimp connection. A wire assembly that includes the crimp connection is associated with a cable harness disposed in a motorized vehicle.

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Boardman, OH, United States of America

Lisa L Flauto