Square D Company

Paul K Campbell

Edward L Nichols, Iii

Harris I Stanback

This disclosure depicts a novel method and system for crimping an elongated malleable metal connector onto two cables or the like and deforming the connector so that in its final crimped condition it is of generally a semi-cruciform/semi-circular shape in transverse cross-section with offset tap cable lodgment. The method comprises placing the connector between first and second opposed pairs of crimping dies, the first pair each having a nose portion for biting into a tap portion of the connector and one of said second pair also having a nose portion for biting into the tap portion of the connector and the other of the second pair has a nest die for crimping a main portion of the connector; moving the dies simultaneously toward one another for gripping the connector at four locations spaced around the connector; applying pressure to the dies to cause them to crimp the connector and effect deformation of the connector to the generally semi-cruciform/semi-circular shape with offset tap cable lodgment, each of the dies being substantially equidistant from its respective two adjacent dies throughout the simultaneous movement thereof; and relasing the dies when an increase in pressure of the dies on the connector reaches a predetermined value, independent of the extent of die movement, thereby terminating the crimping operation. Apparatus is disclosed for implementing the described method.

Method and system for crimping a metal connector

This disclosure depicts a ductile metallic electrical and mechanical connector for attachment to one or more electrical cables and formable by a compressible process. The connector comprises at least one bifurcated body member having first and second leg portions initially connected by a reduced cross-sectional thickness portion of the body member to provide a plastically flowable hinge connection. The first and second leg portions define an initial predetermined angle such that the body member can laterally engage an uninsulated section of an electrical cable. The first leg has on the end opposite the reduced thickness portion an axially extending rib member and axially extending inner and outer ridges disposed on either side of the rib member. The second leg has on the end opposite the reduced thickness portion axially extending inner and outer fingers. The rib member, the inner and outer ridges and the inner and outer fingers are oriented such that the outer finger lies between the outer ridge and the rib member and the inner finger lies between the inner ridge and the rib member, when the body member is closed about an uninsulated section of an electrical cable. The enclosure occurs by pivoting of the leg members about the reduced thickness portion in response to hand applied external pressure. The inner and outer fingers and the rib member are deformed to form a positive mechanical lock when an external crimping force is applied radially to the body member.

Compressible electrical connector with positive mechanical lock

A terminal connector or lug for use as a termination for electrical cables is formed by an impacting process. The connector comprises an apertured mounting pad portion and an integral cylindrical tubular body portion having an open end and a closed end and adapted to be crimped onto an electrical cable. The pad is of a generally rectangular parallelepiped shape and extends longitudinally outwardly from the closed end of the tubular portion adjacent an outer peripheral region thereof. Opposite side portions of the inner end portion of the pad extend inwardly of the closed end of the tubular portion, and the wall closing the closed end of the tubular portion is of uniform thickness and is perpendicular to an upper surface of the pad. The region of intersection of the tubular portion and the pad provides a transitional section permitting the connector to be as short as possible and minimizing metal waste while presenting a current transfer area of adequate cross section so that the current carrying capacity throughout the length of the connector is sufficiently uniform to prevent any hot spots.

Growing community of inventors

Birmingham, AL, United States of America

Paul K Campbell