Method and apparatus for making a crimped, insulation-pierce electrical

Abstract

An insulated conductor is terminated in an insulation-opening portion of an electrical contact and the contact jaws are crimped over the conductor to secure the conductor therein. A tool includes a pair of cutting edges and crimping surfaces for cutting and folding over sections of the contact jaws as the tool presses an insulated conductor into an insulation-opening notch formed by the contact jaws. The tool includes a forward end having a surface for engaging and pressing the conductor into the notch, the surface acting against the conductor as a stop to limit the depth of cut of the cutting edges. The tool may also be used after conductor insertion by other techniques to perform the crimping operation. The side surfaces of the tool slidingly engage the cut edges of the contact jaws and prevent an inward movement of the jaws during cutting and crimping. The resulting electrical connection is mechanically secure in that a normally open conductor-receiving channel is closed by the peeled over sections of the contact jaws there by preventing outward movement of the conductor. The contact structure is of particular advantage where stranded wire is used in that the clamping action of the peeled over sections prevents relaxation distortions of the conductor which has become distorted during insertion and thus prevents pressure drop at the contact jaws which can result from relaxation distortion.