Systems and methods for forming a conductive wire assembly
AssigneeTyco Electronics Corporation
InventorsJohn Anthony Fulponi, Robert Neil Mulfinger, James Scott Showers
Life of this patent
Estimating the term…
Abstract
A shuttle assembly is configured to connect an insulated wire to a contact terminal. The shuttle assembly may include a connecting insert defining an exposed wire-crimping chamber. The connecting insert is configured to receive an exposed end of a conductive wire, and is configured to be crimped to the exposed end of the conductive wire. A seal member is connected to the connecting insert, and is configured to be crimped to an insulating cover of the insulated wire.
Claims20
A shuttle assembly configured to connect an insulated wire to a contact terminal, the shuttle assembly comprising:
- a connecting insert defining an exposed wire-crimping chamber, wherein the connecting insert is configured to receive an exposed end of a conductive wire, and wherein the connecting insert is configured to be crimped to the exposed end of the conductive wire;
- and
- a seal member connected to the connecting insert, wherein the seal member is configured to be crimped to an insulating cover of the insulated wire.
A method of securely connecting a conductive wire assembly to a contact terminal, the method comprising:
- inserting a distal end of a conductive wire into an exposed wire-crimping chamber of a connecting insert;
- viewing the distal end of the conductive wire through a connection window formed through the connecting insert;
- removing the conductive wire from the exposed wire-crimping chamber of the connecting insert when an insulating cover is visible through the connection window;
- determining if at least a portion of a wire connection confirmation lever extends outwardly past an outer wall portion of the connecting insert;
- removing the conductive wire from the exposed wire-crimping chamber of the connecting insert when the at least a portion of the wire connection confirmation lever extends outwardly past the outer wall portion of the connecting insert;
- and
- crimping the contact terminal to the conductive wire assembly in response to the exposed wire-crimping chamber being visible through the connection window and the wire connection confirmation lever being flush with or below an outer wall portion of the connecting insert.
A shuttle assembly configured to connect an insulated wire to a contact terminal, the shuttle assembly comprising:
- a connecting insert defining an exposed wire-crimping chamber, wherein the connecting insert is configured to receive an exposed end of a conductive wire, wherein the connecting insert is configured to be crimped to the exposed end of the conductive wire, wherein the connecting insert include an oxide-permeating mesh structure that is configured to break through aluminum oxides of the exposed end of the conductive wire, wherein the connecting insert comprises (a) a wire-connection confirmation lever that is positioned within a channel formed through a first portion of a main body, and (b) a connection window formed through a second portion the main body;
- and
- a seal member integrally formed with and connected to the connecting insert, wherein the seal member is configured to be crimped to an insulating cover of the insulated wire.
Dependencies are inferred from the claim text.