Corrosion proof terminal for aluminum wire

A crimped, corrosion-proof electrical terminal connection progressively reduced in diameter in a step-wise fashion resulting in a stepped crimp, the combination comprising:

• a terminal having a wire barrel portion,
• an insert received in said wire barrel portion,
• an aluminum wire,
• sealing means covering said aluminum wire and protecting said aluminum wire from corrosion,
• said aluminum wire having an end portion protruding from said sealing means and received internally of said wire barrel portion and said insert,
• said wire barrel portion, said insert and said aluminum wire end portion being crimped together upon application of crimping forces with a relatively deeply depressed first forward crimp portion and an immediately adjacent relatively less deeply depressed second rearward crimp portion,
• said wire barrel portion at least partially receiving said sealing means therein together with said wire end portion,
• said wire barrel portion, said sealing means and said wire end portion being crimped together upon application of crimping forces and providing a third portion adjacent to said relatively less deeply depressed second crimp portion and rearward thereof with said sealing means in compressed sealing relationship between said wire barrel portion and said wire end portion,
• said wire end portion being in compressed relationship at said third crimp portion and providing residual reaction pressure resisting crimping forces producing said third crimp portion, and providing mechanical support at an end of said terminal for resisting vibration and twisting forces tending to destroy said sealing relationship,
• said insert being provided with a plurality of perforations sufficiently large to accept therein extruded portions of said wire in said terminal, said terminal including substantially extruded portions extruded into said insert perforations at said first crimp portion,
• said wire at said first crimp portion including substantially extruded portions extruded into said perforations of said insert and in electrical contact with said extruded portions of said terminal,
• said second crimp portion providing said terminal and said insert and said wire in mechanical locked engagement resisting separation of said wire from said terminal,
• said wire substantially extruded portions having an oxide layer thereon purposely fractured into separated particles with unoxidized surfaces of said wire extruded portions being exposed and extruded into said perforations of said insert and in electrical contact with said extruded portions of said terminal,
• a reservoir internally of said wire barrel portion forwardly of said insert, said first crimp portion being substantially elongated in a forward direction during crimping and said wire conductor being longitudinally extruded within said elongated first forward crimp portion and substantially filling both said first crimp portion and said reservoir.