Electrical connector crimping die with over-crimp prevention surface and method
AssigneeFci USA LLC
InventorsJohn D. Lefavour, Clayton W. Mack, John W. Ayer
Life of this patent
Estimating the term…
Abstract
An electrical connector crimping die comprising a first section for removably connecting the die to an electrical connector compression tool; and a second section connected to the first section for contacting an electrical connector. The second section comprises a generally crescent shaped crimp projection forming a crimp surface and at least one secondary over-crimp prevention surface. The secondary surface is recessed relative to the crimp surface and has a general radius of curvature larger than a general radius of curvature of the crimp surface.
Claims12
An electrical connector crimping die comprising:
- a first section for removably connecting the die to an electrical connector compression tool;
- and
- a second section connected to the first section for contacting an electrical connector, the second section comprising a generally crescent shaped crimp projection forming a crimp surface and at least one secondary over-crimp prevention surface, the secondary surface being recessed relative to the crimp surface and having a general radius of curvature larger than a general radius of curvature of the crimp surface.
An electrical connector hydraulic crimping tool for crimping an electrical connector onto a conductor, the crimping tool comprising:
- a hydraulic drive section generally adapted to provide a maximum hydraulic crimping force of between about 6 to 7 tons;
- and
- an electrical connector crimping die connected to the drive section for movement by the drive section towards a cooperating crimping die, wherein the electrical connector crimping die comprises a crimping projection and at least one over-crimp prevention surface on a side of the crimping projection, wherein the crimping projection comprises a width of about 0.25 inch and a height of about 0.045 inch for crimping the electrical connector onto the conductor without piercing through the connector, wherein the at least one over-crimp prevention surface is recessed relative to the crimping projection, and wherein the conductor has a size of about 350 kcmil and the at least one over-crimp prevention surface is curved with about a same radius of curvature as a barrel section of the electrical connector.
A method for crimping an electrical connector onto a 350 kcmil aluminum electrical conductor comprising steps of:
- providing a hydraulic compression tool with a crimping die, the tool having a maximum hydraulic crimping force of about 6 to 7 tons, and the crimping die having a crimping projection and secondary over-crimp prevention surfaces on opposite sides of the crimping projection, the over-crimp prevention surfaces having curved surfaces with a radius of curvature about the same as an outer dimension of a barrel section of the electrical connector;
- and
- compressing the crimping die against the electrical connector with the crimping projection deforming the electrical connector and the over-crimp prevention surfaces subsequently contacting the electrical connector to prevent the crimping projection from penetrating through the connector or causing the connector to crack, wherein the crimping projection deforms the connector inward at least about 0.045 inch along a width of at least about 0.25 inch without over-crimping the electrical connector.
Dependencies are inferred from the claim text.