Electrical connector for stranded wires

A one-piece terminal having a contact portion (13) extending from a channel section wire connecting portion (11). Limbs (17, 17') extend toward each other from opposite axial ends of the sidewalls (15, 15') with opposed edges defining between them a wire receiving slot (26), a portion (22, 22') of each sidewall (15, 15') adjacent a limb (17, 17') being inclined inwardly of the channel as it extends away from the base (14) and towards the limb (17, 17') to provide a stiffly compliant slot (19). A panel (25) upstands from the base (14) between the sidewalls (15, 15') to provide sealant barrier and a rigid slot (26) aligned with the compliant slot (19). Extensions of the sidewalls (33, 33') are secured together by ties (34, 35).

The invention relates to an electrical terminal for terminating insulated 
stranded wire and particularly to an electrical terminal for terminating 
insulated stranded wires of different sizes and having a large number of 
strands. 
In the interests of economy, there is a widespread requirement for 
terminals which terminate insulated wires without a need for prior 
stripping of the insulation. Such self-stripping terminals may comprise a 
stamped and formed channel section body having sidewalls from axial ends 
of which extend limbs free of the channel base and bent towards each other 
perpendicularly of the channel axis with their opposed edges defining 
between them a wire receiving slot having a mouth remote from the channel 
base. An insulated wire extending axially of the channel can be forced 
through the mouth into the slot so that the edges penetrate the insulation 
and establish a permanent electrical connection to the wire core. 
However, a disadvantage of such prior terminal is that the limbs are 
substantially rigid so that the terminal can be used to terminate reliably 
only wires of a single size. In addition, the rigidity of the limbs makes 
the terminal unsuitable for terminating stranded wire where compliance is 
required to avoid severing the strands during insertion into the slot. 
One prior attempt to overcome the above-mentioned disadvantages is 
disclosed in U.S. Pat. No. 4,346,955 in which the limbs are carried by 
free ends of arms extending axially from the sidewalls and free of the 
base in cantilever beam fashion. 
Whilst this increases the compliance of the slot to enable a small 
variation in the size of stranded wire that can be accommodated, the 
spring characteristic is too soft to enable a connection suitable for 
carrying sufficient high currents for many ordinary purposes such as 
powering automobile accessories. An increase in the thickness of the stock 
will result in an undesirable increase in weight and cost of the terminal, 
while prestressing the limbs together so that the slot edges are in 
abutment with each other may restrict the range of wire gauges that can be 
accommodated. The cantilever spring characteristic is not suitable for 
satisfying all the requirements for connection to a broad range of 
stranded wires with retention of good current carrying capability as well 
as a requirement for economical construction and compact size. 
According to the invention, a terminal as described in the second paragraph 
is characterized in that a portion of at least one of the sidewalls 
adjacent the junction with the limb is inclined inwardly of the channel as 
it extends upwardly, away from the base and toward the limb. This portion 
defines a stiffly resilient gusset which permits the limbs to move 
relatively apart during wire insertion with a torsion spring component to 
enlarge the slot enabling the accommodation of a range of wire sizes while 
maintaining a good current carrying characteristic in the resultant 
connection with the wire. 
Preferably, the portion is defined by pushing in the sidewall along a fold 
line extending from the junction of the limb and the sidewall adjacent the 
base away from the limb and upwardly towards the free end of the sidewall. 
The gusset provides a spring characteristic of progressively increasing 
stiffness from the mouth of the slot to the base of the channel so that 
the force exerted on a wire increases progressively as the wire is forced 
down the slot. 
Desirably, edges of the limbs adjacent the mouth are coined to provide a 
radiussed, flared entry for the wire with insulation penetrating teeth. 
Advantageously, the slot may progressively taper in width as it extends 
from the mouth towards the base. 
In one embodiment, a panel having another, rigid slot is bent to extend 
perpendicularly across the channel with the other slot axially aligned 
with the one slot, the width of the other slot being greater than the one 
slot in an unexpanded wire receiving condition. 
The relative widths of the slots are chosen such that when wires throughout 
the entire range are inserted into the slots, both slots will effect 
electrical connection to the wires. 
Preferably, the panel is pushed out from the channel base and has one or 
more laterally extending lugs received in cut-outs in the sidewalls to 
maintain the panel upstanding from the base during the insertion of the 
wire into the slots with the avoidance of twist of the panel. 
This enables an economical and stable construction to be obtained. 
The fold line may extend between the junction of the limb and the sidewall 
adjacent the base and the cut-outs. 
Axial extensions of the sidewalls may be secured together against spreading 
at a location on a side of the panel remote from the compliant slot and 
formed inwardly in opposed relation to provide a contact portion 
comprising a pair of resilient legs for gripping a tab inserted between 
them. 
As the sidewalls are secured together where not joined by a base, the 
terminal may be made of relatively thin stock while retaining sufficient 
strength for the legs to provide a satisfactory tab gripping force. In 
addition, any tendency for the rigid slot to expand during wire insertion 
will be resisted by the engagement of the sidewalls with the opposite 
edges of the panel which engagement also prevents the sidewalls from being 
moved together and therefore assists in maintaining constant the 
characteristics of the compliant slot. 
Preferably, the sidewalls are secured together by first and second tie 
strips having root ends integral with upper edges of respective sidewalls 
and first and second transverse locking portions extending flag fashion 
adjacent free ends, the strips being bent at their root ends to extend 
towards each other between the sidewalls in overlapping relation and the 
first locking portion being crimped around the second tie strip to trap 
the second locking portion between the first locking portion and the 
sidewall from which it extends. 
According to another aspect of the invention there is provided a one-piece 
stamped and formed terminal comprising a wire connecting portion and a 
contact portion, the wire connecting portion comprising a body of channel 
section having a base wall from respective opposite longitudinal edges of 
which upstand sidewalls, the contact portion comprising a pair of 
resilient legs extending axially from axial extensions of the sidewalls, a 
panel formed with a wire receiving slot being bent up from the base wall 
to extend across the channel thereby to isolate the contact portion from 
the wire connecting portion and tie means extending between the sidewall 
extendions to secure the sidewalls together. 
The slotted panel both prevents any sealant injected into the wire 
connecting portion after wire termination therein from flowing towards the 
contact portion and provides wire connection. 
Preferably, the wire connecting portion includes a second wire receiving 
slot located on a side of the panel remote from the contact portion.

The terminal is stamped and formed from a single piece of sheet metal stock 
and comprises a wire connecting portion 11 including a body portion 12 of 
channel shape and a contact portion 13 extending from one axial end of the 
body portion. 
The body portion comprises a base wall 14 from respective opposite sides of 
which upstand identical sidewalls 15 and 15'. Limbs 17 and 17' extend free 
of the base from axial ends of the respective sidewalls, and are bent 
towards each other perpendicularly of the channel axis so that their 
opposed free edges define between them a wire receiving slot 19 having a 
mouth 20 remote from the base. A portion 22, 22' of each sidewall adjacent 
a junction with a limb is pushed in along a fold line 23, 23' which 
extends from the junction of a limb at the base at its junction with a 
sidewall away from the limb and upwardly towards the free end of the 
sidewall. This portion defines a resilient gusset providing a spring 
characteristic of progressively increasing stiffness as it extends from 
the mouth of the slot to the base. Edge portions 24, 24' of the limbs 
adjacent the mouth are coined to provide a radiussed flared entry with 
insulation penetrating teeth. 
A panel 25 is pushed up from the channel base to extend parallel to the 
limbs between the sidewalls and is formed with a rigid wire receiving slot 
26 axially aligned with the compliant slot 19 and having similar 
insulation penetrating teeth. Lugs 27, 27' extend from opposite sides of 
the panel at an upper end and are received in vertical cut-outs 28, 28' 
extending downwardly from the upper portions of the sidewalls to the fold 
lines 23, 23' which locate the panel securely during wire insertion. 
Stiffening embossments 29 and 30 are formed in the base wall and lower 
sidewalls 14 and the panel 25 respectively to enhance the rigidity of 
those parts. 
The contact portion 13 comprises a pair of tab gripping legs 32, 32' 
extending longitudinally from axial extendions 33, 33' of the sidewalls of 
the body. 
The sidewall extendions 32, 32' are secured together by first and second 
tie strips 34, 35, respectively, having root ends integral with upper 
edges of the extensions and first and second locking portions 36, 37, 
respectively, extending flag fashion adjacent free ends, the strips being 
bent at their root ends to extend towards each other between the sidewalls 
in overlapping relation. The first locking portion 36 comprises arms 
crimped around the second tie strip 35 at a location adjacent the second 
locking portion 37 which is thereby trapped between the first locking 
portion and the sidewall from which it extends. 
A conventional crimping ferrule 41 with longitudinally staggered arms is 
provided as an axial extension 42 of the base wall. A latching detent 43 
is pushed out of the extension 42 to latch the terminal in a housing. 
The terminal is suitable for use with a very wide range of wire gauges, 
e.g., from 0.5 sq. mm to 1.5 sq. mm. 
In use of the terminal, during insertion of an insulated stranded wire into 
the slots, the teeth of the compliant and rigid slots 19 and 26 will 
penetrate the insulation and the slot edges establish connection with the 
wire core throughout the entire range. 
When the wires are inserted into the slots, the compliant slot will open 
progressively with a torsion spring component, penetrating the insulation 
and contacting the core without severing individual strands. The edges of 
the rigid slot may tend to sever some strands of the largest wires but the 
resulting weakened condition will be augmented by the second slot. 
The tie strips both enhance the rigidity of the channel section body 12, 
the rigidity of the slot 26, and enhance the tab gripping force enabling 
the terminal to be made economically from relatively thin stock.