Abstract:
An electrical connection for securing multiple wires within an interior of an electrical connector barrel includes the use of a spacer which is received within the barrel, and which includes guiding spaces to position the plurality of wires.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This application relates to the use of an insert in a terminal to guide and align multiple wires that are to be secured within the terminal. 
         [0002]    Wires are utilized in any number of applications in the prior art. In one common application, multiple wires are brought into a barrel or holding area on an electrical terminal lug. The terminal lug may be of the sort having a generally flat surface with an aperture to make a connection to another component. The barrel may be cylindrical, but may also be other shapes. 
         [0003]    In the prior art, the multiple wires are each stripped at a forward end, and then moved into the lug of the terminal. The lug may then be crimped to lock the wires in place. 
         [0004]    There are challenges with the prior art, in that it is sometimes difficult to move multiple wires into the barrel. Sometimes it is necessary to force the wires into the barrel, and thus the assembly is complex. In addition, it is often the case that un-insulated sections of the wire extend away from the barrel, which is also somewhat undesirable. 
       SUMMARY OF THE INVENTION 
       [0005]    In the disclosed embodiment of this invention, a barrel in a terminal lug receives a spacer which defines spaces to receive portions of multiple wires. The spacer aligns and positions the wires within the barrel, such that assembly is simplified. 
         [0006]    These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  shows a prior art terminal connection. 
           [0008]      FIG. 2A  is an exploded view of the inventive connection. 
           [0009]      FIG. 2B  shows an insert. 
           [0010]      FIG. 2C  shows a cross-section through the assembled components. 
           [0011]      FIG. 3A  shows a final step in the connection. 
           [0012]      FIG. 3B  is a view similar to  FIG. 2C , but after the final step has occurred. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0013]      FIG. 1  shows a prior art connection  20 . Connection  20  includes a barrel  22  extending to a face  26  having an aperture  24 . Elements  22 ,  24 , and  26  form an item known as a terminal lug. As known, the aperture  24  is used to make an electrical connection with another component. Multiple wires  28  and  30  have exposed forward portions  32  where insulation has been removed. These forward portions  32  must be forced into the barrel  22 . It is necessary that the combined size of the forward portions  32  be approximately the same as the size of the barrel  22  such that when the barrel  22  is crimped, the forward portions  32  are captured. On the other hand, by making the combined forward portions  32  approximately the same size as the lug, it becomes difficult to move the wires into the lug for assembly. In addition, as can be appreciated from  FIG. 1 , the forward portions  32  extend un-insulated away from the barrel  22 , which is undesirable. 
         [0014]      FIG. 2A  shows the inventive connection  40 . The terminal lug  22 ,  26 , and  24  is generally as known in the prior art, as are the wires  28  and  30 . The forward portions  42  of the wires are moved into an insert  44 , and its spaces  46 . Separator portions  48  are formed between the guiding spaces  46 . 
         [0015]    As shown in  FIG. 2B , the guiding spaces  46  with the separation portions  48  may be generally symmetrical or they may be asymmetric to accommodate varying numbers and sizes of wires. The sizes of the spaces  46 , and the portions  48 , may be selected to accommodate a particular sized wire, and to be received within a particular sized lug. 
         [0016]    As shown in  FIG. 2C , the components may be easily assembled within the interior of the barrel  22 . 
         [0017]    As shown in  FIG. 3A , the lug may now be crimped to be flattened as shown at  60 . As can also be appreciated from  FIG. 3B , when the crimping occurs, the insert may deform as well as the barrel  22 , and thus the forward portions of the wires  28  and  30  are securely captured within the barrel  22 . 
         [0018]    The insert  44  may be formed of copper or other material that provides good conductivity and is also deformable. 
         [0019]    Of course, more than two wires, and various sized wires, can be utilized. The wires may be of similar sizes, as shown, or different sizes. Also, while crimping is shown as the way the wires are secured, other methods such as brazing or soldering can be used. 
         [0020]    Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.