Abstract:
A connection mechanism includes a metal segment in mechanical and electrical communication with the remainder of the connection mechanism on at least one side. The segment includes at least one tab protruding from the segment on a first side and a central area of the segment with a plurality of metal deformations. When the metal deformations are pressed into aluminum, they are capable of piercing through corrosion on the surface of the aluminum in order to make electrical contact with the aluminum.

Description:
BACKGROUND 
     At the foundation of many electrical technologies is the ability to connect different electrical devices together. It is common to connect these electrical devices using some type of electrical cable assembly that includes an electrical conductor (such as wire or coax cable) and a conductive terminal connected to at least one end of the electrical conductor. The conductive terminal is typically “crimped” to the end of the conductor using a crimping tool, which effectively deforms the terminal around the conductor to form a firm connection. The crimped end of a conductor may also be referred to as a connector. In use, the terminal is used to connect the conductor to the electrical device. Often, the reliability of the electrical device depends in part on the quality of the connection created between the terminal and the conductor (i.e., the “crimp”). Thus, crimping not only provides for electrical connectivity, but also provides a mechanical connection for protection against torsional and tensional forces. These forces can damage the terminal or the wire and disrupt the electrical connection. 
     Known crimp-style connectors tend to use the force or pressure of the crimping action alone to make the electrical and mechanical connections between the terminal and the wire. This force however tends to damage or break either the wire or the terminal. If less crimping force is used to prevent damage or breakage, the electrical or mechanical connections may not be adequate for the needs of the system. Moreover, creating an effective electrical connection between the terminal and the conductor using a pressure contact method is impeded by various corrosion products on the surface of the terminal and the conductor. Various methods have been employed to overcome these impediments, but few have been successful in high volume manufacturing environments. 
     Another consideration is to create an electrical connection that is stable for long periods of time and over many different environmental factors. This often requires the initial mechanical connection to be able to overcome surface corrosion on both the wire and the terminal. This type of connection is especially difficult when aluminum wire is used due to the low hardness of the aluminum combined with corrosion products on the aluminum, which are often much harder than the aluminum itself. 
     Thus, there is a need for a connector that provides a firm electrical and mechanical connection without causing damage or breakage to the wire and/or terminal, and can overcome connection impediments due to corrosion. 
     BRIEF SUMMARY 
     A connection mechanism with a metal segment in mechanical and electrical communication with the remainder of the connection mechanism on at least one side, in which a central area of the segment has at least one tab protruding from each of two opposing sides of the segment. At least the central area includes a plurality of metal deformations which, when pressed into aluminum, are capable of piercing through corrosion on the surface of the aluminum in order to make electrical contact with the aluminum. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  illustrates a connector segment for crimping around a wire, with a knurled metal area and with one tab section on each side; 
         FIG. 1B  illustrates a connector segment for crimping around a wire, with a ridged metal area and with one tab section on each side; 
         FIG. 1C  illustrates a connector segment with one tab on each side wrapped around a wire; 
         FIG. 2A  illustrates a connector segment for crimping around a wire, with a knurled metal area and with two tab sections on each side; 
         FIG. 2B  illustrates a connector segment with two tabs on each side wrapped around a wire; 
         FIG. 3A  illustrates a connector segment with two tabs on each side crimped around a wire and separated by notches, wherein the two tabs are crimped with different levels of force. 
         FIG. 3B  illustrates a connector segment with two tabs on each side crimped around a wire, wherein the two tabs are crimped with different levels of force such that a step is formed. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A connector for establishing an electrical and mechanical connection to a conductor (i.e., wire, cable, etc.) includes a terminal with deformations or knurls, which when crimped around the conductor, provide an electrical connection between the terminal and the conductor notwithstanding corrosion that may be present on the conductor and/or terminal. The deformations also provide mechanical connection and strength when crimped around the conductor. In one exemplary approach, the terminal also includes a plurality of tabs having notches therebetween. The notches allow for the conductor to be partially redistributed through the notch area during the crimping process. For soft metals on which corrosion products have a tendency to build, e.g. aluminum, the notches allow for an increased amount of force to be applied during the crimping process than would be possible without the notches. 
       FIG. 1A  illustrates a portion of a terminal  100  for crimping around a conductor. Segment  100  includes a knurled metal area including a plurality of knurls  106 . The knurl  106  pattern of protuberances shown is representative, and may be any desired pattern. Different knurl  106  patterns will provide different electrical and/or mechanical connection properties. The knurl  106  pattern is also not limited to the area shown and can be extended or reduced in area to meet the needs of the application. Knurls  106  may be designed to make electrical and mechanical connection to a bare wire or, alternatively, to make connection by penetrating a coating on a wire and thereby contacting the wire. Knurls  106  may be replaced by any other deformation which provides the desired electrical and mechanical connection properties. 
     Segment  100  includes one tab section  104  on each side. The tab  104  size and shape as shown are representative, and may be adjusted according to the wire diameter or other parameters of interest. Tabs  104  are shown as mirror images of each other around an axis situated between the two sides and bisecting the distal end  102 . This is an exemplary embodiment, and segment  100  is not limited to this description. Alternative embodiments of segment  100  may include tabs  104  on the two segment sides which are significantly distinct from each other. 
       FIG. 1B  illustrates a similar connector segment to that shown in  FIG. 1A , but with the knurls  106  in a ridge  107  pattern. The number of ridges  107  may be selected according to relevant parameters, and is not limited to what is shown in the figure. Similarly, the dimensions and placement of the ridges  107  may be selected to fulfill the requirements of the application. 
       FIG. 1C  illustrates a connector segment such as the ones illustrated in  FIGS. 1A and 1B  after an exemplary crimping process has been performed on the segment. The tabs  104  are bent around and pressed firmly against wire  120 . Tabs  104  may be designed to wrap only partially around wire  120 , leaving a gap between the crimped tabs  104 . Alternatively, tabs  104  may wrap significantly around wire  120 , such that tabs  104  meet or overlap each other. The crimping process may leave marks in tabs  104 , such as shown by exemplary creases  110 . However, the crimping process may leave tabs  104  with substantially no marks. 
       FIG. 2A  illustrates a connector segment  200  for crimping around a wire. Segment  200  is similar to connector segment  100  shown in  FIG. 1A  except that segment  200  has two tabs  204  with a notch  208  between. The width and shape of notches  208  may be defined as desired. Distal end  202  may terminate the segment  200  as shown, or may be in electrical and mechanical communication with the remainder of the connection mechanism in any form as is appropriate for the application. Knurls  206  cover an area of segment  200  as necessary for appropriate electrical and mechanical connection. Knurls  206  may be of any type or pattern, or may be replaced by any other deformation which provides the desired electrical and mechanical connection properties. 
     Segment  200  is exemplary for a connector segment with a plurality of tabs  204  and a corresponding number of notches  208 . The number of tabs  204  may be a function of the wire diameter, the mechanical connection strength required, the desired electrical stability, or the like. 
       FIG. 2B  illustrates the connector segment  200  of  FIG. 2A  after an exemplary crimping process is performed on the segment. Tabs  204  are bent around and pressed firmly against wire  220 . Tabs  204  may be designed to wrap only partially around wire  220 , leaving a gap between the crimped tabs  204 . Alternatively, tabs  204  may wrap significantly around wire  220 , such that tabs  204  meet or overlap each other. The crimping process may leave marks in tabs  204 , such as shown by exemplary creases  210 . However, the crimping process may leave tabs  204  with substantially no marks. Notches  208  between tabs  204  allow for the aluminum wire to displace when compressed by tabs  204 , thus allowing enough force to be applied to tabs  204  for the knurls  206  to make electrical connection through the corrosion layer on the wire. The expansion of the wire into the notches also provides additional tensional strength to the connection. 
       FIG. 3A  illustrates another novel feature of a connector segment with a plurality of tabs. Segment  300 , an embodiment of a segment such as segment  200 , is shown from a side view perspective. Individual tab pairs  303  and  305 , separated by notches  308 , may each be crimped around the wire with a different force. Segment  300  is shown after a crimping process is complete which leaves the tab  303  pair with a larger effective circumference than the tab  305  pair. This may be necessary where the force required to make an electrical connection is greater than the force required to make a mechanical connection. Due to the shape of the remainder of the connection mechanism in relation to segment  300 , some areas of segment  300  may be more easily damaged than others. A force great enough to make an electrical connection may cause segment  300  material, at e.g. tab pair  303 , to be stressed to the point of damage. Therefore, for example, tab pair  303  may be crimped enough to make a mechanical connection only, whereas tab pair  305  may be crimped enough to also make an electrical connection in addition to the mechanical connection. 
     Segment  300  is not limited to two tabs  303  and  305 , but may include as many tabs and corresponding notches as may be needed to meet the specifications for the connection mechanism. Each of the plurality of tabs may be crimped with a different force to allow for a stepped mechanical connection. The steps may be ascending or descending, or may alternatively be in any other pattern of steps up and steps down. 
       FIG. 3B  illustrates one such step pattern comprising two tab pairs  353  and  355  with very narrow notches between. Tab pair  355  is at a first stage of compression and tab pair  353  is at a second stage of compression as a result of using less crimping force on tab pair  353 . There is a step  358  between crimped tab pair  353  and crimped tab pair  355 . 
     In all of the figures, the tabs have been shown as being paired, one tab on each of the two tabbed sides, aligning with each other for crimping. However, it is not necessary that the tabs align, or that the tabs are of the same number, size or shape on the two sides. 
     The above description is intended to be illustrative and not restrictive. Many alternative approaches or applications other than the examples provided would be apparent to those of skill in the art upon reading the above description. The scope of the invention should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the arts discussed herein, and that the disclosed systems and methods will be incorporated into such future examples. In sum, it should be understood that the invention is capable of modification and variation and is limited only by the following claims. 
     The present embodiments have been particularly shown and described, which are merely illustrative of the best modes. It should be understood by those skilled in the art that various alternatives to the embodiments described herein may be employed in practicing the claims without departing from the spirit and scope as defined in the following claims. It is intended that the following claims define the scope of the invention and that the method and apparatus within the scope of these claims and their equivalents be covered thereby. This description should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application. 
     All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.