Patent Publication Number: US-6666732-B1

Title: Terminal connector

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to terminal connector wherein he wire is secured to the terminal fixture by crimping and by soldering. 
     2. Background of the Prior Art 
     In connecting a wire to a terminal fixture, such as a ring, spade, a male connector, a female connector, etc., a strong mechanical as well as electrical connection is desired. In order to achieve these goals, many prior art devices have been proposed that connect a wire with a terminal fixture. While such prior art devices work with varying degrees of efficiency, such devices suffer from one or more drawbacks. Many terminal fixture connection devices are relatively complex in construction making these devices relatively expensive to manufacture and difficult to use. Some devices provide a relatively weak electrical connection that can fail over time. Some devices, although providing a sufficiently strong electrical connection, provide a relatively weak mechanical connection that can fail over time resulting in failure of the electrical connection. 
     Therefore, there exists a need in the art for a device that mechanically and electrically connects a wire to a terminal fixture wherein both the mechanical connection and the electrical connection are sound and wherein the connection tends not to fail unreasonably over time. Such a device must be of relatively simple design and construction and must be relatively easy to install and maintain. 
     SUMMARY OF THE INVENTION 
     The terminal connector of the present invention addresses the aforementioned needs in the art. The terminal connector mechanically and electrically connects a wire to a terminal fixture wherein both the mechanical connection and the electrical connection are sound and wherein the connection tends not to fail unreasonably over time. The device is of relatively simple design and construction and is relatively easy to install and maintain. 
     The terminal connector of the present invention is comprised of a terminal fixture having a crimpable barrel mechanically and electrically connected thereto. A solder sleeve is provided and abuts the crimpable barrel. A heat shrinkable tubing is provided and is positioned such that the tubing encompasses the solder sleeve and a portion of the barrel. The barrel is adapted to receive a wire and the barrel is crimped thereonto to mechanically and electrically bind the barrel with the wire. Thereafter, the solder sleeve is melted to further mechanically and electrically bind the barrel and the wire and the tubing is heated to encapsulate around the wire and the barrel. The tubing, which acts as an insulator, has an outer surface as well as an inner surface that has an adhesive layer upon the inner surface wherein upon heating the tubing the adhesive layer melts and adhesively binds the terminal fixture, the solder sleeve, the tubing and a portion of insulation encompassing a portion of the wire. The adhesive layer is heat activated and can be co-extruded with the tubing. The terminal fixture can be any appropriate fixture such as a ring, a spade, a male connector, a female connector, etc. The solder sleeve can be a low temperature solder member and can be pre-fluxed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the terminal connector of the present invention. 
     FIG. 2 is an exploded view of the terminal connector. 
     FIG. 3 is an environmental view of the terminal connector about to receive a wire. 
     FIG. 4 is a side sectioned view of the terminal connector after receiving a wire. 
     FIG. 5 is a side sectioned view of the terminal connector bound to the wire. 
    
    
     Similar reference numerals refer to similar parts throughout the several views of the drawings. 
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings, it is seen that the terminal connector, generally denoted by reference numeral  10 , is comprised of a terminal fixture  12  having a crimpable barrel  14  mechanically and electrically connected thereto in any appropriate fashion known in the art. The terminal fixture  12  can be any appropriate fixture such as the illustrated ring, a spade, a male connector, a female connector, etc. A solder sleeve  16  is provided and is positioned so that the solder sleeve  16  abuts the crimpable barrel  14 . The solder sleeve  16  is a tubular member and is a low temperature solder member, a low temperature solder member being defined as a solder member that melts at a temperature no greater than about 300 degrees Fahrenheit at sea level under normal atmospheric conditions. By using a low temperature solder sleeve  16 , the need for special heating devices for melting the solder sleeve  16  is eliminated. The solder sleeve  16  is also a pre-fluxed solder member, the pre-fluxed nature of the solder sleeve  16  providing a cleansing agent to clean the various metal surfaces. 
     A heat shrinkable tubing  18 , which is a hollow tubular member, is provided and is positioned such that the tubing  18  encompasses the solder sleeve  16  and at least a portion of the barrel  14 . The tubing  18  is made from an appropriate heat shrinkable material, such as polyolefin, and has a heat shrink ratio of at least about 2 to 1. The tubing  18  may be at least partially translucent so that the connection of the terminal fixture  12  with the wire  20  can be seen and the tubing  18  may be tinted and may also have certain identification indicia printed thereon. An adhesive layer  24  is located on the inner surface of the tubing  18 . The adhesive layer  24  is heat activated and can be co-extruded with the tubing  18 . 
     A wire  20  having its insulation  22  removed from an end thereof is passed through the tubing  18 , through the solder sleeve  16 , and is received within the barrel  14 . Once so received, the barrel  14  is crimped in appropriate fashion in order to crimp the barrel  14  onto the exposed end of the wire  20 . This provides a mechanical and electrical connection of the barrel  14 , and this the terminal fixture  12 , with the wire  20 . 
     Thereafter, the tubing  18  and the solder sleeve  16  held therein are heated causing the solder sleeve  16  to melt and flow into the deformed areas of the crimped barrel  14  and wire  20 . This adds an additional layer of mechanical and electrical binding of the wire  20  with the terminal fixture  12 . Additionally, the tubing  18 , by being heated, encapsulates the barrel  14  and the wire  20  held therein. Additionally, the adhesive layer  24  melts and adhesively binds the terminal fixture  12 , the tubing  18 , the wire  20 , and a portion of the insulation member  22 . 
     While the invention has been particularly shown and described with reference to an embodiment thereof, it will be appreciated by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention.