Patent Publication Number: US-10763632-B2

Title: Single compression multiple impression crimp tool

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This patent application claims the benefit of U.S. Provisional Patent Application No. 62/393,921 filed on Sep. 13, 2016, which is incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The embodiments described herein relate to crimping tools. 
     BACKGROUND 
     A crimping tool is a device that joins one or more pieces of conductors to a connector by deforming the conductor in a manner that causes the conductor to be secured to the connector. The one or more pieces of conductor may be joined together via a connector such as a compression lug. The compression lug includes a barrel with a hole at one end of the barrel for receiving a conductor such as wiring or cable. The other end of the barrel may terminate into a terminal that can be secured to a circuit or to a terminal of another compression lug. Alternatively, rather than terminating into a terminal, the other end of the barrel may include another hole for receiving another piece of wiring or cable. 
     A crimp tool is used to crimp the barrel of the compression lug to secure the compression lug to the conductor inserted into the compression lug. For example, a Y46 industry standard crimping tool is used to crimp the barrel of the compression lug. Generally, conventional Y46 industry standard crimp tools include a die that creates an impression on the compression lug in order to secure the compression lug to the conductor inserted into the compression lug. 
     To create the impression, a conventional Y46 standard crimp tool applies force to the die which is pressed on the compression lug to create a single impression on the compression lug. However, a single impression on the compression lug is insufficient to adequately secure the conductor to the compression lug. Thus, a conventional Y46 standard crimp tool must apply multiple compressions using the die to create multiple impressions on the compression lug that are sufficient to secure the conductor to the compression lug. Since multiple compressions must be applied to the compression lug, the impressions on the compression lug may be unevenly spaced due to human error in repositioning the compression lug for each compression. Accordingly, conventional Y46 standard crimp tools are inefficient and inaccurate. 
     SUMMARY 
     The embodiments herein describe a crimp tool used to crimp metal. The crimp tool applies a single compression on a connector to create multiple impressions on the connector that are sufficient to secure the connector to conductor that is inserted into the connector. In one embodiment, the crimp tool includes a plurality of die. Each die includes a plurality of impression teeth that are used to make multiple impressions on the connector using a single compression of the plurality of die. As pressure is applied to the plurality of die, multiple impressions are formed around the connector as the plurality of die clamp around the connector thereby securing the connector to the conductor that is inserted into the connector. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  illustrates an isometric frontal view of a crimping tool according to one embodiment. 
         FIG. 1B  illustrates a front view of the crimping tool in the open position according to one embodiment. 
         FIG. 2  illustrates a detailed view of the die included in the crimping tool according to one embodiment. 
         FIG. 3  illustrates a cross-sectional view of the crimping tool according to one embodiment. 
         FIG. 4  illustrates a frontal view of the crimping tool in the closed position according to one embodiment. 
         FIG. 5  illustrates an isometric rear view of the crimping tool according to one embodiment. 
         FIG. 6  illustrates a view of the compression lug in the crimping tool according to one embodiment. 
         FIGS. 7A and 7B  illustrate a different views of the compression lug after crimping according to one embodiment. 
         FIG. 8  illustrates a method of crimping metal using the crimping tool according to one embodiment. 
     
    
    
     The figures depict, and the detail description describes, various non-limiting embodiments for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles described herein. 
     DETAILED DESCRIPTION 
     The embodiments herein describe a crimp tool used to crimp metal. More specifically, the present disclosure is described with respect to an electrical compression lug crimp tool. However, the embodiments herein may be applicable to any other crimp tool that requires multiple impressions to secure a conductor to a connector. 
     In one embodiment, the crimp tool can apply a single compression to a connector to create multiple impressions on the connector that are required to secure the connector to a conductor that is inserted into the connector. Since the crimp tool can make multiple impressions on the connection through a single compression of the connector, the crimp tool can create more uniform impressions on the connector compared to conventional Y46 standard hydraulic crimp tools and are more efficient than conventional Y46 standard hydraulic crimp tools since only a single compression of the crimp tool is required to create multiple impressions. 
     Single Compression, Multiple Impression Crimp Tool 
       FIGS. 1A and 1B  respectively show an isometric frontal view and a frontal view of a crimp tool  100  while in the open position according to one embodiment. The crimp tool  100  can be configured in an “open” position or a “closed” position. While in the open position, the crimp tool  100  is ready to receive a connector for crimping according to one embodiment. While in the closed position, the crimp tool  100  applies pressure on the connector positioned within the crimp tool  100  to create multiple impressions on the connector using a single compression of the connector. In other words, while in the closed position the crimp tool  100  creates crimps on the connector that secure the connector to wiring or cable that is inserted into the connector. 
     The crimp tool includes a housing  101 . The housing  101  is the frame of the crimp tool that supports the different components of the crimp tool  100  that are within the housing  101 . Generally, the housing  101  is made of metal such as steel, but other metals can be used in other embodiments. 
     In one embodiment, the housing  101  includes multiple walls  101 A,  101 B,  101 C, and  101 D. Wall  101 A is the right wall of housing  101  and wall  101 B is the left wall of housing  101 . Wall  101 A and wall  101 B may each be a ¾ inch metal plate with a length of 11⅛ inches and a width of 5¼ inches, for example. Wall  101 C is the top wall of housing  101  and may be a 1 inch metal plate with a length of 6 inches and width of 5¼ inches, for example. Wall  101 D is the bottom wall of housing  101  and may be a ¾ inch metal plate with a length of 10 inches and a width of 5¼ inches, for example. 
     As shown in  FIGS. 1A and 1B , the housing  101  is made of multiple pieces that are secured together via fasteners such as screws, rivets, or nuts and bolts. While the walls  101  are connected to each other, the housing has a rectangular shape. Note that in other embodiments, the housing  101  is formed of a single piece of metal rather than from multiple metal plates. For example, a single piece of metal may be milled to form the housing  101  rather than use multiple pieces of metal to form the housing  101 . 
     The crimp tool  100  also includes a plurality of die  103  that create impressions on a connector  107  (e.g., a compression lug) that is placed in the crimp tool  100 . Specifically, the crimp tool  100  includes an upper die  103 A and lower die  103 B. The upper die  103 A is positioned over the lower die  103 B and the lower die  103 B is positioned under the upper die  103 A as shown in  FIGS. 1A and 1B . As shown in  FIGS. 1  A and  1 B, the connector  107  is placed on the lower die  103 B for crimping. 
     In one embodiment, each die  103  includes a plurality of alternating rows of impression teeth and indentations. The alternating rows of impression teeth are used to form the impressions on the connector  107  positioned within the crimp tool  100  as described in detail with respect to  FIG. 2 . Each die  103  includes at least two rows of impression teeth to form at least two impressions on the connector  107 . 
       FIG. 2  illustrates a detailed view of the lower die  103 B according to one embodiment. Note that the upper die  103 A is substantially identical to the lower die  103 B and the description of the lower die  103 B is applicable to the upper die  103 A. The lower die  103 B is a metal block such as steel that is rectangular in shape. The lower die  103 B includes impression teeth  201 A,  201 B,  201 C, and  201 D and indentations  203 A,  203 B,  203 C,  203 D, and  203 E formed along the length of the lower die  103 B. The impression teeth  201  and the indentations  203  are alternately formed such that each impression tooth  201  is positioned between a pair of indentations  203 . The impression teeth  201  and indentations  203  are formed by milling the impression teeth  201  and indentations  203  into the lower die  103  using a milling machine for example. Compared to the indentations  203 , the impression teeth  201  are formed with a smaller radius than the indentations  203  so that the impression teeth  201  protrude from the die  103 . As shown in  FIG. 2 , the impression teeth  201  and indentations  203  are formed with a “U” shape. Lower die  103 B and upper die  103 B are considered “U-die” given the shape of the impression teeth  201 A and indentations  203 B. Note that in other embodiments, other die shapes may be used. 
     Referring to  FIG. 3 , a cross-sectional view of the crimp tool  100  is shown according to one embodiment. Each impression tooth  201  of the upper die  105 A is vertically aligned with a corresponding impression tooth of the lower die  105 B. By aligning the impression teeth  201  of the upper die  105 A and the lower die  105 B, the impression teeth can  201  form impressions on the connector  107  when the die  105  are clamped around the connector  107 . 
     In one embodiment, at least one of the upper die  103 A and lower die  103 B include an imprint of the die index associated with the die  103 . The die index is an industry standard that specifies the specific die and metal (e.g., wire) that should be used with the connector  107 . In one embodiment, the imprint on one of the upper die  103 A and the lower die  103 B is a protrusion that causes the logo of the die index to be imprinted upon the connector  107  when the die  103  are compressed around the connector  107 . Each die may include a single imprint of the die index or multiple imprints of the die index. 
     Referring back to  FIGS. 1A and 1B , the crimp tool  100  also includes a plurality of die holders  105  that are configured to hold the plurality of die  103 . Specifically, the crimp tool  100  includes an upper die holder  105 A and a lower die holder  105 B. Each die holder  105  is configured to connect to a corresponding die  103  from the plurality of die mentioned above. For example, upper die holder  105 A is connected to upper die  103 A and lower die holder  105 B is connected to die  103 B. Each die  103  may be connected to its corresponding die holder  105  via a connecting mechanism such as a cam spring detent. The connecting mechanism is used to connect and disconnect a die holder  105  from a die  103 . Since each die holder  105  is configured to be detachable from its corresponding die, the die holders  105  can be connected to die having different die indexes that are required depending on the size of the connector  107  needing crimping. 
     In one embodiment, the die holders  105  are made of metal such as steel. However, the die holders  105  may be made of other types of metal in other embodiments. The die holders  105  are rectangular in shape and each die holder  105  includes a slot  115  along the length of the die holder  105 . In one embodiment, a die  103  is connected to a die holder  105  within the slot  115  of the die holder  105 . The slot  115  is created in each die holder  105  my milling out a portion of the die holder  105 . 
     In one embodiment, each die holder  105  includes a spring hole  119  at each side of the slot for placement of springs  111 . For example, a first spring hole is formed to the left of the slot  115  between the ends of the die holder  105  and a second spring hole is formed to the right of the slot  115  between the ends of the die holder  105 . Each spring hole  119  is formed only partially through the thickness of the die holder  105  such as halfway through the thickness of the die holder  105 . 
     In one embodiment, the lower die holder  105 B is connected to the housing  101  via fasteners  109  such as screws and rivets. As shown in  FIG. 1B , the lower die holder  105 B is in contact with the right wall  101 A, left wall  101 B, and bottom wall  101  D of the housing  101 . The lower die holder  105  has a width that is slightly smaller than the opening width of the housing  101 . By having a slightly smaller width than the opening width of the housing  101 , the lower die holder  105 B has a tight fit within the housing so that the lower die holder  105 B does not move while the crimp tool  100  is in use. 
     As shown in  FIGS. 1A and 1B , the upper die holder  105 A is positioned over the lower die holder  103 B. In one embodiment, the upper die holder  105 A is narrower in width than the lower die holder  105 B. The upper die holder  105 A is narrower in width than the lower die holder  105  as the upper die holder  105 A requires freedom to move in the vertical direction in order to press the upper die  103 A onto the connector  107 . 
     The upper die holder  105 A is supported by a plurality of springs  111  that are placed within the spring holes formed in the upper and lower die holders  105 . The plurality of springs  111  respectively support the left and right sides of the upper die holder  105 B so that the upper die holder  105  is suspended above the lower die holder  105 B. The springs  111  return the upper die holder  105 A to the open position as shown in  FIGS. 1A and 1B  after the upper die holder  105 A is compressed by the hydraulic cylinder  113  described below. The springs  111  may have a spring force of 200-250 lb/ft in one embodiment. 
     For example, a first spring  111 A includes a first end and a second end. The first end of the first spring  111 A is placed into the first spring hole in the upper die holder  105 A and the second end of the first spring  111 A is placed into the first spring hole in the lower die holder  105 B. Similarly, the first end of the second spring  111 B is placed into the second spring hole in the upper die holder  105 A and the second end of the second spring  111 B is placed into the second spring hole in the lower die holder  105 B. 
     The upper die holder  105 A is secured over the springs  111  via alignment bolts  116 . In one embodiment, each alignment bolt  116  is arranged through an alignment bolt hole  118  in each corner of the upper die holder  105 A and is threaded into a corresponding alignment bolt hole located in a corner of the lower die holder  105 B. The alignment bolts  116  may be torqued with enough force to slightly compress the springs  111  (e.g., 10 lb/ft). 
     As mentioned above, the crimp tool  100  further includes a hydraulic cylinder  113  that applies force to the upper die holder  105 A. Although a hydraulic cylinder is used in the crimp tool, other types of cylinders may be used such as a pneumatic cylinder. The hydraulic cylinder  113  applies force to the upper die holder  105 A via a piston  401  that extends from the hydraulic cylinder  113  as shown in  FIG. 4 . The hydraulic cylinder  113  may apply up to 50 tons of force to the upper die holder  105 A. The hydraulic cylinder  113  may be connected to the upper wall  101 C via fasteners. 
     Referring to  FIG. 5  showing an isometric rear view of the crimp tool  100 , the hydraulic cylinder  113  includes a hydraulic coupler  501  for connecting the hydraulic cylinder  113  to a hydraulic hose (not shown). As the hydraulic hose applies hydraulic fluid to the hydraulic cylinder  113 , hydraulic fluid within the hydraulic cylinder  113  is displaced thereby causing the piston  401  to extend from the hydraulic cylinder  113  shown in  FIG. 4 . As the piston  401  extends from the hydraulic cylinder  113 , the piston  401  moves the upper die holder  105 A vertically downward. The alignment bolts  116  guide the upper die holder  105 A in a vertical manner as the piston  401  applies force to the upper die holder  105 A. That is, the alignment guide bolts  116  guide the upper die holder  105 A along a pre-determined vertical path that corresponds to the length of the alignment bolts  116 . 
     The hydraulic cylinder  113  moves the upper die holder  105 A from the open position shown in  FIGS. 1A and 1B  to the closed position shown in  FIG. 4  as the piston  401  applies force to the upper die holder  105 A. In the closed position of the crimp tool  100 , the impression teeth  201  of the upper and lower die  103  clamp around the connector  107  and squeeze the connector  107  thereby forming a plurality of impressions around the connector  107  using a single compression of the connector  107 . In one embodiment, the crimp tool  100  is maintained in the closed position for a threshold amount of time (e.g., 5 seconds) before the hydraulic cylinder  113  retracts the piston  401  in order to ensure that the impressions are formed around the connector  107 . After the hydraulic cylinder  113  releases pressure, the piston  401  retracts and the spring force of the springs  111  move the upper die holder  105 A back to the open position shown in  FIGS. 1A and 1B . After the impressions are formed around the connector  107 , the connector  107  is now secured to the conductor (e.g., wiring or cable) inserted into the connector  107  from the resulting ridges formed within the conductor and connector  107 . 
     Referring to  FIGS. 6 and 7A and 7B , the connector  107  includes a plurality of impressions  601 A- 601 D as a result of the die  103  being compressed around the connector  107 . The impressions  601  are evenly spaced apart from each other according to the spacing of the plurality of impression teeth  201  included in the die  103 . Furthermore,  FIGS. 7A and 7B  also illustrate that the connector  107  includes the logo  701  of the die index of the die  103  used to create the impressions  601 . By including the logo  701  of die index on the connector  107 , a person can visually verify that the correct die was used to crimp the connector  107 . As shown in  FIGS. 7A and 7B , a plurality of logos (e.g., “24”)  701 A- 701 D of the die index of the die used to create the impressions on the connector are included on the connector  107 . Each logo  701  is associated with a corresponding impression on the connector  107  and visually indicates the die index of the die used to create the impression on the connector. For example, logo  701 D indicates the index of the die used to create impression  601 A and logo  701 B indicates the index of the die (e.g., “24”) used to create impression  601 B and so on. Each logo  601  is positioned within the impression on the connector  107 . In alternative embodiments, the connector  107  includes a single logo of the die index on the connector  107 . In one embodiment, the logo  701  is only included on one side of the connector  107  or is included on both sides of the connector  107 . 
     Referring back to  FIG. 5 , in one embodiment the crimp tool  100  also includes a positioning platform  503 . The positioning platform  503  is made of metal such as steel, but can be made of any type of metal. In one embodiment, the positioning platform  503  has a horizontal part and a vertical part that are positioned 90 degrees from each other to form an “L” shape. The horizontal part includes slots  505  through the thickness of the positioning platform  603  and span across a width of the horizontal part (e.g., 75 percent of the width). The horizontal part of the positioning platform  503  is connected to the lower wall  101 D of the housing  101  via fasteners placed through the slots  505 . 
     In one embodiment, the positioning platform  503  is used to move the connector  107  into the correct position for crimping within the crimping tool  100 . One end of the connector  107  is abutted against the positioning platform  503  and the positioning platform  503  is moved horizontally to position of the connector  107  within the crimping tool  100 . The slots  505  function as a guide to restrict the movement of the positioning platform  503  along a predetermined path. 
     Method for Single Compression, Multiple Impression Crimping 
       FIG. 8  illustrates one embodiment of a method for crimping a connector using the crimp tool  100  shown in  FIGS. 1 through 7 . Note that in other embodiments, additional steps may be included other than the steps shown in  FIG. 8 . 
     In one embodiment, the method for crimping a connector  107  includes providing  801  a crimp tool  100  that includes a plurality of die  103  where each die includes a plurality of impression teeth  201 . The plurality of die  103  include an upper die  103 A and a lower die  103 B. The plurality of impression teeth  201  are used to create multiple impressions on the connector  107 . The connector  107  is placed  803  within the crimp tool  100 . Specifically, the connector  107  is placed on the lower die  103 B. Pressure is applied  805  on the plurality of die  103  to compress the connector  107 . That is, the hydraulic cylinder  113  applies  805  pressure to a piston  401  that presses down on the upper die  103 A. As the upper die  103 A is pressed downward, the impression teeth  201  of the upper die  103 A contact the connector. As pressure is applied to the die, the impression teeth  201  of the upper die  103 A and the lower die  103 B form impressions around the connector  107 . The impressions secure the connector  107  to a wire or cable that is inserted in the connector. The pressure is released  807  from the plurality of die  103  after the impressions are made around the connector  107 . The connector  107  is then removed  807  from the crimp tool  100 . 
     Although this description has been provided in the context of specific embodiments, those of skill in the art will appreciate that many alternative embodiments may be inferred from the teaching provided. Furthermore, within this written description, the particular naming of the components, capitalization of terms, the attributes, data structures, or any other structural or programming aspect is not mandatory or significant unless otherwise noted, and the mechanisms that implement the described invention or its features may have different names, formats, or protocols. 
     Finally, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter. Accordingly, the disclosure is intended to be illustrative, but not limiting, of the scope of the invention.