Patent Abstract:
Devices and methods to facilitate separation of a crimped wire terminal from a tape terminal carrier strip. The devices and methods weaken the attachment between the crimped wire terminal and the tape terminal carrier strip to facilitate effective, efficient, and reliable removal of the crimped wire terminal from the tape terminal carrier strip.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority from U.S. Provisional Patent Application 61/991,009 filed on May 9, 2014. That Provisional Patent Application is herein incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates generally to the field of electrical terminal crimping machines and methodologies used in the crimp connection process. In particular, the invention relates to a device and method that facilitate effective, efficient, and reliable separation of a crimped wire terminal from a tape terminal carrier strip. 
       BACKGROUND 
       [0003]    In the electrical connector industry, a crimp connection is commonly used to fuse a wire to a wire terminal. A “wire” can be a single wire or a cable comprised of more than one wire. A wire terminal that has not yet been fused to a wire is referred to as an “uncrimped wire terminal.” A wire terminal that has been fused to a wire is referred to as a “crimped wire terminal.” 
         [0004]    Individuals desiring to create numerous crimp connections typically utilize an electrical terminal crimping machine in conjunction with a tape terminal carrier strip. A tape terminal carrier strip is a flexible tape that has numerous wire terminals attached to the tape terminal carrier strip and positioned side-by-side at evenly spaced intervals. 
         [0005]    A conventional electrical terminal crimping machine has a power system and an applicator. The power system produces or conducts the power necessary for movement of the electrical terminal crimping machine&#39;s parts and can include electric, pneumatic, or hydraulic power systems. 
         [0006]    The applicator has a feed mechanism, press assembly, and anvil, each connected to the applicator. The feed mechanism is attached to the applicator via standard fasteners and feeds the tape terminal carrier strip through the applicator. The press assembly is attached to the applicator via standard fasteners, is positioned vertically above the anvil, and has a press that is capable of engaging in vertical upward and downward motion. The anvil is attached to the applicator via a mounting hole and is located directly under the press assembly. The anvil has a crimp surface located on the top surface of the anvil. 
         [0007]    As is known in the art, to create a crimp connection that fuses an uncrimped wire terminal to a wire, the feed mechanism advances the tape terminal carrier strip so that the uncrimped wire terminal, attached to the tape terminal carrier strip, is positioned directly below the press and rests on top of the crimp surface of the anvil. The terminal end of a wire is inserted into the receiving end of the uncrimped wire terminal. The press then moves in a downward vertical direction toward the anvil. The bottom surface of the press contacts the top surface of the uncrimped wire terminal, continues in the downward vertical direction, and applying downward force, momentarily sandwiches the uncrimped wire terminal between the bottom surface of the depressed press and the crimp surface of the anvil, creating a crimp connection that fuses the wire terminal to the wire. The press then moves vertically upward to return to its original position. 
         [0008]    The feed mechanism then advances the tape terminal carrier strip laterally across the top surface of the anvil so that the newly crimped wire terminal, now fused to the wire, is no longer positioned directly below the press, thereby allowing the next successive uncrimped wire terminal attached to the tape terminal carrier strip to be positioned on the crimp surface of the anvil and located directly under the press. 
         [0009]    After the crimp connection occurs, the crimped wire terminal, now fused to the wire, must be removed from the tape terminal carrier strip for industry use. In a conventional electrical terminal crimping machine, and with the conventional crimping method, after the fusion of the wire terminal to the wire and advancement of the tape terminal carrier strip, the newly crimped wire terminal remains in a position that is perpendicular to the tape terminal carrier strip and remains tightly attached to the tape terminal carrier strip. 
         [0010]    Conventional electrical terminal crimping machine devices and crimp connection methods do not facilitate effective, efficient, or reliable removal of the crimped wire terminal from its attachment to the tape terminal carrier strip. Known adaptations for removal of a crimped wire terminal from the tape terminal carrier strip include use of a cutting tool to weaken or break the attachment between the crimped wire terminal and the tape terminal carrier strip, application of manual force to the wire to weaken or break the attachment between the crimped wire terminal and the tape terminal carrier strip, and adaptations to the feed mechanism. However, each one of these known adaptations suffers from one or more of the following disadvantages: non-productive downtime for the operator, damage to the crimped wire terminal or connected wire, damage to or jamming of the feed mechanism or tape terminal carrier strip. 
         [0011]    Therefore, there is a need to adapt the electrical terminal crimping machine, as well as the conventional methods utilized to remove a crimped wire terminal from a tape terminal carrier strip, to facilitate effective, efficient, and reliable removal of a crimped wire terminal from the tape terminal carrier strip. 
       BRIEF SUMMARY 
       [0012]    The preferred embodiments involve devices and methods for providing effective, efficient, and reliable removal of a crimped wire terminal from a tape terminal carrier strip. The devices and methods utilize an applicator for an electrical terminal crimping machine that has an anvil with a separation assistance device, in combination with advancement of the tape terminal carrier strip by the feed mechanism, to weaken the attachment between a crimped wire terminal and the tape terminal carrier strip in order to facilitate separation of a crimped wire terminal from the tape terminal carrier strip. 
         [0013]    In one preferred embodiment, the separation assistance device has a ramp. In another preferred embodiment, the separation assistance device has a traveling ramp that is able to move in the vertical direction. In another preferred embodiment, the separation assistance device has a cylindrical pin. 
         [0014]    A method is also provided for weakening the attachment between a crimped wire terminal and a tape terminal carrier strip to facilitate removal of the crimped wire terminal from the tape terminal carrier strip. The method generally includes: (1) providing a tape terminal carrier strip that has at least one uncrimped wire terminal attached to the tape terminal carrier strip, (2) feeding the tape terminal carrier strip through an electrical terminal crimping machine so that an uncrimped wire terminal rests on the top surface of an anvil and directly under a press, (3) inserting the terminal end of a wire into the receiving end of the uncrimped wire terminal positioned on the top surface of the anvil, (4) the downward vertical motion of the press, (5) the press applying downward vertical force to the top surface of the uncrimped wire terminal and momentarily sandwiching the uncrimped wire terminal and the inserted wire between the bottom surface of the depressed press and the top surface of the anvil, (6) the creation of a crimp connection that fuses the wire to the wire terminal, (7) the vertical upward movement of the press so that the press returns to its original position, (8) advancement of the tape terminal carrier strip so that the tape terminal carrier strip moves laterally across the top surface of the anvil, and (9) contact between a separation assistance device located on the anvil and the crimped wire terminal attached to the advancing tape terminal carrier strip so that the attachment between the crimped wire terminal and the tape terminal carrier strip is weakened. 
         [0015]    In one preferred embodiment, the contact between the separation assistance device and the newly crimped wire terminal attached to the advancing tape terminal carrier strip causes the newly crimped wire terminal to move from a position in which the newly crimped wire terminal is perpendicular to the tape terminal carrier strip to a position in which the newly crimped wire terminal is positioned at non-perpendicular angle in relation to the tape terminal carrier strip. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    A complete understanding of the features, aspects, and advantages of the preferred embodiments will be obtained from the following description when taken in connection with the accompanying drawing figures, wherein like reference numerals identify the same parts throughout. 
           [0017]      FIG. 1  is a front view of an electrical terminal crimping machine with an applicator that has one preferred embodiment, illustrating numerous uncrimped wire terminals all attached side-by-side to a tape terminal carrier strip, the leading uncrimped wire terminal resting on the top surface of the anvil in preparation for the crimp connection process. 
           [0018]      FIG. 2  is a perspective front view of the applicator of  FIG. 1 . 
           [0019]      FIG. 3  is a perspective front view of the applicator of  FIG. 2  and a perspective view of one preferred embodiment. 
           [0020]      FIG. 4  is a perspective front view of one preferred embodiment. 
           [0021]      FIG. 5  is a zoomed-in front view of the electrical terminal crimping machine of  FIG. 1 . 
           [0022]      FIG. 6  is a perspective side view of an electrical terminal crimping machine with an applicator that has one preferred embodiment, illustrating insertion of the terminal end of a wire into the receiving end of an uncrimped wire terminal in preparation for the crimp connection process. 
           [0023]      FIG. 7  is a perspective side view of an electrical terminal crimping machine with an applicator that has one preferred embodiment, illustrating the creation of a crimp connection between a wire terminal and wire by the downward vertical motion of the press. 
           [0024]      FIG. 8  is a perspective side view of an electrical terminal crimping machine with an applicator that has one preferred embodiment, illustrating advancement of the tape terminal carrier strip after the creation of a crimp connection and contact between one preferred embodiment and the newly crimped wire terminal. 
           [0025]      FIG. 9A  is a perspective front view of another preferred embodiment. 
           [0026]      FIG. 9B  is a perspective front view of yet another preferred embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0000]    
       
           10  electrical terminal crimping machine 
           11  press assembly 
           12  applicator 
           13  press 
           14  tape terminal carrier strip 
           15  anvil 
           16  uncrimped wire terminal 
           17  feed mechanism 
           18  feed holes 
           22  key 
           24  mounting hole 
           28  separation assistance device 
           30  ramp 
           32  cylindrical pin 
           34  traveling ramp 
           36  wire 
           38  crimped wire terminal 
           40  crimp surface 
       
     
         [0045]    Referring now to the drawings,  FIG. 1  shows an electrical terminal crimping machine, generally designated  10 . The electrical terminal crimping machine  10  contains a power supply and an applicator  12 . As shown in  FIGS. 1 and 8 , the applicator  12  has the various mechanical parts necessary to perform a crimp connection, including a feed mechanism  17 . A tape terminal carrier strip  14  having numerous evenly-spaced uncrimped wire terminals  16 , each attached to the tape terminal carrier strip  14 , is attached to the applicator  12  via the feed mechanism  17 . 
         [0046]    The feed mechanism  17  feeds the tape terminal carrier strip  14  through the applicator  12  of the electrical terminal crimping machine  10 . In one preferred embodiment, the feed mechanism  17  feeds the tape terminal carrier strip  14  through the applicator  12  of the electrical terminal crimping machine  10  via feed holes  18  located on the tape terminal carrier strip  14 . 
         [0047]    As shown in  FIG. 2 , the applicator  12  has a press assembly  11  and an anvil  15 . The press assembly  11  is attached to the applicator  12  via at least one standard fastener. The press assembly  11  has a press  13  that is moveable in the vertical upward and downward directions as shown in  FIG. 7 . 
         [0048]    As shown in  FIG. 3 , the anvil  15  is attached to the applicator  12  via a mounting hole  24 . As shown in  FIG. 4 , the anvil  15  has a key  22 , a crimp surface  40 , and a separation assistance device  28 . The key  22  helps to ensure that the anvil  15  is properly attached to the applicator  12  and positioned directly under the press  13 . The crimp surface  40  of the anvil  15  could correspond to the type, size, and shape of uncrimped wire terminal  16  attached to the tape terminal carrier strip  14 . 
         [0049]    In one preferred embodiment, the separation assistance device  28  has a ramp  30 . In one preferred embodiment, the ramp  30  has a rounded element. There are various possibilities for the orientation and angles of the top surface of the ramp  30  depending on the type, size, and shape of the uncrimped wire terminal  16  and wire  36  utilized in the crimp connection process. 
         [0050]    As shown in  FIG. 5 , during the crimp connection process, the tape terminal carrier strip  14  containing at least one uncrimped wire terminal  16 , and sometimes numerous attached uncrimped wire terminals  16 , is fed through the applicator  12  so that the leading uncrimped wire terminal  16  attached to the tape terminal carrier strip  14  rests on top of the crimp surface  40  of the anvil  15  in preparation for the crimp connection process. In one preferred embodiment, the press  13  also has a crimp surface  40 . The crimp surface  40  of the press could correspond to the type, size, and shape of uncrimped wire terminal  16 . 
         [0051]    As shown in  FIG. 6 , in general operation of an electrical terminal crimping machine  10 , an operator places the terminal end of a wire  36  into the receiving end of an uncrimped wire terminal  16  that is resting on top of the crimp surface  40  of the anvil  15  in preparation for the crimp connection process. 
         [0052]    As shown in  FIG. 7 , the press  13  moves vertically downward toward the anvil  15 , contacts the top surface of the uncrimped wire terminal  16 , and applying downward force, momentarily sandwiches the uncrimped wire terminal  16  between the bottom surface of the depressed press  13  and the crimp surface  40  of the anvil  15 , thereby creating a crimp connection and fusing the uncrimped wire terminal  16  to the wire  36 . 
         [0053]    As shown in  FIG. 8 , the press  13  then moves vertically upward to its original starting position while the feed mechanism  17  advances the tape terminal carrier strip  14  through the applicator  12  of the electrical terminal crimping machine  10 , and moves the newly crimped wire terminal  38  laterally away from the crimp surface  40  of the anvil  15  and across the top surface of the anvil  15 , thereby positioning the next successive uncrimped wire terminal  16  attached to the tape terminal carrier strip  14  directly on top of the crimp surface  40  of the anvil  15  in preparation for the crimp connection process. During this lateral advancement motion initiated by the feed mechanism  17 , the separation assistance device  28  contacts the crimped wire terminal  38  that is still attached to the tape terminal carrier strip  14 , and applies angular force to the newly crimped wire terminal  38 . This angular force applied by the separation assistance device  28  weakens the crimped wire terminal&#39;s  38  attachment to the tape terminal carrier strip  14 . 
         [0054]    As shown in  FIG. 8 , in one preferred embodiment, at the end stage of the lateral advancement movement initiated by the feed mechanism  17 , the newly crimped wire terminal  38  rests on top of the separation assistance device  28  so that the newly crimped wire terminal  38  is positioned at a non-perpendicular angle in relation to the tape terminal carrier strip  14  and prepared for separation from the tape terminal carrier strip  14 . The newly crimped wire terminal  38  that has a weakened attachment to the tape terminal carrier strip  14  is then separated from the tape terminal carrier strip  14  either by manual force or other separating means. 
         [0055]    As shown in  FIG. 9A , another preferred embodiment has an anvil  15  with a separation assistance device  28  that has a traveling ramp  34 . The traveling ramp  34  is able to move in the vertical direction, and is able to be under various tensions. The traveling ramp  34  applies an upward angular force to the crimped wire terminal  38  as the crimped wire terminal  38  moves laterally across the top surface of the anvil  15  so that the crimped wire terminal&#39;s  38  attachment to the tape terminal carrier strip  14  is weakened in preparation for removal of the crimped wire terminal  38  from the tape terminal carrier strip  14 . In one preferred embodiment, the top surface of the traveling ramp  34  has a rounded element as shown in  FIG. 9A . There are various possibilities for the orientation and angles of the top surface of the traveling ramp  34  depending on the type, shape, and size of the uncrimped wire terminal  16  and wire  36  utilized in the crimp connection process. In one preferred embodiment, the traveling ramp  34  is limited by a mechanical stop (not shown) so that the separation assistance device  28  is prevented from interfering with the crimped wire terminal  38  and attached wire  36 . 
         [0056]    As shown in  FIG. 9B , another preferred embodiment has an anvil  15  with a separation assistance device  28  that has a cylindrical pin  32 . The cylindrical pin  32  could be positioned laterally to the crimp surface  40  of the anvil  15  and below the top surface of the crimp surface  40  of the anvil  15  so that the cylindrical pin  32  applies a force to the crimped wire terminal  38  as the crimped wire terminal  38  moves laterally across the top surface of the separation assistance device  28  and thereby weakens the attachment of the crimped wire terminal  38  to the tape terminal carrier strip  14 . There are various possibilities for the orientation of the cylindrical pin  32  depending on the type, shape, and size of the uncrimped wire terminal  16  and wire  36  utilized in the crimp connection process. 
         [0057]    The present examples and embodiments are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.

Technology Classification (CPC): 8