Patent Description:
A hand tool generally includes a crimp tooling and locator holding a terminal. The locator locates the terminal in a precise position with respect to the crimp tooling to permit the hand tool to properly crimp the terminal. The locator has a number of small volumes holding the terminal and other elements that allow the terminal to be precisely positioned. Manufacturing these small volumes with the required precision, however, requires the use of highly accurate manufacturing methods, which increases the cost of producing the hand tool with the locator.

<CIT> discloses a handheld crimping tool comprising a locator. The locator comprises a fixing plate and a pivoting plate that is pivotably mounted to the fixing plate and includes a terminal receiving nest. The pivoting plate may optionally be provided with a permanent magnet that is configured to releasably secure the pivoting plate in a closed position with respect to the fixing plate.

The present invention provides a terminal locator for a hand tool comprising a base, a magnet, and a holder attached to the base and rotatable with respect to the base between an open position and a closed position. The holder has a magnet passageway, a resilient latch retaining the magnet in the magnet passageway, and an insertion passageway extending into the holder perpendicular to the magnet passageway. The magnet is held between the resilient latch and a projection on a bottom surface of the magnet passageway.

The invention will now be described by way of example with reference to the accompanying Figures, of which:.

A hand tool <NUM> according to an embodiment, as shown in <FIG>, comprises a pair of levers <NUM>, a pair of tool frames <NUM> connected to the pair of levers <NUM>, and a terminal locator <NUM> connected to one of the pair of tool frames <NUM>.

The pair of levers <NUM> include a first lever <NUM> and a second lever <NUM>, as shown in <FIG>. The pair of tool frames <NUM> include a first tool frame <NUM> connected to the first lever <NUM> and a second tool frame <NUM> connected to the second lever <NUM>. The pair of levers <NUM> are pivotable with respect to one another, and pivoting motion of the levers <NUM> moves the pair of tool frames <NUM> toward and away from each other.

The terminal locator <NUM>, as shown in <FIG>, has a base <NUM> attached to the first tool frame <NUM> and a holder <NUM> attached to the base <NUM>.

The base <NUM>, as shown in <FIG>, has an upper surface <NUM> and a lower surface <NUM> opposite the upper surface <NUM>. The base <NUM> has a plurality of standoffs <NUM> protruding from the upper surface <NUM>. In the embodiment shown in <FIG>, each of the standoffs <NUM> has a sloped side <NUM>; the standoffs <NUM> have a larger cross-sectional area at the upper surface <NUM> of the base <NUM> than at an end of the standoff <NUM> opposite the upper surface <NUM> due to the sloped side <NUM>. The base <NUM> has two standoffs <NUM> in the shown embodiment. In other embodiments, the base <NUM> may have only one standoff <NUM> or may have more than two standoffs <NUM>. The base <NUM>, as shown in <FIG>, has a fastener opening <NUM> extending into the upper surface <NUM>.

In the embodiment shown in <FIG>, the base <NUM> is monolithically formed in a single piece with the upper surface <NUM>, the lower surface <NUM>, the standoffs <NUM>, and the fastener opening <NUM>. These portions of the base <NUM> may be formed by molding, for example, by injection molding.

The base <NUM>, as shown in <FIG>, has a pivot shaft <NUM> extending along a side of the base <NUM>. In the shown embodiment, the pivot shaft <NUM> is fixed with respect to the base <NUM>. In other embodiments, the pivot shaft <NUM> may be rotatable with respect to the base <NUM>.

The holder <NUM>, as shown in <FIG>, <FIG>, has an interior surface <NUM> and an exterior surface <NUM> opposite the interior surface <NUM>. The holder <NUM> has a magnet passageway <NUM> extending into the interior surface <NUM> and a resilient latch <NUM> surrounding the magnet passageway <NUM>, as shown in the embodiments of <FIG>. The resilient latch <NUM> has a protrusion <NUM> at an end of the resilient latch <NUM>. In the embodiments shown in <FIG>, the protrusion <NUM> has a flat side <NUM> and a chamfer side <NUM> opposite the flat side <NUM>.

A magnet <NUM>, shown in <FIG> and <FIG>, is positioned and retained in the magnet passageway <NUM>. Different embodiments of the insertion of the magnet <NUM> and retention of the magnet <NUM> by the resilient latch <NUM> are shown in <FIG>.

In the embodiment not according to the invention, shown in <FIG>, the resilient latch <NUM> has a plurality of latch segments <NUM> identical to one another and separated around a circumference of the magnet passageway <NUM>. As shown in the magnified portion M1, the holder <NUM> has a latch recess <NUM> positioned adjacent each of the latch segments <NUM> of the resilient latch <NUM>, on a side of the resilient latch <NUM> opposite the magnet passageway <NUM>. The resilient latch <NUM>, at each of the latch segments <NUM>, is elastically deformable in a deformation direction D toward the latch recess <NUM>.

In the embodiment shown in <FIG>, the magnet <NUM> contacts the chamfer side <NUM> of each of the latch segments <NUM> of the resilient latch <NUM> and deflects the resilient latch <NUM> in the deformation direction D as the magnet <NUM> is inserted into the magnet passageway <NUM>. When the magnet <NUM> is inserted to a position abutting a bottom surface <NUM> of the magnet passageway <NUM>, the latch segments <NUM> of the resilient latch <NUM> elastically return to an undeformed position with the flat side <NUM> abutting the magnet <NUM>, as similarly shown in the embodiment of <FIG>, retaining the magnet <NUM> in the magnet passageway <NUM>.

In the embodiment shown in <FIG>, the holder <NUM> has an insertion passageway <NUM> extending into the holder <NUM> in a direction perpendicular or approximately perpendicular to the magnet passageway <NUM>. The resilient latch <NUM> in the embodiment of <FIG> extends continuously around the circumference of the magnet passageway <NUM>. The bottom surface <NUM> of the magnet passageway <NUM> has a projection <NUM> extending into the magnet passageway <NUM> in the embodiment of <FIG>.

The magnet <NUM> is inserted into the insertion passageway <NUM> in the embodiment of <FIG>. The magnet <NUM> moves along the insertion passageway <NUM> into contact with the projection <NUM>. Contact of the magnet <NUM> with the projection <NUM> tilts the magnet <NUM> and pushes the magnet <NUM> against the resilient latch <NUM>, deflecting the resilient latch <NUM> in the deformation direction D shown in the magnified portion M2 in <FIG>. When the magnet <NUM> is inserted to a position centered on the projection <NUM>, the resilient latch <NUM> elastically returns to an undeformed position with the flat side <NUM> abutting the magnet <NUM>. The magnet <NUM> is held between the resilient latch <NUM> and the projection <NUM>, retaining the magnet <NUM> in the magnet passageway <NUM>.

The holder <NUM>, as shown in <FIG>, <FIG>, and <FIG>, has a plurality of terminal receiving passageways <NUM> extending into the holder <NUM>. The terminal receiving passageways <NUM> extend into the interior surface <NUM> and, in the embodiment shown in <FIG>, extend through the holder <NUM> to the exterior surface <NUM> in a longitudinal direction L of the terminal receiving passageways <NUM>.

Each of the terminal receiving passageways <NUM>, as shown in <FIG>, has a pair of inner walls <NUM>, <NUM> extending along the longitudinal direction L. The pair of inner walls <NUM>, <NUM> include an upper inner wall <NUM> and a lower inner wall <NUM> opposite the upper inner wall <NUM> in a height direction H perpendicular to the longitudinal direction L. The terminal receiving passageway <NUM> has a retention element <NUM> disposed on one of the pair of inner walls <NUM>, <NUM> and extending into the terminal receiving passageway <NUM>. The retention element <NUM> narrows a height <NUM> of the terminal receiving passageway <NUM> in the height direction H. Various embodiments of the retention element <NUM> are shown in <FIG>.

In the embodiment shown in <FIG>, the retention element <NUM> is a step <NUM> on the upper inner wall <NUM> extending into the terminal receiving passageway <NUM>.

In the embodiment shown in <FIG>, the retention element <NUM> is a curved shape <NUM> of each of the upper inner wall <NUM> and the lower inner wall <NUM> along the longitudinal direction L. In another embodiment, the curved shape <NUM> may be on only one of the inner walls <NUM>, <NUM>.

In the embodiment shown in <FIG>, the retention element <NUM> is an elastic portion <NUM> of the upper inner wall <NUM>. The holder <NUM> has an elastic recess <NUM> positioned adjacent the elastic portion <NUM> in the height direction H. The elastic portion <NUM> is elastically deformable in an elastic direction E parallel to the height direction H toward the elastic recess <NUM>. In the embodiment shown in <FIG>, the terminal receiving passageway <NUM> extends into the interior surface <NUM> but does not extend to the exterior surface <NUM>.

Each of the terminal receiving passageways <NUM> receives a terminal <NUM>, as shown in <FIG>, <FIG>. The retention element <NUM>, according to the various embodiments described above with reference to <FIG>, retains and positions the terminal <NUM> in the terminal receiving passageway <NUM> at the narrowed height <NUM>. In the embodiments of <FIG> and <FIG>, the step <NUM> and the curved shape <NUM>, respectively, retain and position the terminal <NUM> as the terminal <NUM> is inserted into the terminal receiving passageway <NUM>. In the embodiment shown in <FIG>, the terminal <NUM> inserted into the terminal receiving passageway <NUM> deflects the elastic portion <NUM> in the elastic direction E. The elastic portion <NUM> applies an elastic force on the terminal <NUM>, retaining and positioning the terminal <NUM> in the terminal receiving passageway <NUM> by an interference fit.

In each of the embodiments shown in <FIG>, the retention element <NUM> prevents movement of the terminal <NUM> in the terminal receiving passageway <NUM> in a lateral direction T shown in <FIG> that is transverse to the longitudinal direction L and the height direction H. In directions other than the lateral direction T, the retention element <NUM> of the embodiment of <FIG> differs in restriction of movement of the terminal <NUM> from the embodiments of <FIG>, as will now be described in greater detail.

The retention element <NUM> formed as the step <NUM> in the embodiment of <FIG> further prevents movement of the terminal <NUM> in a pivot plane P. The pivot plane P spans the longitudinal direction L and the height direction H and is perpendicular to the lateral direction T.

The retention element <NUM> shown in the embodiments of <FIG> retains the terminal <NUM> at the narrowed height <NUM> with either a larger space on both ends of the narrowed height <NUM>, as in <FIG>, or the elastic portion <NUM> creating the narrowed height <NUM>, as in <FIG>. The retention element <NUM> in the embodiments shown in <FIG>, while preventing movement of the terminal <NUM> in the lateral direction T, permits a pivoting movement V of the terminal <NUM> within the terminal receiving passageway <NUM> along the pivot plane P.

The terminal receiving passageway <NUM>, as shown in <FIG>, <FIG>, and <FIG>, is formed of a plurality of cavity features <NUM> in a cross-sectional plane X transverse to the longitudinal direction L. The cavity features <NUM> include a main cavity feature <NUM> and a plurality of extension cavity features <NUM> connected to the main cavity feature <NUM>. In the shown embodiment, each of the cavity features <NUM> has a quadrilateral shape in the cross-sectional plane X. The main cavity feature <NUM> receives the terminal <NUM> and the extension cavity features <NUM> do not receive a portion of the terminal <NUM>.

In the embodiment shown in <FIG>, the terminal locator <NUM> includes an insert <NUM> disposed in each of the extension cavity features <NUM>. In another embodiment, the insert <NUM> may only be disposed in one of the extension cavity features <NUM>. The insert <NUM> aids in the positioning of the terminal <NUM> in the terminal receiving passageway <NUM>. In the embodiment shown in <FIG>, the inserts <NUM> help position the terminal <NUM> in the lateral direction T. In an embodiment, the insert <NUM> is a piece of metal, for example a piece of sheet metal, and is precision sized to fit in the extension cavity feature <NUM>. The insert <NUM> may be precision sized, for example, by photo chemical etching. In other embodiments, the insert <NUM> could be formed of other materials, such as plastics, that permit precision sizing.

In another embodiment shown in <FIG>, the holder <NUM> includes a compliant section <NUM> and a rigid section <NUM> attached to the complaint section <NUM>. The terminal receiving passageway <NUM> extends into the rigid section <NUM>. The compliant section <NUM> connects the rigid section <NUM> to a remainder of the holder <NUM>. The compliant section <NUM> is structured to elastically deform under an applied force; the rigid section <NUM>, although not deforming itself, moves with the deformation of the complaint section <NUM> to which it is attached. In the shown embodiment, the compliant section <NUM> is a linkage connecting the rigid section <NUM> to a remainder of the holder <NUM>. In another embodiment, the compliant section <NUM> is a sponge structure. In an embodiment, the compliant section <NUM> and the rigid section <NUM> are formed of a same material, as described in greater detail below.

The holder <NUM>, as shown in <FIG>, <FIG>, has a plurality of alignment recesses <NUM> extending into the interior surface <NUM>. In the shown embodiments, each of the alignment recesses <NUM> has a sloped side <NUM>; the alignment recesses <NUM> have a larger cross-sectional area at the interior surface <NUM> than at an end of the alignment recess <NUM> disposed between the interior surface <NUM> and the exterior surface <NUM> due to the sloped side <NUM>. The holder <NUM> has two alignment recesses <NUM> in the shown embodiment. In other embodiments, the holder <NUM> may have only one alignment recess <NUM> or may have more than two alignment recesses <NUM>.

The holder <NUM>, as shown in <FIG> and <FIG>, has a plurality of shaft portions <NUM> arranged along a side of the holder <NUM>. In the embodiment shown in <FIG>, each of the shaft portions <NUM> is formed in a C-shape and defines a pivot shaft receiving passageway <NUM>. In another embodiment, each of the shaft portions <NUM> may be formed in an O-shape surrounding the pivot shaft receiving passageway <NUM>.

In each of the embodiments described above and shown in <FIG> and <FIG>, the holder <NUM> is monolithically formed in a single piece. In an embodiment, the holder <NUM> is formed in the single piece by additive manufacturing, such as 3D printing. The holder <NUM> is formed in the single piece with at least one of the magnet passageway <NUM>, the resilient latch <NUM>, the terminal receiving passageway <NUM>, the complaint section <NUM>, the rigid section <NUM>, the alignment recess <NUM>, and the shaft portion <NUM>. The holder <NUM> may be formed of any rigid material that is easily manipulated for additive manufacturing, such as a polymer, a ceramic, or a metal.

To assemble the hand tool <NUM>, as shown in <FIG>, the base <NUM> is attached to the first tool frame <NUM>. The lower surface <NUM> of the base <NUM> is positioned on the first tool frame <NUM> and a plurality of fasteners <NUM>, shown in <FIG> and <FIG>, are inserted extending through the first tool frame <NUM> and through the lower surface <NUM> into the fastener opening <NUM>. A nut <NUM> is positioned on an end of at least one of the fasteners <NUM> and is tightened to hold the base <NUM> on the first tool frame <NUM>. The nut <NUM> is disposed in the fastener opening <NUM> in an assembled position of the base <NUM> on the first tool frame <NUM>. The nut <NUM> is formed of a ferromagnetic material.

As shown in <FIG>, the holder <NUM> is attached to and rotatable about the pivot shaft <NUM> of the base <NUM>, with the upper surface <NUM> facing the interior surface <NUM>. The shaft portions <NUM> of the holder <NUM> are attached to the pivot shaft <NUM>. In the embodiment shown in <FIG>, the C-shaped shaft portions <NUM> are snapped onto the pivot shaft <NUM> and are interference fit with the pivot shaft <NUM>. The holder <NUM> may be attached to the base <NUM> before or after the base <NUM> is attached to the first tool frame <NUM>.

In the open positon O shown in <FIG>, the terminal <NUM> is positioned in the terminal receiving passageway <NUM>. In an embodiment, one terminal <NUM> may be positioned in each of the terminal receiving passageways <NUM>. The retention element <NUM> retains and positions the terminal <NUM> in the terminal receiving passageway <NUM>.

The holder <NUM> is rotatable with respect to the base <NUM> about a rotation direction R between an open position O, shown in <FIG>, and a closed position C, shown in <FIG> and <FIG>. The interference fit of the shaft portions <NUM> with the pivot shaft <NUM> allows the holder <NUM> to remain stationary with respect to the base <NUM> in any position between the open position O and the closed position C. The holder <NUM> rotates to the closed position C in order to position the terminal <NUM> held in the terminal receiving passageway <NUM> in a receiving opening <NUM> between the tool frames <NUM>.

The holder <NUM> is rotated to the closed position C with the terminal <NUM> positioned in the terminal receiving passageway <NUM>. As shown in <FIG>, as the holder <NUM> moves to the closed position C, each of the standoffs <NUM> engages one of the alignment recesses <NUM> to locate the holder <NUM> with respect to the base <NUM> in the closed position C. The interaction of the sloped side <NUM> of the standoff <NUM> with the sloped side <NUM> of the alignment recess <NUM> helps to guide the holder <NUM> into the proper closed position C. As shown in <FIG>, a magnetic force M between the magnet <NUM> and the nut <NUM> also acts to locate the holder <NUM> with respect to the base <NUM> in the closed position C.

The precise locating of the holder <NUM> with respect to the base <NUM> in the closed position C properly positions the terminal <NUM> for crimping in the receiving opening <NUM> shown in <FIG>. Each of the first tool frame <NUM> and the second tool frame <NUM> has a crimp tooling and, when the terminal <NUM> is precisely positioned in the receiving opening <NUM>, the first tool frame <NUM> and the second tool frame <NUM> crimp the terminal <NUM> by action of the pair of levers <NUM> moving the tool frames <NUM> toward each other.

Claim 1:
A terminal locator (<NUM>) for a hand tool (<NUM>), comprising:
a base (<NUM>);
a magnet (<NUM>); and
a holder (<NUM>) attached to the base (<NUM>) and rotatable with respect to the base (<NUM>) between an open position (O) and a closed position (C), the holder (<NUM>) comprising a magnet passageway (<NUM>) in which the magnet (<NUM>) is located;
characterised in that the holder (<NUM>) further comprises a resilient latch (<NUM>) retaining the magnet (<NUM>) in the magnet passageway (<NUM>) and an insertion passageway (<NUM>) extending into the holder (<NUM>) perpendicular to the magnet passageway (<NUM>), the magnet (<NUM>) being held between the resilient latch (<NUM>) and a projection (<NUM>) on a bottom surface (<NUM>) of the magnet passageway (<NUM>).