CRIMPING ASSEMBLY, TOOL AND DIE DESIGN

Abstract

A crimping tool uses a die set with a single point indenter profile to allow of a wide range of electrical connectors and conductors without changing die sets and/or crimping tools. This avoids the need to purchase a separate crimping tool. A die set with an indenter feature in two configurations encompasses the required range of conductors in existing crimping tools, consisting of two pyramid indenter dies and one common wedge die. One advantage of this invention is it allows the strength and versatility of a die set with a single-point indenter without the purchase of a separate crimping tool. The dies of this invention do not require switching out for different sized lugs, thus reducing misplacement and loss. The die halves replace numerous standard U-dies, making the dies of this invention more appealing while offer enhanced pullout strength of connections resulting from this invention.

Claims

1. A crimping assembly for crimping a connector onto a conductor, the crimping assembly comprising: a crimping tool having a frame section and a ram; and a first die and a second die each of which is adapted to be removably coupled to one of the frame section and the ram such that when the conductor and connector are positioned between the first and second dies the crimping tool is operable to crimp the connector onto the conductor; wherein each of the first and second dies has an outer mating surface to removably mate with one of the frame section and the ram; wherein each of the first and second dies has a working surface which confronts one of the connector and the conductor when positioned in the crimping tool; wherein the working surface of the first die has an indenting member projecting therefrom to form an indentation in the connector when crimped to the conductor by the crimping tool.

2. The crimping assembly of claim 1 wherein the indenting member forms a single point indentation in the connector to facilitate removal of the conductor and connector crimped thereon from the crimping tool.

3. The crimping assembly of claim 1 wherein the indenting member has two planes of symmetry oriented perpendicularly to each other.

4. The crimping assembly of claim 2 wherein the indenting member has a pyramidal shape.

5. The crimping assembly of claim 1 wherein the working surface of the first die further comprises: a pair of spaced rims with the indenting member positioned therebetween.

6. The crimping assembly of claim 1 wherein the indenting member has a plurality of generally planar faces.

7. The crimping assembly of claim 1 wherein the identing member has a plurality of generally non-planar faces.

8. The crimping assembly of claim 7 wherein one of the plurality of generally non-planar faces is smoothly continuous and extends from one lateral end of the working surface to an opposite lateral end of the working surface.

9. The crimping assembly of claim 7 wherein two of the plurality of generally non-planar faces are mirror images of each other.

10. The crimping assembly of claim 9 wherein the two of the plurality of generally non-planar faces each comprise a pocket.

11. The crimping assembly of claim 1 wherein the working surface of the second die has a pair of generally planar faces.

12. The crimping assembly of claim 11 wherein the pair of generally planar faces are oriented perpendicularly relative to each other.

13. The crimping assembly of claim 1 wherein the mating surfaces of each of the first and second dies are compatible with both the frame section and the ram.

14. The crimping assembly of claim 1 wherein the connector is of a size between 1000 kcmil to #8 and the crimping tool has a 12 ton capacity.

15. A die set for use in a crimping tool for crimping a connector onto a conductor, the dies set comprising: a first die and a second die each of which is adapted to be removably coupled to one of a frame section and a ram of the crimping tool such that when the conductor and connector are positioned between the first and second dies the crimping tool is operable to crimp the connector onto the conductor; wherein each of the first and second dies has an outer mating surface to removably mate with one of the frame section and the ram; wherein each of the first and second dies has a working surface which confronts one of the connector and the conductor when positioned in the crimping tool; wherein the working surface of the first die has an indenting member projecting therefrom to form an indentation in the connector when crimped to the conductor by the crimping tool.

16. The die set of claim 15 wherein the indenting member forms a single point indentation in the connector to facilitate removal of the conductor and connector crimped thereon from the crimping tool.

17. The die set of claim 15 wherein the indenting member has two planes of symmetry oriented perpendicularly to each other.

18. The die set of claim 17 wherein the indenting member has a pyramidal shape.

19. The die set of claim 15 wherein the working surface of the first die further comprises: a pair of spaced rims with the indenting member positioned therebetween.

20. The die set of claim 15 wherein the indenting member has a plurality of generally planar faces.

21. The die set of claim 15 wherein the identing member has a plurality of generally non-planar faces.

22. The die set of claim 21 wherein one of the plurality of generally non-planar faces is smoothly continuous and extends from one lateral end of the working surface to an opposite lateral end of the working surface.

23. The die set of claim 21 wherein two of the plurality of generally non-planar faces are mirror images of each other.

24. The die set of claim 21 wherein the two of the plurality of generally non-planar faces each comprise a pocket.

25. The die set of claim 15 wherein the working surface of the second die has a pair of generally planar faces.

26. The die set of claim 25 wherein the pair of generally planar faces are oriented perpendicularly relative to each other.

27. The die set of claim 21 wherein the mating surfaces of each of the first and second dies are compatible with both the frame section and the ram.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

[0021] FIG. 1 is a perspective view of one embodiment of a die-set according to this invention;

[0022] FIG. 1A is a perspective view of an exemplary crimping tool into which the die-set of FIG. 1 may be used;

[0023] FIG. 2 is a side elevational view of the die-set of FIG. 1 installed into the jaws of the crimping tool of FIG. 1A;

[0024] FIG. 3A is a cross-sectional view of the arrangement of FIG. 2 with a conductor and lug positioned in the jaws of the crimping tool;

[0025] FIG. 3B is a view similar to FIG. 3A with the jaws and die-set crimping the conductor and lug;

[0026] FIG. 3C is a view similar to FIGS. 3A-3B with the crimped conductor and lug being removed from the jaws;

[0027] FIG. 4 is a perspective view of a second embodiment of a die-set according to this invention;

[0028] FIG. 5 is a side elevational view of the die-set of FIG. 4 installed into the jaws of the crimping tool;

[0029] FIG. 6A is a cross-sectional view of the arrangement of FIG. 5 with a conductor and lug positioned in the jaws of the crimping tool;

[0030] FIG. 6B is a view similar to FIG. 6A with the jaws and die-set crimping the conductor and lug;

[0031] FIG. 6C is a view similar to FIGS. 6A-6B with the crimped conductor and lug being removed from the jaws;

[0032] FIG. 7 is a perspective view of a third embodiment of a die-set according to this invention;

[0033] FIG. 8 is a side elevational view of the die-set of FIG. 7 installed into the jaws of the crimping tool;

[0034] FIG. 9A is a cross-sectional view of the arrangement of FIG. 8 with a conductor and lug positioned in the jaws of the crimping tool;

[0035] FIG. 9B is a view similar to FIG. 9A with the jaws and die-set crimping the conductor and lug;

[0036] FIG. 9C is a view similar to FIGS. 9A-9B with the crimped conductor and lug being removed from the jaws;

[0037] FIG. 10 is a perspective view of a fourth embodiment of a die-set according to this invention;

[0038] FIG. 11 is a side elevational view of the die-set of FIG. 10 installed into the jaws of the crimping tool;

[0039] FIG. 12A is a cross-sectional view of the arrangement of FIG. 11 with a conductor and lug positioned in the jaws of the crimping tool;

[0040] FIG. 12B is a view similar to FIG. 12A with the jaws and die-set crimping the conductor and lug;

[0041] FIG. 12C is a view similar to FIGS. 12A-12B with the crimped conductor and lug being removed from the jaws;

[0042] FIG. 13 is a perspective view of a fifth embodiment of a die-set according to this invention;

[0043] FIG. 14 is a side elevational view of the die-set of FIG. 13 installed into the jaws of the crimping tool;

[0044] FIG. 15A is a cross-sectional view of the arrangement of FIG. 14 with a conductor and lug positioned in the jaws of the crimping tool;

[0045] FIG. 15B is a view similar to FIG. 15A with the jaws and die-set crimping the conductor and lug; and

[0046] FIG. 15C is a view similar to FIGS. 15A-15B with the crimped conductor and lug being removed from the jaws.

DETAILED DESCRIPTION OF THE INVENTION

[0047] A crimping tool and crimping die set commonly used in installing electrical connectors is depicted in FIGS. 1-1A. As shown in FIG. 1A, a conventional crimping tool 10 includes a housing 12, a working head 14, die release buttons 16, a battery 18, a trigger 20, and a ring 21. The housing 12 forms a handle 28. The battery 18 is removably connected to the bottom of the handle 28. The tool 10 can also include additional or alternative components. The housing 12 forms a ram hydraulic drive conduit system. The working head 14 may include a frame section 22 and a ram 24. The frame section 22 is stationarily connected to the front end of the housing 12, but could be rotatable. The ram 24 is movably connected to the frame section 22. The frame section 22 and the ram 24 are adapted to removably receive crimping dies 30 at a conductor receiving area 26. The crimping tool 10 shown and described herein is exemplary and this invention is not limited to any specific crimping tool. One crimping tool which may be used with this invention is model ILBC-12-LIO from Ilsco Corporation.

[0048] The ram 24 moves forward and backward axially as indicated by arrow A. The ram hydraulic drive conduit system is connected between a pump and the rear end of the ram 24. Hydraulic fluid pumped by the pump against the rear end of the ram 24 causes the ram 24 to move forward. A spring (not shown) returns the ram 24 to its rearward home position when hydraulic fluid pressure is released. The ram 24 moves between its rear position (FIG. 2) and its forward position (FIG. 3B).

[0049] Referring to FIGS. 1-2, one embodiment of a die set 30 for use in the crimping tool 10 is shown. The die set 30 and crimping tool 10 may be used to crimp an electrical connector such as a lug 32 shown in cross-section in FIG. 2 onto multiple wires 34 of a conductor 36 for electrical connection between the lug 32 and conductor 36. The die set 30 may have an upper indenter die 30a and a lower common die 30b. The upper die 30a may be mounted to the ram 24 of the crimping tool 10 according to various embodiments of this invention; however, since the crimping tool 10 can accept either die 30a, 30b in either location, the labels of upper die and lower die are for convenience in identification purposes.

[0050] The receiving 26 area of the crimping tool 10 has a pair of jaws 38 opposing one another. Each die 30 is removably mounted into one of the jaws 38. One jaw 38b is found on the frame 22 of the head 14 of the crimping tool 10 and one jaw 38a is found on the ram 24 of the tool 10. Each jaw 38 has a pair of opposed rails 40, one of which is oriented downwardly and one of which is oriented upwardly as shown in FIG. 2. Each jaw 38 has a curved or arcuate concave surface 42 extending between the associated rails 40 thereof.

[0051] An outer mating surface 44 of each die 30 is a generally curved or arcuate convex surface which is sized and configured to mate with the concave surface 42 of the jaws 38 when the die 30 is mated thereto. Each die 30 has a pair of grooves 46, one at each circumferential extent of the concave surface 44. One of the grooves of each die 30 is an upper groove 46a and the other groove of each die is a lower groove 46b. As seen in FIG. 2, the upper rail 40a of each jaw 38 is seated within the upper groove 46a and the lower rail 40b of that jaw 38 is seated within the lower groove 46b of the associated die 30 when the die 30 is mated with the jaw 38. The release button i6 may be depressed to release the die 30 from the associated jaw 38 as needed.

[0052] Each die 30 has a working surface 48 which confronts the working surface 48 of the opposing die 30 of the die set when the dies 30 are mounted in the crimping tool 10. According to various embodiments of this invention, the lower die 30b as a generally V-shaped working surface 48b when the die is viewed from the longitudinal end as in FIG. 2 or a cross-sectional view taken perpendicular to the grooves 46 of the die 30. The working surface 48b of the lower die 30b has a pair of generally planar and rectangular surfaces 50 joined together along a common longitudinal edge by a vertex 52 of the V-shape as seen in FIG. 2. The vertex 52 may have a rounded or other configuration according to various embodiments of this invention.

[0053] The working surface 48a of the upper die 30a according to various embodiments of this invention includes an indenting member 54, an example of which is seen in FIG. 1. The indenting member 54 of FIG. 1 is a generally pyramidal shaped member having four trapezoidal-shaped sides 56 which merge together at a square shaped, generally planar apex 58. The indenting member 54 projects from a generally planar, rectangular shaped base 60 of the working surface 48a of the upper die. The base 60 joins the upper and lower grooves 46 of the upper die 30a together in the embodiment of FIG. 1. The indenting member 54 is positioned generally equal distances from the upper and lower grooves 30 and laterally between the ends of the working surface 48. The indenting member 54 of various embodiments of this invention has two planes or axes of symmetry A1 and A2 as shown in FIG. 1 and other drawings.

[0054] As shown in the drawings, various embodiments of this invention form a single point indentation 62 in the lug or connector 32 and the conductor 36 positioned therein. The single point indentation 62 provides a crimp of sufficient strength and versatility to facilitate removal of the crimped lug or connector 32 and conductor 36 from the crimping tool 10. The die sets 30 of this invention allow for removal of the crimped connector 32 and conductor 36 from 12 ton hand or battery operated tools 10. Single point indentations 62 are preferred by many in the industry and with the components of this invention, the distance within receiving area 26 allows for removal of the crimped members with standard tools 10. 1000 kcmil to #8 connectors 32 may be effectively crimped in such tools 10 and easily removed therefrom.

[0055] FIGS. 3A-3C are sequential views of the lug 32 and conductor 36 being crimped by the die set 30 of FIG. 1 and the crimping tool 10 and then removed from the receiving area 26 between the dies 30 in the crimping tool 10. The arrangements of FIGS. 2 and 3A are similar and represent the maximum extent of the receiving area 26 with the ram 24 and upper die 30a mounted in the associated jaw 38 at the home position fully retracted from the lower die 30b and associated jaw 38 of the crimping tool 10. In FIG. 3B, the position of the upper die 30a relative to the lower die 30b has decreased with the ram 24 of the crimping tool 10 being actuated by a user depressing the trigger 20. The relative movement of the dies 30 toward each other, as indicated by arrows B in FIG. 3A in one embodiment, crimps the lug 32 and conductor 36 therebetween as seen in FIG. 3B. The portion of the lug 32 and wires 34 of the conductor 36 adjacent thereto are deformed into a generally V-shaped configuration similar to the working surface 48b of the lower die 30b. Similarly, the portion of the lug 32 confronting the upper die 30a and the adjacent wires 34 of the conductor 36 are deformed by the indenting member 54 and base 60 of the working surface 48a of the upper die 30a. The indenting member 54 forms an indentation 62 in the lug 32 and adjacent wires 34 of the conductor 36.

[0056] After the ram 24 and upper die 30a mounted thereto has completed the crimping action and/or traveled to the furthest extent of the ram 24, the ram 24 is retraced toward home position to unseat the crimped surfaces of the lug 32 from the respective working surfaces 48 of the die set 30. This allows for removal of the crimped lug and conductor from the receiving area 26 of the crimping tool 10, such as in the direction of arrow C as seen in FIG. 3C.

[0057] Advantageously, the configuration of the dies 30 and associated working surfaces 48 of the die set 30 allows for a secure crimp of a variety of lug 32 and conductor 36 sizes, including large sizes which would otherwise require a different tool and/or die set for such larger sizes thereby increasing the required inventory of dies and/or crimping tools to securely crimp larger diameter lugs and conductors.

[0058] A second embodiment of a die set 30 according to this invention is show in FIG. 4 with the die set 30 mated with the crimping tool 10 shown in FIG. 5. Elements of the die set 30, crimping tool 10, lug 32 and conductor 36 similar to those of the earlier embodiment are identified by similar reference numerals. The lower die 30b of the die set 30 of FIG. 4 is similar to or the same as the lower die 30b of the die set 30 of FIG. 1. The upper die 30a of FIG. 4 differs from the upper die of FIG. 1 by the addition of added indenting members in the form of a pair of rims 54a, 54b each projecting forwardly from the base 60 at a juncture between the base 60 and the associated groove 46 of the upper die 30a. The rims 54a, 54b form recesses 64a, 64b in the lug 32 and adjacent wires 34 of the conductor 36 as shown in FIGS. 6B an 6C. The height of each rim 54a, 54b is less than that of the pyramidal shaped indenting member 54 in the embodiment of FIGS. 4-6C, although other configurations and shapes are within the scope of this invention.

[0059] A third embodiment of a die set 30 according to this invention is show in FIG. 7 with the die set 30 mated with the crimping tool 10 shown in FIG. 8. Elements of the die set 30, crimping tool 10, lug 32 and conductor 36 similar to those of the earlier embodiments are identified by similar reference numerals. The lower die 30b of the die set 30 of FIG. 4 is similar to or the same as the lower die 30b of the die set 30 of FIGS. 1 and 4. The upper die 30a of FIG. 7 differs from the upper dies 30a of FIGS. 1 and 4 by the shape of the indenting member 54 on the working surface 48a. The indenting member 54 of the upper die 30a of the die set 30 of FIG. 7 is a saddle shaped member with a pair of generally oval shaped pockets 66 spaced on either side of a laterally oriented ridge 68. Each of the oval shaped pockets 66 is adjacent to one of the grooves 46 of the upper die 30a. The indenting member 54 of the upper die 30a of FIG. 7 forms a central indentation 62 in the lug 32 bordered on the upper and lower portions of the lug 32 by rounded protrusions 70 as shown in FIG. 9C.

[0060] A fourth and fifth embodiment of a die set 30 according to this invention is show in FIGS. 10 thru 15C with the die set 30 mated with the crimping tool 10 shown in FIGS. 11 and 14. Elements of the die set 30, crimping tool 10, lug 32 and conductor 36 similar to those of the earlier embodiments are identified by similar reference numerals. The lower die 30b of the die set 30 of FIG. 4 is similar to or the same as the lower die 30b of the die set 30 of FIGS. 1 and 4. The upper dies 30a of FIGS. 10 and 13 differs from the upper dies 30a of FIGS. 1 and 4 by the shape of the indenting member 54 on the working surface 48a as shown in FIGS. 10-15C. The indenting member 54 of the embodiments shown in FIGS. 10-15C are similar to each other with the member 54 of FIGS. 10-12C being less pronounced than the member 54 in FIGS. 13-15C. Each of these embodiments of the indenting member 54 has the pair of shaped pockets 66 spaced on either side of the protruding ridge 68. The outermost face of the ridge 68 of the embodiment in FIGS. 10-12C is generally square while the outermost face of the ridge 68 of the embodiment of FIGS. 13-15C is rectangular.

[0061] The various embodiments of the die sets 30 according to this invention each offer the secure crimp of a variety of lug 32 and conductor 36 sizes, including large sizes which would otherwise require a different tool and/or die set for such larger sizes thereby increasing the required inventory of dies and/or crimping tools to securely crimp larger diameter lugs and conductors.

[0062] From the above disclosure of the general principles of this invention and the preceding detailed description of at least one embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.