Note: Descriptions are shown in the official language in which they were submitted.
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Electrical Connector Configuring Dies, Tool and Method
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention relates to configuring an
electrical connector and, more particularly, to a die
set, tool and method for modifying an electrical
connector.
Brief Description of Prior Developments
[0002] U.S. Patent No. 6,792,789 B1 describes a
hydraulic tool having removable cutting dies and crimping
dies. Co-pending U.S. Patent Application No. 12/287,352
filed October 7, 2008 and U.S. Patent Publication No.
2008/0182462 Al, which are hereby incorporated by
reference in their entireties, describe electrical
connectors with reproducibly modifiable lugs.
[0003] Although the electrical connectors described in
U.S. Patent Application No. 12/287,352 and U.S. Patent
Publication No. 2008/0182462 Ai are versatile for
different situations, for an electrical connector having
a very thick lug, or for a large volume of lugs needing
to be modified, it would be difficult for a user to
quickly break off or cut off the end of the lug with a
manually operated hand tool; and could perhaps also be
manually exhausting. Thus, there is a desire to provide
a machine tool which can cut or break off the end of a
lug of an electrical connector.
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SUMMARY
[0004] The following summary is merely intended to be
exemplary. The summary is not intended to limit the
scope of the claimed invention.
[0005] In accordance with one aspect of the invention,
a die set adapted to remove an end of a substantially
flat lug of an electrical connector is provided. The die
set includes a first die and a second die. The first die
includes a first frame and a spring loaded member
connected to the first frame. The first frame includes a
first contact surface adapted to directly contact a first
side of the lug. The second die includes a second frame
having a second contact surface adapted to contact a
second side of the lug at a position offset from the
first contact surface. The spring loaded member is
adapted to contact the first side of the lug directly
opposite the second contact surface. The first and
second contact surfaces are adapted to shear off the end
of the lug from the electrical connector.
[0006] In accordance with another aspect of the
invention, a tool is provided comprising a working head
adapted to remove an end of a substantially flat lug of
an electrical connector, wherein the lug comprises a
laterally extending breakaway recess on an exterior side,
wherein the working head comprises dies configured to
contact opposite sides of the lug and break the lug
proximate the breakaway recess.
[0007] In accordance with another aspect of the
invention, a method is provided comprising placing a
substantially flat lug of an electrical connector between
two dies; and moving the two dies towards each other,
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wherein a first contact surface of a first one of the
dies is offset from a second contact surface of a second
one of the dies to shear off an end of the lug from the
electrical connector, and wherein the first die comprises
a first spring loaded member contacting the lug directly
opposite the second contact surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing aspects and other features of the
invention are explained in the following description,
taken in connection with the accompanying drawings,
wherein:
[0009] Fig. 1 is a perspective view of a hand-held,
battery operated, hydraulic compression tool
incorporating features of the invention;
[0010] Fig. 2 is a side view of the working head of
the tool shown in Fig. 1;
[0011] Fig. 3 is a perspective view of a conventional
electrical connector;
[0012] Fig. 4 is a perspective view of an alternate
embodiment of the electrical connector shown in Fig. 3;
[0013] Fig. 5 is a side view of the electrical
connector shown in Fig. 4 being used to connect two
conductors together;
[0014] Fig. 6 is a side view of the electrical
connector shown in Fig. 4 with a front lug portion
removed and being used to connect two conductors
together;
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[0015] Fig. 7 illustrates a pair of dies, for use with
the tool shown in Fig. 1, comprises features of the
invention;
[0016] Fig. 8 is a side view illustrating the dies of
Fig. 7 and tool of Fig. 1 being used to modify a
connector of Fig. 3 or 4;
[0017] Fig. 9 is a partial and cut away view of the
tool shown in Fig. 1 with an alternate embodiment of the
lug cutting dies;
[0018] Fig. 10 is a side view of the working head of
the tool shown in Fig. 1 with another alternate
embodiment of the lug severing dies;
[0019] Fig. 11 is a side view of the dies shown in
Fig. 10 showing placement of one of the connectors of
Figs. 3 or 4 on the first die for subsequent
modification;
[0020] Fig. 12 is a partial cross sectional view of
another alternate embodiment of the lug modifying dies;
[0021] Fig. 13 is a partial cross sectional view of
the dies shown in Fig. 12 showing placement of one of the
connector of Fig. 4 on the first die for subsequent
modification;
[0022] Fig. 14 is a perspective view of the working
head of the tool shown in Fig. 1 with another alternate
embodiment of the lug severing dies and the connector 132
clamped between the dies; and
[0023] Fig. 15 is a perspective view as in Fig. 14
from another angle.
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DETAILED DESCRIPTION OF EMBODIMENTS
[0024] Referring to Fig. 1, there is shown a
perspective view of a tool 24. Although the invention
will be described with reference to the exemplary
embodiments shown in the drawings, it should be
understood that the invention can be embodied in many
alternate forms of embodiments. In addition, any
suitable size, shape or type of elements or materials
could be used.
[0025] The tool 24 is a hand-held battery operated
hydraulic crimping tool. However, in alternate
embodiments, features of the invention could be used in
any suitable type of hydraulic tool or fluid tool such as
a pneumatic tool for example, or any tool having a
movable ram. The tool 24 generally comprises a main
section 26, a working head 28, and a battery 30. In this
embodiment the working head 28 is adapted to receive
removable dies 32. The dies 32 are crimp dies, but as
seen in Fig. 7, the dies could be cutting dies. In
alternate embodiments the working head might have non-
removable cutting sections rather than removable cutting
dies.
[0026] The main section 26 generally comprises an
exterior housing 34, an electric motor 36, a hydraulic
pump 38, a fluid conduit system 40 including a fluid
reservoir for conduiting fluid to and from the working
head 28, and a control system including user actuated
triggers 42, 43. In an alternate embodiment, the main
section 26 could be adapted to be connected to a remote
hydraulic fluid supply by hydraulic hoses. The housing
34 comprises a handle 44. The triggers 42, 43 are
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mounted on the handle. The battery 30 is removably
mounted to the bottom of the handle 44. The battery
comprises a rechargeable battery. In an alternate
embodiment the battery might not be removable or might
not be rechargeable.
[0027] Referring also to Fig. 2, the working head 28
generally comprises a frame 46, a ram 48, a die holder
section 50 at a top end of the ram 48, and a spring 52.
The frame 46 comprises a first frame member 54 fixedly
connected to a frame of the fluid conduit system 40 and a
second frame member 56. The first frame member 54
comprises an inlet/outlet aperture 58 and a ram receiving
area 60. The second frame member 56 is fixedly connected
to the first frame member to substantially enclose the
ram receiving area 60 except at the aperture 58 and a ram
hole 62 through the second frame member 56. The spring
52 is located in the ram receiving area 60. The ram 48
is movably connected to the frame in a first longitudinal
direction 49, wherein the ram is adapted to be moved
relative to the frame by hydraulic fluid. The spring 52
biases the ram 48 in a retracted position as shown.
However, the bias of the spring can be overcome by
hydraulic fluid entering the area 60 from the aperture
58.
[0028] The second frame member 56 comprises a general
C shaped profile. However, in alternate embodiments
other types of shapes could be provided. The second
frame member 56 is preferably a one-piece metal member.
The bottom end of the C shaped profile is mounted to the
first frame member 54. The C shaped profile comprises a
first section 63 which forms a portion of the hydraulic
cylinder area, an opposite second section 66 which forms
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a top section, and a middle section which forms a side
extension 64. The middle section connects the first and
second sections 63, 66 to each other. The top section 66
forms an upper die holder section 67 located opposite the
lower die holder section 50 of the ram 48. The ram 48 is
adapted to move the lower die holder section 50 towards
and away from the upper die holder section 67.
[0029] The ram 48 and the lower die holder section 50
could be a one piece member. Alternatively, the ram and
the second movable member could be two members.
[0030] Referring also to Fig. 3, a perspective view of
a conventional electrical connector 128 is shown. The
connector 128 is a BURNDYO two hole HYLUGTM electrical
conductor. The connector 128 generally comprises a tube
section 112 forming a cable receiving area with an
inspection window 114, and a lug section 130 with two
holes 118. The lug section 130 is mounted to another
member by receiving two mounting posts; one in each one
of the holes 118.
[0031] The two hole connector 128 is used rather than
a one hole connector because a larger surface area of
contact between the connector and the other member (such
as along the bottom surface of the lug section) is needed
for electrical reasons. However, a one hole connector
can be used in some circumstances rather than the two
hole connector 128 because the one hole connector can be
less expensive than the two hole connector 128.
[0032] In some circumstances, because of the
environment, only enough space is available for a one
hole connector to be used. This is described in U.S.
patent publication No. 2008-0182462 Al, which is hereby
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incorporated by reference in its entirety. The size of
the lug section 130 of the two hole connector 128 would
be too large for use in the available area for the
connector. However, a user might only have the two hole
connector 128 available. In this instance, installers
are cutting the two-hole lug section 130 with a saw to
make a one-hole lug section. A problem is that only the
whole connector having the two-hole lug section is UL
approved. Modifications to the two-hole lug could void
the Underwriters Laboratories Inc. (UL) approval,
especially if an installer gets a bit aggressive while
removing the extra lug hole portion of the two-hole lug.
[0033] Referring now to Fig. 4, a perspective view of
a portion of an electrical connector 132 described in
U.S. patent publication No. 2008-0182462 Al is shown.
This type of connector can be modified by a user from a
two hole lug into a one hole lug without voiding the UL
certification.
[0034] The connector 132 generally comprises a one-
piece metal member having a first connection section 134
and a second connection section 136. The first
connection section 134 could comprise any suitable
connection section for connection to another member, such
as a tube section to be crimped onto a wire or cable for
example. The second connection section 136 is a lug
section or pad or tongue having two mounting holes 118
similar to the connector 128 shown in Fig. 3. However,
the lug section 136 has a front portion 138 and a rear
portion 140 connected by a weakened section 142. The
weakened section 142 comprises laterally extending
recesses 160, 162 along the top and bottom sides of the
lug section 136 between the front portion 138 and the
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rear portion 140. The weakened section 142 provides a
section of the lug which has a different cross section
than the rest of the lug. Preferably, this reduced cross
section is weaker than the cross section of the lug at
the holes 118. In alternate embodiments, only the top
side recess 160 or the bottom side recess 162 could be
provided. In another alternate embodiment one or both
recesses could comprise a series of non-connected
indentations or holes through the height of the lug
section. In alternate embodiments, any suitable type or
shape of weakened section could be provided.
[0035] The weakened section 142 allows a user to
separate the front portion 138 from the rear portion 140
in a controlled manner. With multiple connectors 132,
the separation can be performed in a repeatable manner.
As shown in Fig. 5, the connector 132 can be used to
connect the cable 124 to the member 122' without
separating the front portion 138. The lug section 136
can be mounted to the two posts 120 with the fasteners
126. However, as shown in Fig. 6, the same connector can
be modified by a user/installer removing the front
portion 138 to form the connector 132' for connection to
the member 122.
[0036] The separation of the front portion 138 from
the rear portion 140 could comprise, for example, the use
of pliers to bend the lug section at the weakened section
and, through metal fatigue, break the weakened section.
As another example, a saw could be used to cut the
weakened section with the groove(s) of the weakened
section forming a guide for the saw. In an alternate
embodiment, more than two lug portions could be provided
and more than one weakened section could be provided.
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[0037] In a preferred method, the connector will be UL
approved in both its one-hole version, such as 132' for
example, and its multi-hole version, such as 132 for
example. Thus, a two-hole lug can be modified, in a
controlled, reproducible manner into a one-hole lug
without voiding the UL approval.
[0038] Referring also to Fig. 7, a pair of dies 70, to
be used with the tool 24 shown in Fig. 1 (or a similar
tool), is shown which are adapted to cut a lug of a
connector, such as the connectors 128 or 132 for example.
The cutting dies 70 are used in the tool instead of the
crimping dies 32. In this example embodiment, a first
one 72 of the dies 70 comprises a frame 74 and a spring
loaded member 76. The frame 74 comprises a one-piece
metal member. The frame 74 has a general stepped shape
with a first stepped surface 80 forming a first shearing
surface or first contact surface at the first stepped
surface. The spring loaded member 76 is located in a
bottom step area 82 of first frame 74 and the first
contact surface 80 is at a top step area of the first
frame 74. The spring loaded member 76 comprises a one-
piece metal member which is located, at least partially,
in the bottom step area 82. Springs 78 connect the
member 76 to the frame 74.
[0039] In this example embodiment, a second one 74 of
the dies 70 comprises a frame 86. The second frame 86
has a second stepped surface with a second shearing
surface 88 at the second stepped surface. The second
shearing surface 88 is located opposite the spring loaded
member 76. The second frame 86 is a one-piece metal
member. The bottom step area 90 of the second frame 86
is sized and shaped to at least partially receive the
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first stepped surface 80. The pair 70 of dies are
adapted to be removably connected to the tool 24.
[0040] Referring also to Fig. 8, the pair of dies are
shown being used to modify a connector 128 or 132 from a
lug having a two holes to a shorter length lug having
only one hole (see Figs. 5-6 for example) . When the ram
48 moves the second die 74 towards the first die 72, the
rear portion of the lug is clamped between the spring
loaded member 76 and the surface 88. With further
movement of the ram 48 forward, the member 76 is pressed
deeper into the area 82 with the springs 78 compressing.
The surface 80 contacts the top side of the lug. With
further movement of the ram 48 forward, the two surfaces
80, 88 shear off the front end 138 of the lug at shear
line 92 (which could be the weakened section 142 if the
connector 132 is being cut).
[0041] It has been discovered that by clamping the
rear portion of the lug by the spring loaded member 76, a
cleaner or more uniform cut is left at the shear line 92.
In addition, with the example embodiment, a machine tool
can be used to modify a connector lug rather than merely
a manual hand tool. This can be useful if a large number
of lugs need to be modified, or if the lugs do not have
weakened sections, or if the thickness of the lug is very
large (even with a weakened section).
[0042] Referring also to Fig. 9 an alternate
embodiment of the invention is shown. In this example
embodiment the tool 24 has a pair of dies 94, 96. The
first die 94 is connected to the upper die holder section
67. The first die 94 comprises a frame 98 and the spring
loaded member 76. Two springs 78 connect the spring
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loaded member 76 to the frame 98 similar to the
embodiment shown in Figs. 7-8. The frame 98 is different
from the frame 74 in that it is mounted to the upper die
holder section 67 generally orthogonal to the orientation
in the embodiment of Figs. 7-8. However, the frame 92
has a stepped surface similar to the stepped surface 80
with a shearing surface and a bottom step area which the
member 76 can be compressed into.
[0043] The second die 96 is connected to the lower die
holder section on the ram 48. The second die 96
comprises a frame 100 and a second spring loaded member
102. Two springs 78 connect the second spring loaded
member 102 to the frame 100. The second frame 100 has a
stepped surface 104 forming a top shear surface 106 and a
bottom step area 108.
[0044] When the ram 48 moves the second die 96 towards
the first die 94, the rear portion of the lug is clamped
between the spring loaded member 76 and the surface 106.
Likewise, the front portion of the lug is clamped between
the spring loaded member 102 and the surface 80. With
further movement of the ram 48 forward, the member 76 is
pressed deeper into the area 82 with the springs 78
compressing. The member 102 is pressed deeper into the
area 108 with the springs 78 compressing. The surface 80
contacts the top side of the lug and the surface 106
contacts the bottom side of the lug. With further
movement of the ram 48 forward, the two surfaces 80, 106
shear off the front end 138 of the lug at a shear line
(which could be the weakened section 142 if the connector
132 is being cut). This clamping before and during
shearing results in a cleaner and more accurate cut at
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the shear line without deforming other portions of the
lug.
[0045] Referring also to Figs. 10-11, another example
embodiment of the invention is shown. In this embodiment
the dies 200, 202 are each a one-piece metal member. The
first die 200 comprises a pocket 204 and first lug
contact surfaces 206 on opposite sides of the pocket 204.
The second die 202 comprises a projection 208 and second
lug contact surfaces 210 on opposite sides of the
projection 208, wherein the projection is located
directly opposite the pocket 204. The first lug contact
surfaces 206 are configured to contact a side of the lug
on opposite sides of the breakaway recess 160, 162 (see
Fig. 4) while the projection 208 severs the lug at the
breakaway recess.
[0046] Referring also to Figs. 12-13, another
alternate example embodiment is shown. In this
embodiment the first die 220 comprises a pocket 222 and
lug support surfaces 224 on opposite sides of the pocket
222. The second die 226 comprises a projection 228 with
an angled leading surface 230. When the two dies 220,
226 are moved towards each other, the surface 230 can cut
through the connector 132. The pocket 222 can receive
portions of the projection 228 after the portions pass
through the lug of the connector 132. Recess 160 can be
used with the projection 228 to center the lug's weakened
area at the projection 228 and pocket 222.
[0047] Referring now also to Figs. 14-15, another
alternate example embodiment is shown. In this example
embodiment the working head 28 of the tool 24 has two
dies 240, 242 removably connected to the working head.
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, . ,
The first die 240 comprises a frame 244 and a spring
loaded member 246. The frame 244 comprises a first frame
member 248 and a second frame member 250. The second
frame member 250 is attached to a lateral side of the
first frame member 248. The second frame member 250 has
a leading end 252 located in front of the front of the
first frame member 248. The leading end 252 forms a
shearing surface for directly contacting the lug of the
connector 132.
[0048] A spring 254 extends from the front of the
first frame member 248. The spring loaded member 246 is
attached to the end of the spring 254. The spring loaded
member 246 has a front face which is initially located
past the leading end 252. However, as the lug of the
connector 132 is clamped between the two dies 240, 242,
the member 246 is moved into the space 256 and the spring
254 is compressed. The second die 242 is a one-piece
metal member with a top surface which contacts the
opposite side of the lug of the connector 132. The
inward edge of the leading end 252 of the second frame
member 250 is located slightly laterally past the outer
lateral side 258 of the second die 242.
[0049] The weakened section 142 of the lug is located
at the shear area between the leading end 252 and the
side 258. The lug is initially clamped between the
spring loaded member 246 and the second die 242. Further
movement of the frame 244 by the ram of the tool 24
causes the leading end 252 of the second frame member 250
and the second die 242 at the side 258 to shear off the
front portion 138 from the rear portion 140 of the lug
136 at the weakened section 142. Because the front
portion 138 of the lug 136 is clamped between the spring
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loaded member 246 and the second die 242, the sheared end
of the rear portion 140 at the former weakened section
142 is relatively clean and precise; without
irregularities which use of a hand saw might otherwise
produce. In addition, the locational accuracy of the
shear cut on a lug section is repeatable for multiple
connectors subsequently modified by the tool and dies.
[0050] A die set can be provided which is adapted to
remove an end of a substantially flat lug of an
electrical connector, the die set comprising a first die
comprising a first frame and a spring loaded member
connected to the first frame, wherein the first frame
comprises a first contact surface adapted to directly
contact a first side of the lug; and a second die
comprising a second frame having a second contact surface
adapted to contact a second side of the lug at a position
offset from the first contact surface, wherein the spring
loaded member is adapted to contact the first side of the
lug directly opposite the second contact surface, and
wherein the first and second contact surfaces are adapted
to shear off the end of the lug from the electrical
connector.
[0051] The first frame can have a first stepped
surface with a first shearing surface at the first
stepped surface. The spring loaded member can be located
in a bottom step area of first frame and the first
contact surface is at a top step area of the first frame.
The second frame can have a second stepped surface with a
second shearing surface at the second stepped surface.
The second die can further comprise a second spring
loaded member connected to the second frame, wherein the
second spring loaded member is adapted to contact the
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second side of the lug directly opposite the first
contact surface. The second spring loaded member can be
located in a bottom step area of second frame and the
second contact surface is at a top step area of the
second frame. The second die can further comprise a
second spring loaded member connected to the second
frame, wherein the second spring loaded member is adapted
to contact the second side of the lug directly opposite
the first contact surface. The second frame can be a
one-piece metal member. The one-piece metal member can
have a stepped surface with a shearing surface between
steps of the stepped surface. The first contact surface
can be located laterally offset from the second frame.
[0052] A tool can be provided comprising a working
head comprising the die set described above at the
working head. The tool can further comprise a tool frame
forming at least a portion of the working head; a
hydraulic drive system in the tool frame; and a ram
movably mounted to the tool frame, wherein the dies of
the die set are respectively connected to the ram and the
tool frame at the working head.
[0053] A tool can be provided comprising a working
head adapted to remove an end of a substantially flat lug
of an electrical connector, wherein the lug comprises a
laterally extending breakaway recess on an exterior side,
wherein the working head comprises dies configured to
contact opposite sides of the lug and break the lug
proximate the breakaway recess. The dies can comprise a
first die comprising a first frame and a spring loaded
member connected to the first frame, wherein the first
frame comprises a first contact surface adapted to
directly contact a first one of the sides of the lug; and
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a second die comprising a second frame having a second
contact surface adapted to contact a second one of the
sides of the lug at a position offset from the first
contact surface, wherein the spring loaded member is
adapted to contact the first side of the lug directly
opposite the second contact surface, and wherein the
first and second contact surfaces are adapted to shear
off the end of the lug from the electrical connector. A
first one of the dies can comprise a pocket and first lug
contact surfaces on opposite sides of the pocket; and a
second one of the dies comprises a projection and second
lug contact surfaces on opposite sides of the projection,
wherein the projection is located directly opposite the
pocket, wherein the first lug contact surfaces are
configured to contact a side of the lug on opposite sides
of the breakaway recess while the projection severs the
lug at the breakaway recess. The projection can have a
angled leading edge.
[0054] A method can be provided comprising placing a
substantially flat lug of an electrical connector between
two dies; and moving the two dies towards each other,
wherein a first contact surface of a first one of the
dies is offset from a second contact surface of a second
one of the dies to shear off an end of the lug from the
electrical connector, and wherein the first die comprises
a first spring loaded member contacting the lug directly
opposite the second contact surface.
[0055] During the step of moving, the second die can
comprise a second spring loaded member contacting the lug
directly opposite the first contact surface. The first
spring loaded member can contact the lug before the first
contact surface contacts the lug. The first die can
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comprise a first frame with a stepped surface and a
shearing surface between steps of the stepped surface,
and wherein the first spring loaded member is located in
a bottom step area of first frame such that the first
spring loaded member is compressed into the bottom step
area by the lug.
[0056] It should be understood that the foregoing
description is only illustrative of the invention.
Various alternatives and modifications can be devised by
those skilled in the art without departing from the
invention. For example, features recited in the various
dependent claims could be combined with each other in any
suitable combination(s). In addition, features from
different embodiments described above could be
selectively combined into a new embodiment. Accordingly,
the invention is intended to embrace all such
alternatives, modifications and variances which fall
within the scope of the appended claims.
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