Abstract: A cable assembly includes a terminal crimped to a conductor. The terminal has a plurality of crimps spaced from one another and a transition crimp disposed therebetween. A method includes deforming the terminal about the conductor to define the plurality of crimps having different crimp heights, and deforming the terminal about the conductor to define the transition crimp between each of the plurality of crimps. The transition crimp has a crimp height different than each of the plurality of crimps.

Abstract: A cable includes a plurality of cable strands, an insulator disposed on a portion of the plurality of strands such that the plurality of strands are at least partially exposed, and a sealant disposed between gaps of the plurality of strands and at least partially under the insulator. Moreover, a method includes stripping an insulator from an end of the cable to expose a plurality of cable strands, and applying a sealant to the cable strands such that the sealant is drawn under the insulator and fills in gaps between the cable strands by capillary action.

Abstract: A connection mechanism includes a metal segment in mechanical and electrical communication with the remainder of the connection mechanism on at least one side. The segment includes at least one tab protruding from the segment on a first side and a central area of the segment with a plurality of metal deformations. When the metal deformations are pressed into aluminum, they are capable of piercing through corrosion on the surface of the aluminum in order to make electrical contact with the aluminum.

Abstract: A cable assembly includes a terminal crimped to a conductor. The terminal has a plurality of crimps spaced from one another and a transition crimp disposed therebetween. A method includes deforming the terminal about the conductor to define the plurality of crimps having different crimp heights, and deforming the terminal about the conductor to define the transition crimp between each of the plurality of crimps. The transition crimp has a crimp height different than each of the plurality of crimps.

Abstract: A cable includes a terminal crimped onto the wire. The terminal defines a knurl having a first portion in contact with the wire and a second portion integrally formed with the first portion and in contact with the wire. The first portion is wider than the second portion. The terminal includes a material having a unitary configuration and configured to be crimped onto the wire. A plurality of knurls, each defining the first portion and the second portion, are integrally formed with the material, and the first portion is wider than the second portion. Moreover, a method includes deforming the terminal to have a substantially U-shaped knurl, wherein the U-shaped knurl has the first portion and the second portion, and deforming the second portion of the U-shaped knurl such that the first portion is wider than the second portion.

Abstract: A cable includes a plurality of cable strands, an insulator disposed on a portion of the plurality of strands such that the plurality of strands are at least partially exposed, and a sealant disposed between gaps of the plurality of strands and at least partially under the insulator. Moreover, a method includes stripping an insulator from an end of the cable to expose a plurality of cable strands, and applying a sealant to the cable strands such that the sealant is drawn under the insulator and fills in gaps between the cable strands by capillary action.

Abstract: A connection mechanism includes a metal segment in mechanical and electrical communication with the remainder of the connection mechanism on at least one side. The segment includes at least one tab protruding from the segment on a first side and a central area of the segment with a plurality of metal deformations. When the metal deformations are pressed into aluminum, they are capable of piercing through corrosion on the surface of the aluminum in order to make electrical contact with the aluminum.

Abstract: A system for validating a proposed crimp includes a pre-crimp modeler configured to establish a geometry for the proposed crimp, a plurality of virtual testing modules configured to determine at least one characteristic of the proposed crimp, and a virtual validation module configured to compare results from each of the plurality of virtual testing modules to predetermined criteria.

Abstract: A shielded electric cable assembly comprises a shielded electric cable and a shield terminal. The shield terminal comprises an inner ferrule and an outer ferrule. The inner ferrule is disposed between an inner insulation jacket of shielded electric cable and an exposed end portion of a conductive layer surrounding the inner insulation jacket. The outer ferrule is crimped about the exposed end portion of the woven metal shield to clamp exposed end portion of the conductive layer between the inner ferrule and the outer ferrule. The material of the outer ferrule is harder than the material of the inner ferrule so that crimped outer ferrule interlocks with the inner ferrule in the longitudinal direction.

Abstract: A shield terminal engageable with a shield of an electrical cable includes a first member having a first contact surface inclined at an acute angle relative to a longitudinal axis of the terminal and a second member having a second contact surface inclined at an acute angle relative to the longitudinal axis of the terminal. When the shield terminal is attached to the shield the first and second contact surfaces engage the shield. The second contact surface of the second member is disposed adjacent the first contact surface of the first member. A distance between the second contact surface and the first contact surface is less than a thickness of the shield.

Abstract: A system for validating a proposed crimp includes a pre-crimp modeler configured to establish a geometry for the proposed crimp, a plurality of virtual testing modules configured to determine at least one characteristic of the proposed crimp, and a virtual validation module configured to compare results from each of the plurality of virtual testing modules to predetermined criteria.

Abstract: A shielded electric cable assembly comprises a shielded electric cable and a shield terminal. The shield terminal comprises an inner ferrule and an outer ferrule. The inner ferrule is disposed between an inner insulation jacket of shielded electric cable and an exposed end portion of a conductive layer surrounding the inner insulation jacket. The outer ferrule is crimped about the exposed end portion of the woven metal shield to clamp exposed end portion of the conductive layer between the inner ferrule and the outer ferrule. The material of the outer ferrule is harder than the material of the inner ferrule so that crimped outer ferrule interlocks with the inner ferrule in the longitudinal direction.

Abstract: An electrical connection is achieved via crimping a conventional terminal about a solid conductor. The terminal has first and second wings projecting laterally outward and in opposite directions from a base portion. An inner surface of the base portion is in electrical contact with the conductor side opposite the groove, and the outreaching wings are curled about the conductor and extend into the groove. An outer surface, opposite the inner surface, of the first and second wings engage each other within the groove to prevent spring-back of the wings out of the groove thereby assuring structural mechanical integrity of the electrical connection.

Abstract: An electrical connection is achieved via crimping a conventional terminal about a solid conductor. The terminal has first and second wings projecting laterally outward and in opposite directions from a base portion. An inner surface of the base portion is in electrical contact with the conductor side opposite the groove, and the outreaching wings are curled about the conductor and extend into the groove. An outer surface, opposite the inner surface, of the first and second wings engage each other within the groove to prevent spring-back of the wings out of the groove thereby assuring structural mechanical integrity of the electrical connection.

Abstract: The invention is directed to a spark plug boot with an improved lubricant including a perfluoroalkylpolyether, which may be blended with an extender such as a polydimethylsiloxane grease. A mixture of ratios can be utilized for desired characteristics ranging from 100:0 to 25:75 weight percent perfluoroalkylpolyether to polydimethylsiloxane.