Abstract: A wire harness manufactured by a new method and a new apparatus is provided. A covered wire paid out from a selected one of reels is extended in a predetermined lay-out and fixed. The thus fixed wire is cut-off from the reel. Then, another wire is paid out from another reel for arranging it in a juxtaposing relation to the previously laid-out wire and cut off from the reel. After repeating the above steps, the arranged wires are tied up to form a wire harness. There is also provided a device which puts the above method into practice, thereby reducing complicated assorting work involved in the manufacture of a wire harness. A method and a device for automatically uncovering end portions of each wire of the wire harness and attaching terminals thereto are also provided to greatly increasing the productivity.

Abstract: A connector for a coaxial cable comprises a single stamping having four equally spaced branches 1 to 4 and defining a central aperture 5. Each branch 1 to 4 has spring clip portions 6 at its free end and wing portions 8. To attach the connector the outer conductor of the cable, which consists of a plurality of parallel strands, is stripped of insulation. The strands revealed are split into four groups 11 which are laid in the four branches 1 to 4 and the wing portions 8 closed over them while the central conductor 12 of the cable is pushed through the aperture 5. The branches 1 to 4 are then folded through 90.degree. so that their end edges form the sides of a square and their spring clip portions 6 can receive the four spades of a complementary connector part which surround a central socket for the reception of the central conductor 12. The connector may have more or less than four branches and the branches may be individual connectors.

Abstract: A contact is bulk fed into the side of a guide block where it is raised up into a crimping head. A sectioned funnel guides wire ends into the positioned contact, after which the sections move apart to permit bottoming of the wires in the contact, and then the contact is crimped to the wire.

Abstract: A body implantable lead having a barrel-shaped ring electrode with the ends of the barrel embedded into the lead casing material. A cylindrical flange within the bore of the ring electrode contacts the lead conductor. The lead and electrode are formed by placing the lead in a press with the electrode between a pair of collets with elliptical working surfaces and the lead casing and conductor passing through the axial bore of the collets, and forcing the collets together to shape the electrode and to force the ends of the ring into the casing and the flange into contact with the lead conductor.

Abstract: Apparatus to automatically attach a terminal to electrical wire and thereafter to install insulating pods on the terminal. The apparatus includes a press which attaches the terminal to form a terminated wire and a transfer block which moves the terminated wire to an insulation pod installation station. The pods are delivered to the pod installation station in an interconnected fashion so as to form a strip of pods. The first pod on the strip is separated from the rest of the strip and placed on the terminated wire.

Abstract: A method of crimping contact wires (24) into a holder (26) of a brush contact (24) in which a converging series of indentors (16) each having a Vee-shaped tip (72) are advanced into the holder by a cam sleeve (30) engaging cam surfaces (18) on each indentor, to form valley-shaped crimp recess (78) forcing the holder material between adjacent pairs of contact wires (24), which arrange themselves in a symmetrical pattern during the crimping. A series of flats (70) are also formed on the holder (26) end to tightly bundle the contact wires (24) projecting from the holder (26). The indentors (16) and holder (26) are mounted in a nest (14) during the crimping process.

Abstract: A novel automatic multiple wire terminal applying machine which is selectively operable to simultaneously attach to one or both of the adjacent or opposite ends of multiple lengths of wire either a single terminal common to all of the wires or an individual terminal on each wire.

Abstract: A continual crimper for pressing an electric wire to an electric terminal, which is belted intermittently one by one, to make the wire fixed to the terminal respectively. The crimper is so constructed that the intermittently belted terminals may be transferred to its position of the next pressing step at a predetermined distance in relation with the returning action of a movable die which presses the terminal.

Abstract: One end portion of a cable comprising a multiplicity of core wires is inserted into a cylindrically shaped electrically conductive member one end of which is flared. A band made of synthetic resin or synthetic rubber or the like is provided on the end portion of the cable, and the cylindrical electrically conductive member, except for flared portion thereof, is pressed into a rectangular shape.

Abstract: A method and apparatus are disclosed for terminating multi-conductor cable. A plurality of terminals are preloaded partially into a housing leaving their crimped terminating portions extending therefrom in such a position as they can be readily crimped connected to a cable. This allows for the terminals to be gang handled during the loading of the housing and yet be separated for individual termination on the cable. The cable can be crimped simultaneously to all of the terminals and the terminals fully inserted into the housing in subsequent operations. The terminal used with the subject method and apparatus includes an extra tine which serves alignment, stabilization, and cable positioning functions.

Abstract: An electrical connector progressively made from a one piece blank has a reinforced wire barrel, integral strain relief ferrule, and an internal wire ramp therebetween. The reinforced wire barrel includes nested cylindrical walls having side edges contacting opposite surfaces of an offset web extending between and interconnecting the two cylindrical walls.

Abstract: A method of making a releasable electrical connector assembly having a brush-type contact including the steps of: positioning an elongated electrical conductor having an axial passage extending therethrough; sliding over the conductor an elongated body having a flanged end portion extending radially outwardly; inserting several straight wires of electrically conductive material into one end of the conductor; securing together the wires, the conductor and the elongated body, the wires forming a brush for releasably mating with a like bunch of wires; inserting an exposed electrically conducting end portion of a cable into the opposite end of the conductor and into engagement with the ends of the wires; securing the end portion of the cable and the conductor together, thereby establishing an electrical circuit relationship between the cable, the straight wires and the conductor and thereby providing the brush-type contact.

Abstract: An electrical connector for a multiconductor cable is disclosed where the connector is formed at one end of a conductor disposed in a flexible metal conduit by providing the conductor with a terminal at the one end and placing at least a portion of the terminal along with portions of the conductor and the flexible metal conduit in a connector forming cavity to thereafter form insulating material about the terminal, conductor and flexible metal conduit portions in the cavity. By this technique the insulating material may be made to conform to the exterior of the flexible metal conduit portion and also to conform to a section of the interior of that conduit along a length extending beyond the cavity thereby providing an extremely rugged and serviceable connector arrangement. The terminal may be simply crimped about the conductor near the end thereof and somewhat beyond the end of the flexible metal conduit and the insulating material formed by an injection molding technique.

Abstract: Method and apparatus for cutting and stripping a plurality of wires, applying terminals to the ends of the wires, and inserting wires en masse into the cavities in a connector housing. A shuttle having telescoping tubes which contain the wires therein is attached to carriage which travels on a rail and delivers wires axially at a first fixed spacing on a linear path to an operating zone, insertion station, and strip and shear station. Tubing collapses to extrude wire into operating zone where wires are compensated by deflecting laterally of their axes various amounts such that subsequent rolling into a template will restore the wire ends to a straight array so they can be terminated to a strip of terminals at a second fixed spacing. Tubes expand to draw terminated wires therein as shuttle retreats, then connector housing is delivered onto linear path and shuttle advances to insert terminated wires therein.

Abstract: A discharge electrode assembly (14) and the method of assembly thereof for use in a wet electrostatic precipitator includes a flat grid-like frame comprised of four vertical tubes 50, 52, 54, 56 and a pair of horizontal tubes (58, 60). Crimpable tubes (70, 72) are welded in holes formed in the end vertical tubes in a staggerred relationship to engage the tip ends of electrode wire segments (62, 64). Such wires are generally J-shaped and are inserted into the crimp tubes so that each pair of adjacent wires forms a single loop. The wires are secured to the frame only at their ends by crimping the crimp tubes.

Abstract: In the method, lengths of wire are drawn from wire supplies and cut, each end of each cut wire being stripped of insulation and terminated, and the cut wire then being laid along a predetermined path defined by guide pins on a loom board. The wire lengths are then bound together and removed from the board. The wire is handled by a mechanical gripper which moves and is actuated under preprogrammed electronic control.The apparatus comprises a loom board or the means by which such a loom board can be made, an automatic manipulator having a controlled gripper to draw wire from a preselected supply, a cutter to cut the wire, a wire stripper and insulative sleeve applicator and a terminal supply and crimper, both accessible to the gripper which can then lay the terminated wire lengths along predetermined paths on the loom board, and a tape binder which binds the laid wires together to form the required wiring loom.

Abstract: A pair of feeder bowls are placed one above the other to simultaneously feed two different types of wire contacts onto two different tracks, and into separate alignment openings in a guide block. A pivotally mounted crimper is selectively moved to position the crimper head over the selected alignment opening. A rod extending from the crimper automatically positions a selector bar to actuate a plunger rod to move the selected contact into position to be crimped.

Abstract: Apparatus comprises a plug holder having a passage therein profiled to axially receive a plug body with a metal sleeve preassembled thereto. Neck dies slideably mounted in the holder move radially inward to shear sleeve and crimp it into a circumferential recess in the plug body and a nose die slideably mounted in the holder moves axially inward to form the sleeve to a tapered leading end of the plug.

Abstract: A sound, low resistance joint is provided between two electrically conductive members, at least one having a bonded insulation coating thereon. In one form of the method of the present invention, a continuous metallic penetrator having sharp edges or burrs, such as a brass screen, is interwoven about at least two bonded insulation coated conductive members. The coated conductive members and interwoven penetrator are placed in a conductive connector member having chamfered holes therein. Welding electrodes subject the connector member to heat and pressure with welding current flowing between the welding electrodes. At least some of the welding current flows through the continuous metallic penetrator before the penetrator makes electrical contact to the insulation coated conductive members. The penetrator becomes heated by thermal heat from the welding electroides and resistance heat as the welding current passes therethrough.

Abstract: A method for manufacturing an encapsulated probe or measuring head on sheathed thermocouples, in which thermocouple wires are imbedded in an outer metal sheath with the interposition of an insulating material, and wherein a thermal bead is produced by either an electric or autogeneous process at the sections of the thermocouple wires projecting from the metal sheath at the measuring head end of the wire.

Abstract: This invention relates to methods and apparatus for making electrical connectors and, in one embodiment suitable for use with a multiplicity of parallel planar arrayed, spaced-apart insulated conductors, comprises means for and the steps of retainably positioning the conductor array above the crimp retainer portions of interconnected connector members, inserting the conductors into the connectors, positionally affixing the conductors to the connectors as by crimp means encircling the cable insulation and crimp means enveloping the exposed cable conductors, shearing the strips which interconnect the connector members to each other, and inserting the cables and their associated connectors into an associated connector block.

Abstract: According to the method for joining a fiberglass plastic rod to a metal fitting of an electrical device, a bore is first provided in the metal fitting, the diameter of said bore being somewhat greater than that of the fiberglass plastic rod. One of the rod's ends is then installed in the bore, and the gap defined between the bore formed in the metal fitting and fiberglass plastic rod is filled with a porous material. The whole is then compressed by using the pulse loading technique. The use of pulse loading for joining the fiberglass plastic rod to the metal fitting makes it possible to develop a high pressure in the zone of the joint without destroying the rod; this task is facilitated by the presence of the porous layer between the rod and metal fitting. Compression by pulse loading does not necessitate the use of expensive equipment, nor does it impose stringent accuracy requirements upon the elements to be joined.

Abstract: A heat-recoverable article comprises a memory metal member to which has been imparted both thermally-recoverable and resiliently-recoverable strain. The resilient strain is retained by means of a disburdenable keeper, preferably one made from fusible or chemically degradable material, which can be removed, for example, by heating or chemical treatment, to allow resilient recovery. The article is preferably so constructed that it can be heated to obtain both thermal and resilient recovery simultaneously. One preferred form of article is a radially expanded longitudinally split tube, the keeper being positioned in the split. Such an article can be used as a connector to secure an earth lead to the sheath of a mineral-insulated cable.

Abstract: A dimensionally-recoverable article comprising a hollow resilient member which has been expanded to a dimensionally unstable configuration in which it is retained by a keeper positioned between and separating two parts of the hollow member away from the path of recovery thereof. The keeper is preferably made from a fusible or chemically degradable material so that it can be removed, for example, by heating or chemical treatment to allow the hollow member to recover towards its original configuration. One preferred form of article is a radially-expanded longitudinally split tube having the keeper positioned within the split. Such an article may be used as a connector to secure an earth lead to the sheath of a mineral-insulated cable.

Abstract: There is provided a method for stripping the jacket from a multi-pair flat cable having a plurality of coplanar insulated conductors. Each side of the jacket of the cable is scored near the end to be terminated. The alternate conductors are separated into two groups pointing in two different directions extending a certain distance from the end of the cable. The first group of conductors is pulled in a direction away from the second group, thereby separating one side of the jacket of the cable from the other. Each side of the separated jacket is peeled away from the conductors on both sides of the cable, starting at the scorings and moving away from the end of the cable. The cable conductors may then be readily gang terminated to a connector.

Abstract: An electrical connector having a head that includes a bottom and two upstanding, parallel, spaced ridges or members. The bottom and the upstanding members define a slot or groove adapted to receive an electrical wire. The end of a wire such as an electric resistance heating element can be inserted into the slot. Then, using an orbital riveter to apply a plurality of spaced, angular blows to the ridges, the wire can be staked to the head by riveting the ridges so that material is forced over the wire in the slot.

Abstract: Electrical connecting device is intended to be applied to a wire comprises an insulating housing having a wire-receiving end and a cavity extending into the wire-receiving end. A terminal is partially inserted into the cavity so that the crimp portion of the terminal is outside of the cavity and adjacent to the wire-receiving end. After the crimp portion has been crimped onto a wire, the terminal is moved to a fully inserted condition so that the finished termination is completely insulated. The housing and partially inserted terminal are produced as an endless strip which can be fed to a crimping machine.