Wire connector

Abstract

The invention relates to a wire connector. A wire terminal assembly includes a wire terminal having a wire terminal terminal and a wire terminal housing holding the wire terminal terminal. The wire terminal includes a wire tube extending between a first end configured to receive an end of a first wire and a second end configured to receive an end of a second wire. The spool has a crush barrel at an end configured to be crimped to the wire. The wire connector housing includes a cavity that receives a wire connector terminal. The wire tab housing includes a first funnel portion at the first end portion configured to guide a first wire to the first end portion of the wire tab terminal. The wire tab housing includes a second funnel portion at the second end portion configured to guide a second wire to the second end portion of the wire tab terminal. The wire connector assembly includes a carrier strip integral with the wire connector housing, the carrier strip extending from the wire connector housing for connecting the wire connector housing to other wire connectors. The wire connector housing is configured to be singulated from the carrier strip.

Description

Technical Field

[0001] The subject matter herein generally relates to methods and apparatus for joining two wires together at an in-line connection. Background Art

[0002] Wire connectors are used in electrical systems to facilitate secure and reliable interconnection of wires in various applications. Conventional wire connectors typically face challenges during their production and assembly, resulting in inefficiencies in electrical systems and impaired overall performance. Existing methods and apparatus for wire splicing can involve complex assembly steps, complex tool requirements, or limitations in accommodating different ranges of wire types and sizes. These challenges impede the manufacturing process and compromise the integrity of the electrical connection. Some systems use manual tools to connect wire connector products to wires. Such assembly methods are slow and labor-intensive. Other systems use mass production machines to form spliced leads. However, these processes typically use loose-piece connector elements that are difficult for wire harness manufacturing machines to handle in high-volume wire harness manufacturing. Some mass production methods use tapes to hold the connector elements together. However, production can slow down due to improper positioning or handling of the tapes and wire connector elements during the manufacturing process.

[0003] There is still a need for a wire connector assembly for repeatable and efficient wire harness production. Summary of the Invention

[0004] In one embodiment, a wire connector assembly is provided, and the wire connector assembly includes a wire connector that includes a wire connector terminal and a wire connector housing that holds the wire connector terminal. The wire connector terminal includes a wire tube that extends between a first end configured to receive an end of a first wire and a second end configured to receive an end of a second wire. The wire tube has a first crush tube at the first end that is configured to be crimped to the first wire. The wire tube has a second crush tube at the second end that is configured to be crimped to the second wire. The wire connector housing includes a cavity that receives the wire connector terminal. The wire connector housing includes a first funnel portion at the first end that is configured to guide the first wire to the first end of the wire connector terminal. The wire connector housing includes a second funnel portion at the second end that is configured to guide the second wire to the second end of the wire connector terminal. The wire connector assembly includes a carrier strip that is integral with the wire connector housing. The carrier strip extends from the wire connector housing for connecting the wire connector housing to other wire connectors. The wire connector housing is configured to singulate from the carrier strip.

[0005] In another embodiment, a wire splice assembly is provided, and the wire splice assembly includes a wire splice that includes a wire splice terminal and a wire splice housing that holds the wire splice terminal. The wire splice terminal includes a wire tube that extends between a first end configured to receive an end of a first wire and a second end configured to receive an end of a second wire. The wire tube has a first crimp barrel at the first end that is configured to be crimped to the first wire. The wire tube has a second crimp barrel at the second end that is configured to be crimped to the second wire. The wire splice housing includes a cavity that receives the wire splice terminal. The wire splice housing includes a first funnel portion at the first end that is configured to guide the first wire to the first end of the wire splice terminal. The wire splice housing includes a second funnel portion at the second end that is configured to guide the second wire to the second end of the wire splice terminal. The wire splice assembly includes a first heat shrink sleeve coupled to the first end of the wire splice housing that is configured to be heat-shrunk onto the first wire. The wire splice assembly includes a second heat shrink sleeve coupled to the second end of the wire splice housing that is configured to be heat-shrunk onto the second wire. The wire splice assembly includes a carrier strip integral with the wire splice housing. The carrier strip extends from the wire splice housing for connecting the wire splice housing to other wire splices. The wire splice housing is configured to be singulated from the carrier strip.

[0006] In a further embodiment, a method of assembling a wire splice assembly is provided, and the method includes providing a plurality of wire splice terminals. Each wire splice terminal includes a wire tube that extends between a first end configured to receive an end of a first wire and a second end configured to receive an end of a second wire. The wire tube has a first crimp barrel at the first end. The wire tube has a second crimp barrel at the second end. The method provides a plurality of wire splice housings. Each wire splice housing includes a cavity that receives the wire splice terminal. The wire splice housing includes a first funnel portion at the first end. The wire splice housing includes a second funnel portion at the second end. The plurality of wire splice housings are connected by a carrier strip molded integrally with the wire splice housing. The method loads the wire splice terminals into the cavities of the corresponding wire splice housings. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a perspective view of a wire splice assembly according to an exemplary embodiment.

[0008] Figure 2 is a perspective view of a wire splice assembly according to an exemplary embodiment.

[0009] Figure 3 is a perspective view of a wire splice assembly according to an exemplary embodiment, showing a plurality of wire splices arranged on a carrier strip.

[0010] Figure 4is a perspective view of a wire splice assembly according to an exemplary embodiment, which shows a plurality of wire splices disposed on a carrier strip and having heat shrink sleeves applied to the ends of the wire splices.

[0011] Figure 5 is a perspective view of a plurality of wire splice terminals according to an exemplary embodiment.

[0012] Figure 6 is a perspective view of a plurality of wire splice housings according to an exemplary embodiment.

[0013] Figure 7 is a cross-sectional view of a wire splice assembly according to an exemplary embodiment, which shows wires electrically connected through the wire splice.

[0014] Figure 8 is a cross-sectional view of a wire splice assembly according to an exemplary embodiment, which shows a heat shrink sleeve attached to the wire splice housing.

[0015] Figure 9 is a schematic view of a wire splice assembly process according to an exemplary embodiment. DETAILED DESCRIPTION

[0016] Figure 1 is a perspective view of a wire splice assembly 100 according to an exemplary embodiment. Figure 2 is a perspective view of a wire splice assembly 100 according to an exemplary embodiment. Figure 2 shows a wire splice assembly 100 using heat shrink sleeves 300, 350 to provide moisture protection for the wire splice assembly 100. Figure 1 shows the wire splice assembly 100 without the heat shrink sleeves 300, 350. The wire splice assembly 100 is used to facilitate a firm and reliable connection between a first wire 110 and a second wire 120. The wire splice assembly 100 includes a wire splice 102 having wire splice terminals 150 and a wire splice housing 200 that holds the wire splice terminals 150. The wire splice terminals 150 are used to electrically connect the first wire 110 and the second wire 120. The wire splice housing 200 provides an insulating cover for the connection between the wire splice terminals 150 and the wires 110, 120. Figure 1 shows the first wire 110 coupled to the wire splice 102. Figure 2 shows the second wire 120 coupled to the wire splice 102. During final assembly, both wires 110, 120 are coupled to the wire splice terminals 150.

[0017] The first wire 110 includes a first conductor 112 and a first insulator 114 surrounding the first conductor 112. The first conductor 112 can be a solid wire or a stranded wire. The first insulator 114 can be extruded onto the first conductor 112. In various embodiments, the first wire 110 can be a small gauge wire, such as 10 - 12 AWG. In various other embodiments, the first wire 110 can be a large gauge wire, such as 22 - 26 AWG. In various other embodiments, the first wire 110 can be a medium gauge wire, such as 14 - 16 AWG or 18 - 22 AWG. In an exemplary embodiment, different side wire splice assemblies 100 can be provided to handle different wire sizes.

[0018] The second wire 120 includes a second conductor 122 and a second insulator 124 surrounding the second conductor 122. The second conductor 122 can be a solid wire or a stranded wire. The second insulator 124 can be extruded onto the second conductor 122. Optionally, the second wire 120 can be the same size as the first wire 110. However, in other embodiments, the wire splice 102 can accommodate splicing wires of different sizes. In various embodiments, the second wire 120 can be a small gauge wire, such as 10 - 12 AWG. In various other embodiments, the second wire 120 can be a large gauge wire, such as 22 - 26 AWG. In various other embodiments, the second wire 120 can be a medium gauge wire, such as 14 - 16 AWG or 18 - 22 AWG. In an exemplary embodiment, different side wire splice assemblies 100 can be provided to handle different wire sizes.

[0019] During manufacturing, when the first wire 110 and the second wire 120 are inserted into opposite ends of the wire splice 102, the wire splice terminal 150 can be crimped or otherwise squeezed or compressed to form a compression connection between the wire splice terminal 150 and the first wire 110 and the second wire 120. The wire splice housing 200 is flexible to allow crimping or compressing the wire splice terminal 150. The wire splice 102 can be applied to the ends of the wires 110, 120 using a manual tool, such as a crimping tool. In an alternative embodiment, the wire splice 102 can be applied to the ends of the wires 110, 120 by a machine, such as an applicator, a crimping machine, or a wire harness manufacturing machine, such as for high volume wire harness production.

[0020] Figure 3 is a perspective view of a wire splice assembly 100 according to an exemplary embodiment, showing a plurality of wire splices 102 arranged on a carrier strip 250. Figure 4 is a perspective view of the wire splice assembly 100, showing a plurality of wire splices 102 arranged on a carrier strip 250 and having heat shrink sleeves 300, 350 applied to the ends of the wire splices 102.

[0021] The carrier strip 250 holds the wire connectors 102 in a chain to allow for easier manufacturability and material handling, such as for high-volume wire harness production. The carrier strip 250 holds the wire connectors 102 at a pre-determined spacing from each other. In an exemplary embodiment, the carrier strip 250 and the wire connectors 102 can be wound on a reel for transportation and handling during manufacturing. The carrier strip 250 is used to convey the wire connectors 102 through one or more processing machines during manufacturing.

[0022] In an exemplary embodiment, the wire connector housing 200 is integrally formed with the carrier strip 250 during a co-manufacturing process. For example, the wire connector housing 200 can be co-molded with the carrier strip 250 during a co-molding process to ensure reliable positioning and retention of the wire connector housing 200 for processing during manufacturing. The carrier strip 250 is made of the same material (such as a plastic material) as the wire connector housing 200. For example, the carrier strip 250 and the wire connector housing 200 are a single integral structure.

[0023] In an exemplary embodiment, the carrier strip 250 can be approximately centered relative to the wire connector housing 200. For example, the carrier strip 250 is approximately centered between opposite ends of the wire connector housing 200. The carrier strip 250 can be located at the bottom of the wire connector housing 200. In an exemplary embodiment, the wire connector housing 200 is configured to be singulated from the carrier strip 250, such as by cutting the wire connector housing 200 from the carrier strip 250 or otherwise separating it from the carrier strip 250.

[0024] Figure 5 is a perspective view of a plurality of wire connector terminals 150 according to an exemplary embodiment. In an exemplary embodiment, the wire connector terminals 150 are terminals that are stamped and formed. For example, the wire connector terminals 150 can be stamped from a metal blank or sheet and formed into a generally cylindrical shape. For example, the ends of the stamped terminals can be bent or curled into a tubular shape.

[0025] In an exemplary embodiment, a plurality of wire connector terminals 150 are held together by a terminal carrier strip 190. The terminal carrier strip 190 can be stamped together with the wire connector terminals 150. The terminal carrier strip 190 holds the wire connector terminals 150 in pre-determined positions relative to each other for loading into a machine (such as a terminal insertion machine for inserting the wire connector terminals 150 into the wire connector housing 200). For example, when the wire connector terminals 150 are loaded into the wire connector housing 200, the wire connector terminals 150 can be singulated from the terminal carrier strip 190 by a machine.

[0026] Each wire connection terminal 150 includes a wire tube 152 extending between a first end 160 and a second end 170. The wire tube 152 is configured to receive a first wire 110 at the first end 160 and a second wire 120 at the second end 170. In an exemplary embodiment, the second end 170 is connected to a carrier strip 190, such as using a connection tab 192. When the wire connection terminal 150 is singulated from the carrier strip 190, the connection tab 192 can be cut or otherwise separated from the wire connection terminal 150.

[0027] In an exemplary embodiment, the wire tube 152 includes a window 154 that may be approximately centered between the first end 160 and the second end 170. The window 154 can be used for visual inspection, such as to confirm that the ends of the wires 110, 120 are fully loaded into the wire tube 152. The window 154 can provide space for material flow during the crimping process in which the wire tube 152 is crimped to the conductors of the wires 110, 120. The wire tube 152 includes a connection track 156 below the window 154. The connection track 156 connects portions of the wire tube 152 on opposite sides of the window 154.

[0028] The wire tube 152 includes a first crimp barrel 162 at the first end 160. The first crimp barrel 162 is configured to be crimped onto the end of the first wire 110. The first crimp barrel 162 extends between the window 154 and a first edge 164 of the wire tube 152 at the first end 160. In an exemplary embodiment, the first end 160 of the wire tube 152 flares outwardly at the first edge 164. For example, the wire tube 152 expands at the first end 160. In an exemplary embodiment, the wire tube 152 forms a terminal funnel 166 at the first end 160. The terminal funnel 166 is used to guide the end of the first wire 110 into the wire tube 152. The flared portion of the wire tube 152 at the first end 160 can be used to position the wire connection terminal 150 in a wire connection housing 200, such as to restrain or limit the loading of the wire connection terminal 150 into the wire connection housing 200.

[0029] The wire tube 152 includes a second crimping cylinder 172 at the second end portion 170. The second crimping cylinder 172 is configured to be crimped onto the end of the second wire 120. The second crimping cylinder 172 extends between the window 154 and the second edge 174 of the wire tube 152 at the second end portion 170. In an exemplary embodiment, the wire tube 152 is generally cylindrical and has a constant diameter along the second end portion 170, rather than flaring out as at the first end portion 160. Accordingly, the second end portion 170 of the wire tube 152 can be easily loaded into the wire splice housing 200. In an alternative embodiment, the first end portion 160 can be similar to the second end portion 170, such as having no flared portion forming the terminal funnel 166. In other alternative embodiments, the second end portion 170 can include a flared portion forming a terminal funnel (not shown) at the second end portion 170.

[0030] Figure 6 is a perspective view of a plurality of wire splice housings 200 according to an exemplary embodiment. In an exemplary embodiment, the wire splice housing 200 is a molded component. The wire splice housings 200 can be co-molded with each other, such as using a carrier strip 250 and molding strips 280, 290 at opposite ends of the wire splice housings 200. During the molding process, molding material (e.g., plastic) can flow between the wire splice housings 200 through the carrier strip 250 and the molding strips 280, 290. The carrier strip 250 and the molding strips 280, 290 position the wire splice housings 200 relative to each other. In an exemplary embodiment, the molding strips 280, 290 are removed during the removal process for separation from the wire splice housings 200, leaving the wire splice housings 200 on the carrier strip 250, and the carrier strip 250 can be wound on a reel for transportation and distribution during a later manufacturing process.

[0031] Each wire splice housing 200 includes a housing body 202 that forms a cavity 204 extending between a first end portion 210 and a second end portion 220 of the wire splice housing 200. The cavity 204 is configured to receive a wire splice terminal 150. The cavity 204 is open at the first end portion 210 to receive a first wire 110 and open at the second end portion 220 to receive a second wire 120. In an exemplary embodiment, the first end portion 210 is open to receive the wire splice terminal 150 during assembly. However, in an alternative embodiment, the wire splice terminal 150 can be loaded into the second end portion 220. In an exemplary embodiment, the housing body 202 is generally tubular in shape. For example, the housing body 202 can be cylindrical. In various other embodiments, the housing body 202 can have one or more flat surfaces, such as flat surfaces along the bottom and / or top and / or sides.

[0032] In an exemplary embodiment, the wire splice housing 200 includes a first funnel portion 212 at a first end 210. The first funnel portion 212 is configured to guide an end of a first wire 110 into the cavity 204. The first funnel portion 212 may expand relative to a central portion 206 of the housing body 202. The first funnel portion 212 expands to provide a larger opening for receiving the end of the first wire 110. The first funnel portion 212 may taper inwardly to the cavity 204 to guide the first wire 110 into the wire splice terminal 150 held in the cavity 204. In an exemplary embodiment, a first heat shrink sleeve 300 ( Figure 4 ) may be applied to the first funnel portion 212.

[0033] In an exemplary embodiment, the wire splice housing 200 includes a second funnel portion 222 at a second end 220. The second funnel portion 222 is configured to guide an end of a second wire 120 into the cavity 204. The second funnel portion 222 may expand relative to a central portion 206 of the housing body 202. The second funnel portion 222 expands to provide a larger opening for receiving the end of the second wire 120. The second funnel portion 222 may taper inwardly to the cavity 204 to guide the second wire 120 into the wire splice terminal 150 held in the cavity 204. In an exemplary embodiment, a second heat shrink sleeve 350 ( Figure 4 ) may be applied to the second funnel portion 222.

[0034] In an exemplary embodiment, a carrier strip 250 extends from a side of the central portion 206. The carrier strip 250 may be approximately centered between the first funnel portion 212 and the second funnel portion 222. For example, the carrier strip 250 may be spaced apart from the first funnel portion 212 and spaced apart from the second funnel portion 222. In an exemplary embodiment, the wire splice housing 200 spans the carrier strip 250. For example, the carrier strip 250 is oriented perpendicular to the central portion 206 of the wire splice housing 200. In an exemplary embodiment, the carrier strip 250 extends across the bottom of the wire splice housing 200. For example, the carrier strip 250 may be continuous with the central portion 206 of the wire splice housing 200 located above the carrier strip 250. Optionally, the wire splice housing 200 may be singulated from the carrier strip 250 by making a horizontal cut between the wire splice housing 200 and the carrier strip 250, such that the carrier strip 250 remains intact to continue pulling the wire splice housing through a manufacturing machine. However, in other embodiments, the wire splice housing 200 may be singulated from the carrier strip 250 by making a vertical cut between the wire splice housing 200 and the carrier strip 250 along the side of the central portion 206.

[0035] Figure 7 is a cross-sectional view of a wire splice assembly 100 according to an exemplary embodiment, showing wires 110, 120 electrically connected by a wire splice 102. Figure 8is a cross-sectional view of a wire splice assembly 100 showing heat shrink sleeves 300, 350 attached to a wire splice housing 200 according to an exemplary embodiment. Figure 8 , wires 110 , 120 are removed to illustrate components of wire joint 102 .

[0036] In an exemplary embodiment, the heat shrink sleeves 300, 350 are attached to the first end 210 and the second end 220 of the wire joint housing 200, respectively. In an exemplary embodiment, the first heat shrink sleeve 300 is separate and discrete from the second heat shrink sleeve 350. For example, the wire joint 102 does not include a single heat shrink sleeve that spans the entire wire joint 102. For example, because the carrier strip 250 extends from both sides of the wire joint housing 200, it may not be possible to use a single heat shrink sleeve on the wire joint 102. In addition, it may be undesirable to dispose the heat shrink sleeves 300, 350 on portions of the wire joint housing 200 associated with the crush barrels 162, 172. For example, the crimping tool may damage or tear the heat shrink sleeve material covering such portions of the wire joint housing 200, which may cause the heat shrink sleeve material to attach to the crimping tool or otherwise hinder the proper operation of the crimping tool.

[0037] In an exemplary embodiment, the first heat shrink sleeve 300 includes a housing attachment end 302 and a wire attachment end 304. The housing attachment end 302 is attached to the wire joint housing 200. For example, the housing attachment end 302 is attached to the first funnel portion 212. In an exemplary embodiment, the inner surface of the heat shrink sleeve 300 at the housing attachment end 302 includes an adhesive layer to fix the housing attachment end 302 to the first funnel portion 212. The housing attachment end 302 can be attached to the wire joint housing 200 by applying heat during the heat shrink application. The housing attachment end 302 can form a moisture barrier between the heat shrink sleeve 300 and the wire joint housing 200. In an exemplary embodiment, when the housing attachment end 302 is attached to the first funnel portion 212, the wire attachment end 304 is shielded from the application of heat. As such, when the housing attachment end 302 is attached to the wire joint housing 200, the wire attachment end 304 does not shrink inward. Instead, the wire attachment end 304 remains flared outward to form a large gathering space for loading the first wire 110 into the wire header 102. After the wire header 102 is terminated to the first wire 110, the wire attachment end 304 of the first heat shrink sleeve 300 can be attached to the outer surface of the insulation 114 of the first wire 110. For example, heat can be applied to the wire attachment end 304 during the heat shrink application, causing the wire attachment end 304 to shrink inward and attach to the insulation 114. The wire attachment end 304 can form a moisture barrier between the heat shrink sleeve 300 and the first wire 110.

[0038] In an exemplary embodiment, the second heat shrinkable sleeve 350 includes a housing attachment end 352 and a wire attachment end 354. The housing attachment end 352 is attached to the wire joint housing 200. For example, the housing attachment end 352 is attached to the second funnel portion 222. In an exemplary embodiment, the inner surface of the heat shrinkable sleeve 350 at the housing attachment end 352 includes an adhesive layer to fix the housing attachment end 352 to the second funnel portion 222. The housing attachment end 352 can be attached to the wire joint housing 200 by applying heat during heat shrinkage application. The housing attachment end 352 can form a moisture barrier between the heat shrinkable sleeve 350 and the wire joint housing 200. In an exemplary embodiment, when the housing attachment end 352 is attached to the second funnel portion 222, the wire attachment end 354 is shielded from the application of heat. Accordingly, when the housing attachment end 352 is attached to the wire joint housing 200, the wire attachment end 354 does not shrink inward. Instead, the wire attachment end 354 remains outwardly open to form a large gathering space for loading the second wire 120 into the wire joint 102. After the wire joint 102 is terminated to the second wire 120, the wire attachment end 354 of the second heat shrinkable sleeve 350 can be attached to the outer surface of the insulator 124 of the second wire 120. For example, heat can be applied to the wire attachment end 354 during heat shrinkage application, causing the wire attachment end 354 to shrink inward and attach to the insulator 124. The wire attachment end 354 can form a moisture barrier between the heat shrinkable sleeve 350 and the second wire 120.

[0039] The wire joint housing 200 holds the wire joint terminals 150. The wire joint housing 200 is made of an insulating material to insulate the wire joint terminals 150 and the wires 110, 120. The heat shrinkable sleeves 300, 350 are configured to be heat shrinkably applied to the wires 110, 120 to provide moisture protection for the electrical connection. The wire joint 102 can be utilized with or without the heat shrinkable sleeves 300, 350, depending on the specific application and end use of the wire harness.

[0040] During assembly, the wire joint terminals 150 are loaded into the cavity 204 of the wire joint housing 200. For example, the second end 170 of the wire joint terminal 150 is loaded into an opening at the first end 210 of the wire joint housing 200 in the wire joint housing 200. The first funnel portion 212 can be used to guide the second end 170 of the wire joint terminal 150 into the cavity 204. In an exemplary embodiment, the inner diameter of the wire joint housing 200 is approximately equal to the outer diameter of the wire tube 152 such that the wire joint terminals 150 are tightly held in the cavity 204. The wire joint terminals 150 can be held in the cavity 204 by an interference fit.

[0041] In an exemplary embodiment, the wire splice housing 200 includes a positioning lip 224 at the second end 220. The second edge 174 of the wire splice terminal 150 at the second end 170 is configured to abut against the positioning lip 224 when the wire splice terminal 150 is loaded into the cavity 204. The positioning lip 224 is used to position the wire splice terminal 150 in the cavity 204. The positioning lip 224 restricts the movement of the wire splice terminal 150 beyond the positioning lip 224. For example, the positioning lip 224 prevents overloading of the wire splice terminal 150 in the cavity 204. The positioning lip 224 positions the second crimp barrel 172 in the central portion 206 of the wire splice housing 200.

[0042] In an exemplary embodiment, the wire splice housing 200 includes a funnel notch 214 at the first end 210. The funnel notch 214 receives the terminal funnel 166 at the first end 160 of the wire splice terminal 150. In an exemplary embodiment, the wire splice terminal 150 has an enlarged diameter at the terminal funnel 166. The enlarged diameter is greater than the inner diameter of the cavity 204 of the wire splice housing 200 to prevent the terminal funnel 166 from being loaded into the central portion 206 of the wire splice housing 200. The terminal funnel 166 bottoms out against the wire splice housing 200 in the funnel notch 214 to prevent overloading of the wire splice terminal 150 into the cavity 204. The terminal funnel 166 and the funnel notch 214 are used to position the wire splice terminal 150 in the wire splice housing 200, such as to align the first crimp barrel 162 with the central portion 206 of the wire splice housing 200.

[0043] During assembly, the end of the first wire 110 is loaded into the first end of the wire splice 102. For example, the first funnel 212 receives the end of the first wire 110. The first funnel 212 guides the end of the conductor 112 of the first wire 110 into the wire splice terminal 150. The first funnel 212 provides an introduction for the first wire 110 to enter the wire splice terminal 150. In an exemplary embodiment, the terminal funnel 166 of the wire splice terminal 150 guides the conductor 112 of the first wire 110 into the first crimp barrel 162. The terminal funnel 166 provides an introduction for the first conductor 112 to enter the first crimp barrel 162. After the first wire 110 is loaded into the wire splice 102, the first crimp barrel 162 can be crimped to the first conductor 112. In an exemplary embodiment, the material of the wire splice housing 200 is compliant to allow a crimping tool to compress the wire splice housing 200 enough to crush the first crimp barrel 162 to terminate the wire splice 102 to the first wire 110.

[0044] During assembly, the end of the second wire 120 is loaded into the second end of the wire connector 102. For example, the second funnel portion 222 receives the end of the second wire 120. The second funnel portion 222 guides the end of the conductor 122 of the second wire 120 into the wire connector terminal 150. The second funnel portion 222 provides an introduction for the second wire 120 into the second crimp barrel 172 of the wire connector terminal 150. After the second wire 120 is loaded into the wire connector 102, the second crimp barrel 172 can be crimped to the second conductor 122. In an exemplary embodiment, the material of the wire connector housing 200 is compliant to allow a crimping tool to compress the wire connector housing 200 enough to crush the second crimp barrel 172 to terminate the wire connector 102 to the second wire 120.

[0045] In an exemplary embodiment, during manufacturing, the wire connector 102 is separated from the carrier strip 250. After the wires 110, 120 are loaded into the wire connector 102 and / or after the wire connector 102 is terminated to the ends of the wires 110, 120 (such as after a crimping process), the wire connector 102 can be separated from the carrier strip 250.

[0046] Figure 9 is a schematic view of a wire connector assembly process according to an exemplary embodiment. Refer to Figure 9 Describe an exemplary method of forming a wire harness from a wire connector assembly. In an alternative embodiment, the method may include additional processes or steps. In various other embodiments, the processes or steps described herein may be omitted.

[0047] In an exemplary embodiment, a wire connector terminal forming machine 500 is provided for forming wire connector terminals. A wire connector housing forming machine 510 is provided for forming wire connector housings. An assembly machine 520 is provided for assembling wire connector terminals and wire connector housings to connect wires to form a wire harness.

[0048] The wire connector terminal forming machine 500 includes a stamping machine 502, a forming machine 504, and a spooling machine 506. The wire connector terminals are stamped from a metal sheet at the stamping machine 502. In an exemplary embodiment, the wire connector terminals are arranged on a terminal carrier strip that is stamped together with the wire connector terminals at the stamping machine 502. The wire connector terminals are formed into a pre-determined shape at the forming machine 504. For example, the wire connector terminals are formed into a generally tubular shape. Optionally, one or both ends may be flared outward to form a terminal funnel portion for guiding the end of a wire into the wire tube of the wire connector terminal. The wire connector terminals and the terminal carrier strip are wound onto a spool by the spooling machine 506. The terminal carrier strip allows the product to be wound onto a spool at the spooling machine 506 for transportation, handling, and / or further processing.

[0049] The wire joint housing forming machine 510 includes a molding machine 512, a heat shrinkable sleeve applying machine 514, and a spooling machine 516. The wire joint housing is formed at the molding machine 512. For example, the wire joint housing may be injection molded at the molding machine 512. In an exemplary embodiment, the wire joint housing is molded integrally with a carrier strip as a single structure. The wire joint housing is formed to include a cavity sized and shaped to receive the wire joint terminal. Optionally, at the heat shrinkable sleeve applying machine 514, the ends of the wire joint housing may receive heat shrinkable sleeves attached thereto. The wire joint housing and the carrier strip are wound onto a spool by the spooling machine 516 for transportation, handling, and / or further processing.

[0050] Both a spool including the wire joint terminal and a spool including the wire joint housing are presented to an assembly machine 520. The assembly machine 520 includes a terminal loading machine 522, one or more wire loading machines 524, one or more crimping machines 526, one or more heat shrink applying machines 528, and a carrier strip removing machine 530. The wire joint terminal is loaded into the wire joint housing at the terminal loading machine 522. For example, the wire joint terminal is singulated from a terminal carrier strip and inserted into the cavity of the wire joint housing at the end of the wire joint housing. The ends of the wire are loaded into the wire joint by the wire loading machines 524. The wire joint is terminated to the ends of the wire by the crimping machines 526. When using a heat shrinkable sleeve, the heat shrink applying machine 528 applies the heat shrinkable sleeve to the wire. The wire joint is removed from the carrier strip by the carrier strip removing machine 530. For example, the wire joint may be cut from the carrier strip to singulate a wire harness in the case of a wire harness connecting wire of the wire joint. The wire harness may be further processed by other machines.

[0051] It will be understood that the foregoing description is intended to be illustrative and not restrictive. For example, the embodiments (and / or aspects thereof) described above may be used in combination with each other. Additionally, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. The dimensions, types of materials, orientations of the various components, and the number and locations of the various components described herein are intended to define parameters of certain embodiments and are by no means restrictive, but rather are exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those skilled in the art upon review of the foregoing description. Accordingly, the scope of the invention should be determined with reference to the appended claims along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms "comprising" and "in which" are used as the plain-English equivalents of the respective terms "including" and "wherein." Further, in the following claims, the terms "first," "second," and "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Moreover, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted under 35 U.S.C. § 112, ¶ 6, unless and until such claim limitations expressly use the phrase "means for" followed by a statement of function without further structure.

Claims

1. A wire joint assembly, comprising: A wire joint, which includes a wire joint terminal and a wire joint housing for holding the wire joint terminal. The wire joint terminal includes a wire tube that extends between a first end configured to receive an end of a first wire and a second end configured to receive an end of a second wire. The wire tube has a first crimping cylinder at the first end configured to be crimped to the first wire, and a second crimping cylinder at the second end configured to be crimped to the second wire. The wire joint housing includes a cavity for receiving the wire joint terminal. The wire joint housing includes a first funnel portion at the first end configured to guide the first wire to the first end of the wire joint terminal, and a second funnel portion at the second end configured to guide the second wire to the second end of the wire joint terminal; and A carrier strip integral with the wire joint housing, the carrier strip extending from the wire joint housing for connecting the wire joint housing to other wire joints, wherein the wire joint housing is configured to be separated from the carrier strip.

2. The wire joint assembly according to claim 1, wherein, The carrier strip and the wire joint housing are a single integral structure.

3. The wire joint assembly according to claim 1, wherein, The carrier strip is located between the first end and the second end of the wire joint housing.

4. The wire joint assembly according to claim 1, wherein, The carrier strip is approximately centered along the wire joint housing between the first end and the second end.

5. The wire joint assembly according to claim 1, wherein, The carrier strip is located at the bottom of the wire joint housing.

6. The wire joint assembly according to claim 1, wherein, The wire joint is configured to be wound on a reel together with the carrier strip in the other wire joints.

7. The wire joint assembly according to claim 1, wherein, The wire joint terminal includes a terminal introduction portion at the first end, and the terminal introduction portion forms a terminal funnel portion configured to guide the first wire into the first crimping cylinder.

8. The wire joint assembly according to claim 1, wherein The wire joint housing includes a positioning lip, and the second end of the wire joint terminal engages the positioning lip to position the wire joint terminal in the cavity.

9. The wire joint assembly according to claim 1, wherein The first funnel portion has a first funnel portion diameter, the second funnel portion has a second funnel portion diameter, the cavity has a cavity diameter smaller than the first funnel portion diameter and the second funnel portion diameter, and the second end of the wire terminal has a diameter smaller than the cavity diameter to load the wire tube of the wire joint terminal into the cavity. The first end of the wire tube flares outward, thereby forming and having a large diameter greater than the cavity diameter to constrain the first end from entering the cavity.

10. The wire joint assembly according to claim 1, further comprising: A first heat shrinkable sleeve coupled to the first end of the wire joint housing, the first heat shrinkable sleeve configured to be heat-shrunk onto the first wire; And a second heat shrinkable sleeve coupled to the second end of the wire joint housing, the second heat shrinkable sleeve configured to be heat-shrunk onto the second wire.

11. A wire joint assembly, comprising: A wire connector, comprising a wire connector terminal and a wire connector housing for holding the wire connector terminal, the wire connector terminal including a wire tube that extends between a first end configured to receive an end of a first wire and a second end configured to receive an end of a second wire, the wire tube having a first crimping cylinder configured to be crimped to the first wire at the first end, the wire tube having a second crimping cylinder configured to be crimped to the second wire at the second end, the wire connector housing including a cavity for receiving the wire connector terminal, the wire connector housing including a first funnel portion at a first end configured to guide the first wire to the first end of the wire connector terminal, the wire connector housing including a second funnel portion at a second end configured to guide the second wire to the second end of the wire connector terminal; A first heat shrinkable sleeve coupled to the first end of the wire connector housing and configured to be heat shrinkably applied to the first wire; A second heat shrinkable sleeve coupled to the second end of the wire connector housing and configured to be heat shrinkably applied to the second wire; And A carrier strip integral with the wire connector housing and extending from the wire connector housing for connecting the wire connector housing to other wire connectors, wherein the wire connector housing is configured to be singulated from the carrier strip.

12. The wire joint assembly according to claim 11, wherein, The first heat shrinkable sleeve includes a first housing attachment end attached to the wire connector housing and a first wire attachment end extending beyond the first end of the wire connector housing, the first wire attachment end configured to be attached to the first wire, the second heat shrinkable sleeve includes a second housing attachment end attached to the wire connector housing and a second wire attachment end extending beyond the second end of the wire connector housing, the second wire attachment end configured to be attached to the second wire.

13. The wire joint assembly according to claim 11, wherein, The first heat shrinkable sleeve is separate and discrete from the second heat shrinkable sleeve, and the first heat shrinkable sleeve is spaced apart from the second heat shrinkable sleeve.

14. The wire joint assembly according to claim 11, wherein, The carrier strip is located between the first heat shrinkable sleeve and the second heat shrinkable sleeve.

15. The wire joint assembly according to claim 11, wherein, The first heat shrinkable sleeve is coupled to the first funnel portion away from the portion of the wire connector housing holding the first crimping cylinder, and wherein the second heat shrinkable sleeve is coupled to the second funnel portion away from the portion of the wire connector housing holding the second crimping cylinder.

16. A method of assembling a wire connector assembly, comprising: Providing a plurality of wire connector terminals, each wire connector terminal including a wire tube that extends between a first end configured to receive an end of a first wire and a second end configured to receive an end of a second wire, the wire tube having a first crimping cylinder at the first end and a second crimping cylinder at the second end; Provide a plurality of wire connector housings, each wire connector housing including a cavity for receiving the wire connector terminals, the wire connector housing including a first funnel portion at a first end and a second funnel portion at a second end, the plurality of wire connector housings being connected by a carrier strip integrally molded with the wire connector housings; Load the wire connector terminals into the cavities of the corresponding wire connector housings.

17. The method according to claim 16, wherein, The providing the plurality of wire connector terminals includes disposing the wire connector terminals on a terminal carrier, the method further including singulating the wire connector terminals from the terminal carrier before loading the wire connector terminals into the cavities of the corresponding wire connector housings.

18. The method according to claim 16, further including singulating the wire connector housings from the carrier strip after loading the wire connector terminals into the corresponding wire connector housings.

19. The method according to claim 16, further including attaching a first heat shrinkable sleeve to the first end of the wire connector housing and attaching a second heat shrinkable sleeve to the second end of the wire connector housing.

20. The method according to claim 16, wherein, The providing the plurality of wire connector housings connected to the carrier strip includes co - molding the carrier strip with the plurality of wire connector housings.

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