Wire connection

Abstract

A wire connection assembly includes a wire connection having a wire connection terminal and a wire connection housing that holds the wire connection terminal. The wire connection 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 wire tube has crimp sleeves at the ends that are configured to be crimped onto the wires. The wire connection housing includes a cavity that receives the wire connection terminal. The wire connection housing includes a first cone at a first end that is configured to guide the first wire to the first end of the wire connection terminal.The wire bonding housing includes a second cone at a second end configured to guide the second wire to the second end of the wire bonding terminal. The wire bonding assembly includes a carrier strip integrated with the wire bonding housing and extending from the wire bonding housing to connect the wire bonding housing to other wire bonding locations. The wire bonding housing is configured to be separable from the carrier strip.

Description

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to methods and apparatus for connecting two wires at a wire joint.

[0002] Wire splices are used in electrical systems to enable secure and reliable connection of wires in various applications. Conventional wire splices often face challenges in their production and assembly processes, leading to inefficiencies and compromises in the overall performance of electrical systems. Existing wire splice methods and equipment can involve complicated assembly steps, complicated tooling requirements, or limitations in adapting to a variety of wire types and sizes. These issues complicate the manufacturing process and compromise the integrity of the electrical connection. Some systems use hand tools to splice the wire splice product to the wires. This assembly method is slow and labor-intensive. Other systems utilize mass-production machines to create spliced leads.However, these processes typically use loose piece splice elements, which are difficult for harness manufacturers to handle when producing harnesses in large quantities. Some mass production processes use tape to hold the splice elements together. However, improper positioning or handling of the tape and wire splices during the manufacturing process can slow production.

[0003] There remains a need for a wire connection assembly for repeatable and efficient wire harness manufacturing. BRIEF DESCRIPTION OF THE INVENTION

[0004] In one embodiment, a wire connection assembly is provided and includes a wire connection comprising a wire connection terminal and a wire connection housing that holds the wire connection terminal. The wire connection 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 wire tube has a first ferrule at the first end configured to be crimped onto the first wire. The wire tube has a second ferrule at the second end configured to be crimped onto the second wire. The wire connection housing includes a cavity that receives the wire connection terminal.The wire bonding housing includes a first cone at a first end configured to guide the first wire to the first end of the wire bonding terminal. The wire bonding housing includes a second cone at a second end configured to guide the second wire to the second end of the wire bonding terminal. The wire bonding assembly includes a carrier strip fixedly connected to the wire bonding housing. The carrier strip extends from the wire bonding housing for connecting the wire bonding housing to other wire bonds. The wire bonding housing is configured to be separable from the carrier strip.

[0005] In another embodiment, a wire connection assembly is provided and includes a wire connection comprising a wire connection terminal and a wire connection housing that holds the wire connection terminal. The wire connection 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 wire tube has a first ferrule at the first end configured to be crimped onto the first wire. The wire tube has a second ferrule at the second end configured to be crimped onto the second wire. The wire connection housing includes a cavity that receives the wire connection terminal.The wire bonding housing includes a first cone at a first end configured to guide the first wire to the first end of the wire bonding terminal. The wire bonding housing includes a second cone at a second end configured to guide the second wire to the second end of the wire bonding terminal. The wire bonding assembly includes a first heat shrink sleeve connected to the first end of the wire bonding housing and configured to be shrunk onto the first wire. The wire bonding assembly includes a second heat shrink sleeve connected to the second end of the wire bonding housing and configured to be heat shrunk onto the second wire. The wire bonding assembly includes a carrier strip fixedly connected to the wire bonding housing.

[0006] The carrier strip extends from the wire bonding housing to connect the wire bonding housing to other wire bonds. The wire bonding housing is configured to be separated from the carrier strip.

[0007] In another embodiment, a method of assembling a wire bonding assembly is provided, comprising providing a plurality of wire bonding terminals. Each wire bonding terminal comprises 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 wire tube has a first ferrule at the first end. The wire tube has a second ferrule at the second end. The method provides a plurality of wire bonding housings. Each wire bonding housing includes a cavity that receives the wire bonding terminal. The wire bonding housing includes a first cone at a first end. The wire bonding housing includes a second cone at a second end.The plurality of wire bonding housings are connected by a carrier strip that is integrally molded with the wire bonding housings. In the process, the wire bonding terminals are received in the cavities of the corresponding wire bonding housings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of a wire connection assembly in accordance with an exemplary embodiment. Fig. 2 is a perspective view of the wire connection assembly in accordance with an exemplary embodiment. Fig. 3 is a perspective view of the wire bonding assembly according to an exemplary embodiment, showing a plurality of wire bonds arranged on a carrier strip. Fig. 4 is a perspective view of the wire splice assembly showing the plurality of wire splices disposed on the carrier strip and having heat shrink sleeves applied to the ends of the wire splices according to an exemplary embodiment. Fig. 5 is a perspective view of a plurality of wire connection terminals according to an exemplary embodiment. Fig. 6 is a perspective view of a plurality of wire bonding housings in accordance with an exemplary embodiment. Fig. 7 is a cross-sectional view of the wire bonding assembly according to an exemplary embodiment, showing the wires electrically connected by the wire bond. Fig. 8 is a cross-sectional view of the wire bonding assembly according to an exemplary embodiment showing the heat shrink sleeves attached to the wire bonding housing. Fig. 9 is a schematic diagram of a wire connection assembly according to an exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] Fig. 1 is a perspective view of a wire connection assembly 100 in accordance with an exemplary embodiment. Fig. 2 is a perspective view of the wire connection assembly 100 in accordance with an exemplary embodiment. Fig. 2 shows the wire connection assembly 100 using heat shrink sleeves 300, 350 to protect the wire connection assembly 100 from moisture. Fig. 1 shows the wire connection assembly 100 without the heat shrink sleeves 300, 350. The wire connection assembly 100 is used to establish a secure and reliable connection between a first wire 110 and a second wire 120. The wire connection assembly 100 includes a wire connection 102 with a wire connection terminal 150 and a wire connection housing 200 that houses the wire connection terminal 150. The wire connection terminal 150 serves to electrically connect the first and second wires 110, 120. The wire connection housing 200 forms an insulating cover for the connection between the wire connection terminal 150 and the wires 110, 120. Fig. 1 shows the first wire 110 connected to the wire connection 102. Fig. Figure 2 shows the second wire 120 connected to the wire connection 102. During final assembly, the two wires 110, 120 are connected to the wire connection terminal 150.

[0009] The first wire 110 includes a first conductor 112 and a first insulator 114 surrounding the first conductor 112. The first conductor 112 may be a solid wire or a stranded wire. The first insulator 114 may be extruded over the first conductor 112. In various embodiments, the first wire 110 may be a small gauge wire, such as 10-12 AWG. In other embodiments, the first wire 110 may be a large gauge wire, such as 22-26 AWG. In other embodiments, the first wire 110 may be a medium gauge wire, such as 14-16 AWG or 18-22 AWG. In one exemplary embodiment, wire bonding assemblies 100 with different sides may be provided to handle the different wire sizes.

[0010] The second wire 120 includes a second conductor 122 and a second insulator 124 surrounding the second conductor 122. The second conductor 122 may be a solid wire or a stranded wire. The second insulator 124 may be extruded over the second conductor 122. Optionally, the second wire 120 may be the same size as the first wire 110. However, in other embodiments, the wire joint 102 may also allow for the connection of wires of different sizes. In various embodiments, the second wire 120 may be a small gauge wire, such as 10-12 AWG. In other embodiments, the second wire 120 may be a large gauge wire, such as 22-26 AWG. In other embodiments, the second wire 120 may be a medium gauge wire, such as 14-16 AWG or 18-22 AWG.In an exemplary embodiment, wire connection assemblies 100 with different sides may be provided to handle the different wire sizes.

[0011] During manufacturing, when the first and second wires 110, 120 are inserted into the opposite ends of the wire splice 102, the wire splice terminal 150 may be crimped or otherwise squeezed or compressed to create a pressure connection between the wire splice terminal 150 and the first and second wires 110, 120. The wire splice housing 200 is flexible to allow crimping or compression of the wire splice terminal 150. The wire splice 102 may be applied to the ends of the wires 110, 120 using a hand tool, such as a crimping tool. In alternative embodiments, the wire splice 102 may be applied to the ends of the wires 110, 120 using a machine, such as an applicator, a crimping machine, or a conductor fabricator, for example, for high-volume wire harness production.

[0012] Fig. 3 is a perspective view of the wire bond assembly 100 according to an exemplary embodiment, showing a plurality of the wire bonds 102 arranged on a carrier strip 250. Fig. 4 is a perspective view of the wire bonding assembly 100 showing the plurality of wire bonds 102 disposed on the carrier strip 250 and having heat shrink sleeves 300, 350 attached to the ends of the wire bonds 102.

[0013] The carrier strip 250 holds the wire splices 102 in a chain to enable easier manufacturability and material handling, for example, when manufacturing wire harnesses in large quantities. The carrier strip 250 holds the wire splices 102 at predetermined distances from each other. In an exemplary embodiment, the carrier strip 250 and the wire splices 102 can be wound onto a spool for shipping and handling during manufacturing. The carrier strip 250 is used to guide the wire splices 102 through one or more processing machines during manufacturing.

[0014] In an exemplary embodiment, the wire bonding housings 200 are integrally molded with the carrier strip 250 during a common manufacturing process. For example, the wire bonding housings 200 may be molded together with the carrier strip 250 during a common molding process to ensure reliable positioning and retention of the wire bonding housings 200 for processing during manufacturing. The carrier strip 250 is made of the same material as the wire bonding housings 200, for example, a plastic material. For example, the carrier strip 250 and the wire bonding housings 200 form a unitary monolithic structure.

[0015] In an exemplary embodiment, the carrier strip 250 may be approximately centered relative to the wire bond housings 200. For example, the carrier strip 250 is disposed approximately midway between the opposite ends of the wire bond housings 200. The carrier strip 250 may be located at the bottom of the wire bond housings 200. In an exemplary embodiment, the wire bond housings 200 are configured to be separated from the carrier strip 250, for example, by cutting or otherwise separating the wire bond housings 200 from the carrier strip 250.

[0016] Fig. 5 is a perspective view of a plurality of wire bonding terminals 150 according to an exemplary embodiment. In an exemplary embodiment, wire bonding terminals 150 are stamped and formed terminals. For example, wire bonding terminals 150 may be stamped from a metal blank or sheet and formed into a generally cylindrical shape. For example, the ends of the stamped terminal may be bent or rolled into a tubular shape.

[0017] In an exemplary embodiment, a plurality of the wire bond terminals 150 are held together by a carrier strip 190. The terminal carrier strip 190 may be loaded with the wire bond terminals 150. The carrier strip 190 holds the wire bond terminals 150 in predetermined positions relative to one another for loading into a machine, such as a terminal insertion machine used to load the wire bond terminals 150 into the wire bond housings 200. The wire bond terminals 150 may be separated from the carrier strip 190 by the machine, for example, when loading the wire bond terminals 150 into the wire bond housing 200.

[0018] 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 the first wire 110 at the first end 160 and the second wire 120 at the second end 170. In an exemplary embodiment, the second end 170 is connected to the carrier strip 190, for example, with a connection tab 192. The connection tab 192 can be cut or otherwise severed from the wire connection terminal 150 when the wire connection terminal 150 is separated from the carrier strip 190.

[0019] In an exemplary embodiment, the wire tube 152 includes a window 154, which may be located approximately midway between the first end 160 and the second end 170. The window 154 may be used for visual inspection, for example, to confirm that the ends of the wires 110, 120 are fully received within the wire tube 152. The window 154 may provide a space for material flow during the crimping process, wherein the wire tube 152 is crimped to the conductors of the wires 110, 120. The wire tube 152 includes a connector bar 156 below the window 154. The connector bar 156 connects the sections of the wire tube 152 on opposite sides of the window 154.

[0020] The wire tube 152 includes a first crimp sleeve 162 at the first end 160. The first crimp sleeve 162 is configured to be crimped onto the end of the first wire 110. The first crimp sleeve 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 is flared outwardly at the first edge 164. For example, the wire tube 152 is flared at the first end 160. In an exemplary embodiment, the wire tube 152 forms a terminal cone 166 at the first end 160. The terminal cone 166 serves 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 may be used to position the wire connection terminal 150 within the wire connection housing 200, for example, to restrict or limit the receipt of the wire connection terminal 150 into the wire connection housing 200.

[0021] The wire tube 152 includes a second ferrule 172 at the second end 170. The second ferrule 172 is configured to be crimped onto the end of the second wire 120. The second ferrule 172 extends between the window 154 and a second edge 174 of the wire tube 152 at the second end 170. In an exemplary embodiment, the wire tube 152 is generally cylindrical and has a constant diameter along the second end 170, while not flaring outwardly like the first end 160. Thus, the second end 170 of the wire tube 152 can be easily received within the wire connection housing 200. In alternative embodiments, the first end 160 can be similar to the second end 170, for example, without the flared portion that forms the terminal cone 166.In other alternative embodiments, the second end 170 may include a flared portion forming a terminal cone (not shown) at the second end 170.

[0022] Fig. 6 is a perspective view of a plurality of wire bonding housings 200 in accordance with an exemplary embodiment. In an exemplary embodiment, the wire bonding housings 200 are molded. The wire bonding housings 200 may be molded together, for example, with the carrier strip 250 and the molding strips 280, 290 at opposite ends of the wire bonding housings 200. During the molding process, the molding material (e.g., plastic) may flow between the wire bonding 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 bonding housings 200 relative to one another.In an exemplary embodiment, the mold strips 280, 290 are severed from the wire bonding housings 200 during a removal operation, leaving the wire bonding housings 200 on the carrier strip 250, which can be wound onto a spool for transport and dispensing during later manufacturing processes.

[0023] Each wire bonding housing 200 includes a housing body 202 defining a cavity 204 extending between a first end 210 and a second end 220 of the wire bonding housing 200. The cavity 204 is configured to receive the wire bonding terminal 150. The cavity 204 is open at the first end 210 to receive the first wire 110 and at the second end 220 to receive the second wire 120. In an exemplary embodiment, the first end 210 is open to receive the wire bonding terminal 150 during assembly. However, in alternative embodiments, the wire bonding terminal 150 may also be received within the second end 220. In an exemplary embodiment, the body of the housing 202 is generally tubular. For example, the body of the housing 202 may be cylindrical.In other embodiments, the housing body 202 may have one or more planar surfaces, such as a planar surface along the bottom and / or the ceiling and / or the sides.

[0024] In an exemplary embodiment, the wire connection housing 200 includes a first cone 212 at the first end 210. The first cone 212 is used to guide the end of the first wire 110 into the cavity 204. The first cone 212 may be enlarged relative to a central portion 206 of the housing body 202. The first cone 212 is enlarged to provide a larger opening for receiving the end of the first wire 110. The first funnel 212 may taper inward toward the cavity 204 to guide the first wire 110 into the wire connection terminal 150 held in the cavity 204. In an exemplary embodiment, the first heat shrink sleeves 300 ( Fig. 4) are applied to the first funnel 212.

[0025] In an exemplary embodiment, the wire connection housing 200 includes a second cone 222 at the second end 220. The second cone 222 is used to guide the end of the second wire 120 into the cavity 204. The second cone 222 may be enlarged relative to a central portion 206 of the housing body 202. The second cone 222 is enlarged to provide a larger opening for receiving the end of the second wire 120. The second cone 222 may taper inward toward the cavity 204 to guide the second wire 120 into the wire connection terminal 150 held in the cavity 204. In an exemplary embodiment, the second heat shrink sleeves 350 ( Fig. 4) be applied to the second funnel 222.

[0026] In an exemplary embodiment, the support strip 250 extends from the sides of the central portion 206. The support strip 250 may be located approximately midway between the first and second cones 212, 222. For example, the support strip 250 may be spaced apart from the first cone 212 and the second cone 222. In an exemplary embodiment, the wire bonding housings 200 extend over the support strip 250. For example, the support strip 250 is oriented perpendicular to the central portions 206 of the wire bonding housings 200. In an exemplary embodiment, the carrier strip 250 extends across the bottom of the wire bonding housings 200. For example, the carrier strip 250 may be continuously connected to the central portions 206 of the wire bonding housings 200 that are located above the carrier strip 250.Optionally, the wire bonding housings 200 can be separated from the carrier strip 250 by making a horizontal cut between the wire bonding housings 200 and the carrier strip 250, leaving the carrier strip 250 intact for further pulling the wire bonding housings through the manufacturing machines. In other embodiments, the wire bonding housings 200 can be separated from the carrier strip 250 by making vertical cuts between the wire bonding housings 200 and the carrier strip 250 along the sides of the center portion 206.

[0027] Fig. 7 is a cross-sectional view of the wire bond assembly 100 in accordance with an exemplary embodiment, showing the wires 110, 120 electrically connected by the wire bond 102. Fig. Figure 8 is a cross-sectional view of the wire connection assembly 100 according to an exemplary embodiment, showing the heat shrink sleeves 300, 350 attached to the wire connection housing 200. The wires 110, 120 are in Fig. 8 to illustrate the components of the wire connection 102.

[0028] In an exemplary embodiment, the heat shrink sleeves 300, 350 are attached to the first and second ends 210, 220 of the wire bond 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 bond 102 does not include a single heat shrink sleeve extending across the entire wire bond 102. For example, because the carrier strip 250 extends from both sides of the wire bond housing 200, it may not be possible to use a single heat shrink sleeve for the wire bond 102. Furthermore, it may be undesirable to attach the heat shrink sleeves 300, 350 to the portions of the wire bond housing 200 that connect to the ferrules 162, 172.For example, the crimping tool may damage or tear the heat shrink sleeve material covering such portions of the wire bonding housing 200, which may cause the heat shrink sleeve material to become stuck or otherwise interfere with the proper operation of the crimping tool.

[0029] 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 connection housing 200. For example, the housing attachment end 302 is attached to the first cone 212. In an exemplary embodiment, an inner surface of the heat shrink sleeve 300 at the housing attachment end 302 includes an adhesive layer to secure the housing attachment end 302 to the first cone 212. The housing attachment end 302 can be attached to the wire connection housing 200 through the application of heat during a shrink application. The housing attachment end 302 can form a moisture barrier between the heat shrink sleeve 300 and the wire connection housing 200.In an exemplary embodiment, the wire attachment end 304 is shielded from heat when the housing attachment end 302 is attached to the first cone 212. Therefore, the wire attachment end 304 does not shrink inward when the housing attachment end 302 is attached to the wire connection housing 200. Rather, the wire attachment end 304 remains flared outward to form a large receiving space for receiving the first wire 110 into the wire connection 102. After the wire connection 102 is completed with 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 insulator 114 of the first wire 110. For example, the wire attachment end 304 may be subjected to heat during a shrinking process, causing the wire attachment end 304 to shrink inward and attach to the insulator 114.The wire attachment end 304 may form a moisture barrier between the heat shrink sleeve 300 and the first wire 110.

[0030] In an exemplary embodiment, the second heat shrink sleeve 350 includes a housing attachment end 352 and a wire attachment end 354. The housing attachment end 352 is attached to the wire bonding housing 200. For example, the housing attachment end 352 is attached to the second cone 222. In an exemplary embodiment, an inner surface of the heat shrink sleeve 350 at the housing attachment end 352 includes an adhesive layer to secure the housing attachment end 352 to the second cone 222. The housing attachment end 352 can be attached to the wire bonding housing 200 through the application of heat during a shrink application. The housing attachment end 352 can form a moisture barrier between the heat shrink sleeve 350 and the wire bonding housing 200.In an exemplary embodiment, the wire attachment end 354 is shielded from heat exposure when attaching the housing attachment end 352 to the second cone 222. Thus, the wire attachment end 354 does not shrink inward when the housing attachment end 352 is attached to the wire connection housing 200. Rather, the wire attachment end 354 remains flared outward to form a large receiving space for receiving the second wire 120 into the wire connection 102. After the wire connection 102 is completed with the second wire 120, the wire attachment end 354 of the second heat shrink sleeve 350 can be attached to the outer surface of the insulator 124 of the second wire 120. For example, the wire attachment end 354 may be subjected to heat during a shrinking process, causing the wire attachment end 354 to shrink inward and become attached to the insulator 124.The wire attachment end 354 may form a moisture barrier between the heat shrink sleeve 350 and the second wire 120.

[0031] The wire splice housing 200 houses the wire splice terminal 150. The wire splice housing 200 is constructed of an insulating material to insulate the wire splice terminal 150 and the wires 110, 120. The heat shrink sleeves 300, 350 are configured to be shrunk onto the wires 110, 120 to provide moisture protection for the electrical connection. The wire splice 102 can be used with or without the heat shrink sleeves 300, 350, depending on the particular application and the end use of the wiring harness.

[0032] During wire connection assembly, the wire connection terminal 150 is received within the cavity 204 of the wire connection housing 200. For example, the second end 170 of the wire connection terminal 150 is received within the opening in the wire connection housing 200 at the first end 210 of the wire connection housing 200. The first cone 212 may be used to guide the second end 170 of the wire connection terminal 150 into the cavity 204. In an exemplary embodiment, the inner diameter of the wire connection housing 200 is approximately equal to the outer diameter of the wire tube 152 so that the wire connection terminal 150 is snugly retained within the cavity 204. The wire connection terminal 150 may be retained within the cavity 204 by an interference fit.

[0033] In an exemplary embodiment, the wire bonding housing 200 includes a positioning lip 224 at the second end 220. The second edge 174 of the wire bonding terminal 150 at the second end 170 is configured to abut the positioning lip 224 when the wire bonding terminal 150 is received into the cavity 204. The positioning lip 224 serves to position the wire bonding terminal 150 within the cavity 204. The positioning lip 224 restricts movement of the wire bonding terminal 150 beyond the positioning lip 224. For example, the positioning lip 224 prevents overloading of the wire connection terminal 150 in the cavity 204. The positioning lip 224 positions the second ferrule 172 in the center portion 206 of the wire connection housing 200.

[0034] In an exemplary embodiment, the wire bonding housing 200 includes a funnel pocket 214 at the first end 210. The funnel pocket 214 receives the terminal cone 166 at the first end 160 of the wire bonding terminal 150. In an exemplary embodiment, the wire bonding terminal 150 has an enlarged diameter at the terminal cone 166. The enlarged diameter is larger than the inner diameter of the cavity 204 of the wire bonding housing 200 to prevent the terminal cone 166 from being received into the central portion 206 of the wire bonding housing 200. The terminal cone 166 abuts the wire bonding housing 200 within the funnel pocket 214 to prevent overloading of the wire bonding terminal 150 within the cavity 204.The terminal cone 166 and the funnel pocket 214 are used to position the wire bond terminal 150 within the wire bond housing 200, for example, to align the first ferrule 162 with the central portion 206 of the wire bond housing 200.

[0035] During assembly, the end of the first wire 110 is received into the first end of the wire connection 102. For example, the first cone 212 receives the end of the first wire 110. The first cone 212 guides the end of the conductor 112 of the first wire 110 into the wire connection terminal 150. The first cone 212 serves to insert the first wire 110 into the wire connection terminal 150. In an exemplary embodiment, the terminal cone 166 of the wire connection terminal 150 guides the conductor 112 of the first wire connection 110 into the first ferrule 162. The terminal cone 166 serves to insert the first conductor 112 into the first ferrule 162. The first ferrule 162 can be crimped onto the first conductor 112 after the first wire 110 has been received into the wire connection 102.In an exemplary embodiment, the material of the wire connection housing 200 is compliant so that the crimping tool can compress the wire connection housing 200 sufficiently to crimp the first ferrule 162 to connect the wire connection 102 to the first wire 110.

[0036] During assembly, the end of the second wire 120 is received into the second end of the wire joint 102. For example, the second cone 222 receives the end of the second wire 120. The second cone 222 guides the end of the conductor 122 of the second wire 120 into the wire joint terminal 150. The second funnel 222 guides the second wire 120 into the second ferrule 172 of the wire joint terminal 150. The second ferrule 172 can be crimped onto the second conductor 122 after the second wire 120 is received into the wire joint 102. In an exemplary embodiment, the material of the wire connection housing 200 is compliant so that the crimping tool can compress the wire connection housing 200 sufficiently to crimp the second ferrule 172 to complete the wire connection 102 with the second wire 120.

[0037] In an exemplary embodiment, the wire bond 102 is separated from the carrier strip 250 during manufacturing. The wire bond 102 may be separated from the carrier strip 250 after the wires 110, 120 have been incorporated into the wire bond 102 and / or after the wire bond 102 has been terminated at the ends of the wires 110, 120, for example, after the crimping process.

[0038] Fig. Figure 9 is a schematic view of a wire connection assembly according to an exemplary embodiment. An exemplary method for manufacturing wire harnesses from wire connection assemblies is described with reference to Fig. 9. In alternative embodiments, the method may include additional processes or steps. In other embodiments, the processes or steps described herein may be omitted.

[0039] In an exemplary embodiment, a machine 500 is provided for forming wire bond terminals. A wire bond housing manufacturing machine 510 is provided for manufacturing wire bond housings. An assembly machine 520 is provided for assembling the wire bond terminals and wire bond housings to connect the wires into a wire harness.

[0040] The wire bond terminal forming machine 500 includes a punching machine 502, a forming machine 504, and a coiling machine 506. The wire bond terminals are punched from a metal sheet in the punching machine 502. In one exemplary embodiment, the wire bond terminals are arranged on a carrier strip, which is punched out with the wire bond terminals in the punching machine 502. The wire bond terminals are formed into a predetermined shape at the forming machine 504. For example, the wire bond terminals are formed into a generally tubular shape. Optionally, one or both ends can be flared outward to form a terminal cone, which serves to guide the ends of the wires into the wire tube of the wire bond terminal. The wire bond terminals and the carrier strip for the terminals are wound onto a coil by the winding machine 506.The terminal carrier strip enables the product to be wound onto a reel on the reel machine 506 for transportation, handling, and / or further processing.

[0041] The wire bonding housing forming machine 510 includes a forming machine 512, a heat shrink sleeve application machine 514, and a coiling machine 516. The wire bonding housings are formed in the forming machine 512. For example, the wire bonding housings may be injection molded on the forming machine 512. In an exemplary embodiment, the wire bonding housings are injection molded with a carrier strip as a one-piece structure. The wire bonding housings are formed to include a cavity sized and shaped to receive the wire bonding terminals. Optionally, the ends of the wire bonding housings may be provided with heat shrink sleeves that are attached to the heat shrink sleeve application machine 514. The wire bonding housings and carrier strip are wound onto a spool by the spool machine 516 for transportation, handling, and / or further processing.

[0042] Both the terminal comprising the wire bond terminals and the terminal comprising the wire bond housings are fed to the assembly machine 520. The assembly machine 520 includes a terminal insertion machine 522, one or more wire insertion machines 524, one or more crimping machines 526, one or more heat-shrink tubing applicators 528, and a carrier strip removal machine 530. The wire bond terminals are loaded into the wire bond housings at the terminal loading machine 522. For example, the wire bond terminals are separated from the carrier strip of the terminal and inserted into the cavity of the wire bond housing at the end of the wire bond housing. The ends of the wires are loaded into the wire bond by the wire loading machines 524. The wire bond is terminated at the ends of the wires using the crimping machines 526.When heat shrink sleeves are used, heat shrink machines 528 apply the heat shrink sleeves to the wires. The wire splices are removed from the carrier strip using removal machine 530. For example, the wire splices can be separated from the carrier strip to separate the wire harness, with the wire splice connecting the wires of the wire harness. The wire can be further processed using other machines.

[0043] It should be understood that the above 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 one another. Furthermore, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, material types, orientations of the various components, and the number and arrangement of the various components described herein are intended to define parameters of particular embodiments and are in no way restrictive and merely represent 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 above description.The scope of the invention should therefore be determined by reference to the appended claims, along with the full scope of equivalents to which those claims are entitled. In the appended claims, the terms "including" and "wherein" are used as simple equivalents of the respective terms "comprising" and "wherein." Furthermore, 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 subject matter. Further, the limitations of the following claims are not in the "means plus function" format and are not intended to be construed based on 35 USC 8 112(f) unless such claim limitations expressly use the phrase "means for" followed by an explanation of the function without further structure.

Claims

[1] Wire connection assembly comprising: a wire connection comprising a wire connection terminal and a wire connection housing that holds the wire connection terminal, the wire connection terminal comprising 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 wire tube having a first ferrule at the first end configured to be crimped onto the first wire, the wire tube having a second ferrule at the second end configured to be crimped onto the second wire, the wire connection housing comprising a cavity that receives the wire connection terminal, the wire connection housing comprising a first cone at a first end configured to guide the first wire to the first end of the wire connection terminal,wherein the wire connection housing includes a second cone at a second end configured to guide the second wire to the second end of the wire connection terminal; and, a carrier strip integrated with the wire bonding housing, the carrier strip extending from the wire bonding housing for connecting the wire bonding housing to other wire bonds, the wire bonding housing being configured to be separated from the carrier strip. [2] The wire bonding assembly of claim 1, wherein the carrier strip and the wire bonding housing form a unitary monolithic structure. [3] The wire connection assembly of claim 1, wherein the carrier strip is disposed between the first and second ends of the wire connection housing. [4] The wire connection assembly of claim 1, wherein the carrier strip is disposed approximately centrally along the wire connection housing between the first and second ends. [5] The wire bonding assembly of claim 1, wherein the carrier strip is located at a bottom of the wire bonding housing. [6] The wire bond assembly of claim 1, wherein the wire bond is configured to be wound onto a spool with the carrier strip in the other wire bonds. [7] The wire connection assembly of claim 1, wherein the wire connection terminal includes a terminal entry at the first end forming a terminal cone configured to guide the first wire into the first ferrule. [8] The wire connection assembly of claim 1, wherein the wire connection housing includes a positioning lip, the second end of the wire connection terminal engaging the positioning lip to position the wire connection terminal in the cavity. [9] The wire connection assembly of claim 1, wherein the first cone has a first cone diameter, the second cone has a second cone diameter, the cavity has a cavity diameter smaller than the first and second cone diameters, the second end of the wire connection terminal has a diameter smaller than the cavity diameter to receive the wire tube of the wire connection terminal into the cavity, the first end of the wire tube being flared outwardly and having a large diameter larger than the cavity diameter to prevent the first end from entering the cavity. [10] The wire connection assembly of claim 1, further comprising a first heat shrink sleeve connected to the first end of the wire connection housing and configured to be heat shrunk onto the first wire, and a second heat shrink sleeve connected to the second end of the wire connection housing and configured to be heat shrunk onto the second wire. [11] Wire connection assembly comprising: a wire connection having a wire connection terminal and a wire connection housing that holds the wire connection terminal, wherein the wire connection terminal comprises 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, wherein the wire tube has a first ferrule at the first end configured to crimp onto the first wire, wherein the wire tube has a second ferrule at the second end configured to crimp the second wire, wherein the wire connection housing has a cavity that receives the wire connection terminal, wherein the wire connection housing has a first cone at a first end configured to guide the first wire to the first end of the wire connection terminal,wherein the wire connection housing has a second cone at a second end configured to guide the second wire to the second end of the wire connection terminal; a first heat shrink sleeve coupled to the first end of the wire connection housing and configured to be heat shrunk onto the first wire; a second heat shrink sleeve connected to the second end of the wire connection housing and configured to heat shrink onto the second wire; and a carrier strip integrated with the wire bonding housing, the carrier strip extending from the wire bonding housing for connecting the wire bonding housing to other wire bonds, the wire bonding housing being configured to be separated from the carrier strip. [12] The wire connection assembly of claim 11, wherein the first heat shrink sleeve comprises a first housing attachment end attached to the wire connection housing and a first wire attachment end extending beyond the first end of the wire connection housing and configured to be attached to the first wire, wherein the second heat shrink sleeve comprises a second housing attachment end attached to the wire connection housing and a second wire attachment end extending beyond the second end of the wire connection housing and configured to be attached to the second wire. [13] The wire connection assembly of claim 11, wherein the first heat shrink sleeve is separate and discrete from the second heat shrink sleeve, the first heat shrink sleeve being spaced apart from the second heat shrink sleeve. [14] The wire connection assembly of claim 11, wherein the carrier strip is disposed between the first heat shrink sleeve and the second heat shrink sleeve. [15] The wire connection assembly of claim 11, wherein the first heat shrink sleeve is connected to the first cone remote from the portion of the wire connection housing that holds the first ferrule, and wherein the second heat shrink sleeve is connected to the second cone remote from the portion of the wire connection housing that holds the second ferrule. [16] A method of assembling a wire connection assembly, comprising: Providing a plurality of wire connection terminals, each wire connection terminal comprising 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 wire tube having a first ferrule at the first end and the wire tube having a second ferrule at the second end; Providing a plurality of wire bonding housings, each wire bonding housing comprising a cavity that receives the wire bonding terminal, the wire bonding housing comprising a first carrier strip at a first end, the wire bonding housing comprising a second carrier strip at a second end, the plurality of wire bonding housings being connected by a carrier strip integrally molded with the wire bonding housings; Insert the wire connection terminals into the cavities of the corresponding wire connection housings. [17] The method of claim 16, wherein providing the plurality of wire bonding terminals comprises providing the wire bonding terminals on a terminal carrier, the method further comprising separating the wire bonding terminals from the terminal carrier prior to receiving the wire bonding terminals into the cavities of the respective wire bonding housings. [18] The method of claim 16, further comprising separating the wire bonding housings from the carrier strip after the wire bonding terminals have been received into the respective wire bonding housings. [19] The method of claim 16, further comprising attaching a first heat shrink sleeve to the first end of the wire connection housing and attaching a second heat shrink sleeve to the second end of the wire connection housing. [20] The method of claim 16, wherein providing a plurality of wire bonding housings connected to the carrier strip comprises co-molding the carrier strip with a plurality of wire bonding housings.

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