METHOD OF CONNECTING AN ELECTRICAL TERMINAL TO AN ELECTRICAL WIRE CABLE AND A WIRE HARNESS ASSEMBLY MANUFACTURED ACCORDING TO SAID METHOD

摘要

A method of connecting an electrical wire cable having a plurality of uninsulated wire strands to an electrical terminal is presented. The method includes the steps of crimping an electrical wire cable within a crimping feature of an electrical terminal having wire strands protruding from the crimping feature and fusing the wire strands of protruding portion, or “wire brush” so that the wire strands are in intimate contact, thereby eliminating voids between individual wire strands of the wire brush. The wires may be fused by laser welding, soldering, or brazing. The method may be especially beneficial for wire strands having an insulative oxide layer, such as aluminum. The bonding reduces the resistance between the wire strands due to insulating oxide layers on the surface of the wire strands and inhibiting of corrosion by eliminating inter-strand gaps where electrolytes in solution may enter and cause galvanic corrosion.

主权项

1. A method of connecting an electrical wire cable having a plurality of uninsulated wire strands to an electrical terminal, said method comprising the steps of:
crimping an uninsulated end of the electrical wire cable within a crimping feature of the electrical terminal, wherein a portion of the plurality of uninsulated wire strands protrudes from the crimping feature; and fusing the wire strands of said protruding portion so that the wire strands are in intimate contact, thereby eliminating voids between individual wire strands of the protruding portion.