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Method for increasing the contact cross-section of a cable Disclosure Number: IPCOM000218051D
Publication Date: 2012-May-16

Publishing Venue

The Prior Art Database

Related People

Schmidt Rainer: INVENTOR [+1]


Abstract The present invention relates to a method for increasing a contact cross-section of a cable (100). The method comprises providing a cable (100) with cable strands (102) surrounded by a cable sheathing (101) and dismantling the cable strands (102) within a dismantled end section (103) of the cable (100). The method further comprises fixing a free end (107) of the dismantled end section (103) and winding an intermediate section (109) of the dismantled end section (103) to achieve an elongated n-fold winding (120) while the free end (107) is fixed and releasing the free end (107) of the dismantled end section (103).

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Page 01 of 17


Method for increasing the contact cross-section of a cable

     1. Field of the invention 5

The present invention relates to a method for increasing the contact cross-section of a cable, in particular to improve mechanical and electrical connection properties between an electrical cable of small cross-section and a larger or standard sized contact terminal.

      2. Technical background 10

In many fields of applications, it is necessary to provide ends of electrical cables with secure and reliable connection elements to connect the cables for example to further cables or electric components. To this end, usually an end section of a cable is dismantled,

      i.e. a cable sheathing for insulating conductive cable strands is removed and the strands 15

are connected to the corresponding contact element like for example to a contact terminal.

In order to improve the quality of such a connection, a contact cross-section, i.e. the diameter of the dismantled cable end section can be increased. For example, the contact


cross-section can be doubled by bending the cable end section backwards by about 180°.

A corresponding method for improving such a connection is described in the US patent no. 3,008,221. Therein it is described to connect a dismantled cable end section to a contact element which is provided in form of a ceramic resistant body which is coated by


electrically conductive material such as for example lustrous carbon. This ceramic body is provided with an elongate socket for the reception of the dismantled cable end section. In order to provide a strong mechanical and a good electrical connection, before inserting the dismantled cable end section into the socket, the cable end section is bent backwards essentially by 180° degrees to form essentially a U-shaped end section. The U-shaped end


section is pressed into the socket whereby the metal of the cable strands deforms being pressed against inner walls of the elongate socket.

Page 02 of 17


In particular in the field of automotive applications, it is common to connect cables to corresponding contact terminals by crimping. Via crimping, generally a dismantled cable end section is placed in a crimping portion of a contact terminal and crimping wings of said crimping portion are bent and pressed around the cable end section such that the cable is firmly attached to the contact terminal. This technique is a standard technique


which is commonly used. However, due to increasing complexity of electronics and the resulting increasing amount of necessary cables, cables of smaller cross-sections are required, i.e. cables of cross-sections as small as 0.08 mm2. In order to crimp cables of such small cross-sections to contact terminals, terminals with a correspondingly small cross-section are required to allow for sufficiently strong crimping connections. However,


it is desirable to develop techniques which allow to use cables of reduced cross-section with already existing electric str...