US2457796A - Method of forming and assembling connecting sleeves - Google Patents

Description

Dec. 28, 1948 v J. M. WHITE 2,457,796

I METHOD OF FORMING AND ASSEMBLING CONNECTING SLEEVES Filed Oct. 10, 1944 a so 31 lll'ili A 15 x Q;

JESSE M. WHITE INVENTOR.

Patented Dec. 28, 1948 UNITED STATES PATENT OFFICE METHOD OFFORMING AND ASSEMBLING CONNECTING SLEEVES Jesse M. White, Philadelphia, Pa. 1 Application October 10, 1944, Serial No. 558,097

9 Claims.

This invention relates to harnesses such as are employed in conjunction with the wiring of motor vehicles and is concerned primarily with the construction and assembly of the connecting sleeves included in such harnesses.

This application is a continuation in part of application Serial No. 481,639, filed April 2, 1943 (now abandoned) which is a division of my application Serial No. 199,579, filed April 2, 1938, now

Patent No. 2,318,647, which issued under date of May 11, 1943.

At the present time it is common practice in this art to utilize a connecting sleeve whichcomprises an outer sleeve member of appropriate insulating material, and within which is assembled an inner sleeve of conducting material. .This inner sleeve carries, adjacent each extremity, an inwardly extending protuberance designed for cooperation with a groove on a terminal which may be inserted into thesleeve, and the inner sleeve is anchored to the outer insulating sleeve in a manner which is not meeting with complete satisfaction in this art, and which is intended to be improved by the present invention,

Accordingly, this invention has in view, as its foremost objective, the provision of a connecting sleeve of the character above noted which embodies improved means. for assembling the inner conducting sleeve with the outer insulating sleeve.

More in detail this invention contemplates an arrangement wherein the insulating sleeve is maintained uniform and even so far as the outer cylindrical walls thereof are concerned, but which includes on the wall of the bore extending therethrough an inwardly projecting lug. The inner conducting sleeve is of a split construction, and intermediate its extremities is cut away to, provide a recess for receiving the lug.

A particularly important object of the invention is the provision of a novel method offassembling an inner conducting sleeve of the character above noted with the outer insulating sleeve. This method essentially involves the formation of the split sleeve construction with the edge at each side of the split notched to ultimately provide a recess for receiving the lug. The blank or metal from which the sleeve is formed is then deformed into a sleeve-like formation, with one end compressed to a greater degree than the other end, to cause the edges of the split to overlap, whereupon the sleeve may be inserted with the constricted portion riding over the lug in the outer insulating sleeve. Subsequent expansion of the split sleeve by an appropriate tool insures l l 2 of a firm anchorage of the inner sleeve within the outer insulating sleeve.

Another highly important object of the present invention is to provide, in a connecting sleeve of the character above noted, an innerconducting sleeve which includes novel andimproved projections designed to cooperate withterminals which may be inserted thereinto.

More in detail this invention has as an object the provision of an inner conducting sleeve which is formed at each end with a projection extending into the bore thereof, and which projection is characterized as including a gradually inclined surface extending toward the open end of the sleeve, and which terminates in a sharp shoulder. These protuberances may be formed by being struck from the blank of metal prior to the latter being deformed into the sleeve formation.

Various othermore detailed objects and advantages such as arise in connection with forming the outer insulating and inner conducting sleeves respectively, and assembling the same in accordance with this invention, will in part become apparent and in part be hereinafter stated.

The invention, therefore, comprises a connecting sleeve which consists of an outer insulating sleeve having a bore which is interrupted by an inwardly extending lug. Received within the bore is an inner conducting sleeve of a split construction, and having a recess for receiving the said lug. The inner conducting sleeve is also formed adjacent each extremity with an inwardly extending protuberance which presents a gradually inclined surface extending towards the open end of the sleeve, and which terminates in an abrupt shouler. A particularly important part of the invention is the method of assembling the inner conducting sleeve with the outer insulated sleeve.

For a full and more complete understanding of the invention reference may be had to the following description and accompanying drawings, wherein Figure l is 'a side view of an outer insulating sleeve made in accordance with the precepts of this invention. In this view a part of the sleeve has been broken away to bring out the construction of the inwardly extending lug;

Figure 2 is a view in end elevation of the sleeve shown in Figure 1, and is taken in the direction indicated by the arrow 2 of Figure 1;

Figure 3 is a similar view taken from the other end looking in the direction of the arrow 3;

Figure 4 is a plan view of a blank of metal prior to being deformed into the sleeve-like formation;

Figure 5 shows the blank of metal after it has been partially deformed, while Figure 6 develops the inner sleeve in condition for being inserted into the outer sleeve;

Figure '1' is an elevational showing through the connecting sleeve as an entirety developing a terminal as assembled therewithin;

Figure 8 is a sectional View of certain die pressing apparatus which may be;emp loyed.in.;the manufacture of the outer insulating sleeve;

Figure 9 is a plan view of a modified form of conductor means or insert means; and

Figure 10 is a perspective. View showing. the conductor means or insert means illustratedin Figure 9 in a contracted state ready for insertion into the insulator housing.

Referring now to the drawings: wherein-like.

reference characters denote corresponding parts,

and more particularly to Figures 1, 2 and-3;; am.

outer insulating sleeve intended to constitute an essential-.gpa-rtl t th-e -co nnecting-; sleeve of this invention is identified by the reierencecharacter I ll andis shown as .-having;.a;1;substantially smooth everrputer cylindrical, wall This sleeve; I 0 .may-

be made-from any appropriate insulating:- mate.- ia i bu e m ea 2 21 ar rs in-min 34 131161191 condensation products which is susceptible, while in atplasticstate, to being formed byv die-- pressing;operationsdnto the construction he e n i e eser b d; net l-3 The: sleeve i lli hasran inner cylindricalbore I I whieh1is interrupted by. a lug; designated I2 hez q i'? a e eial sed m yr considered to be a. cavity apenture-g chamber" or pocket. The-dug I 2 ;is-.forme d :irr thebore l i substantially equiedistant the.'g61fldS thl3r80f,1 and. one edge thereof ,is;cut away; to: provide a-Joevel designated I 3, this for salpurpose to be hereinafter described;

Theendofthesleeve I O-towards which thebeveled-f edge: %I 3 is I disposed is; provided with suitable.

indicia,; such 'asthenick shown" at 92in. Figure 2,

this-for, the-purposevof ;indicating twhich. end is to be used in inserti ithe, innerjconnecting sleeve into. this outertinsulating sleeve;

It is aparticularly notable. that the lug I2 extends onl-y avshort distance into the= bore I I, as. depictedsiimfl-igures z ands 3,; leaving: sufiicient; roomfor :thednsertion of the inner sleeve; as will.

b e er n ite pa nted t.

Inasmuch as the-invention has in view. .thelformation of the outer insulating -sleeve=l 0 l by; a .die. pressingoparationa reference is il'lQwimEtditQjFig ure 8. Which' shows; an;outergcontainingrmcld eleament g I A formed;..with: a-borezl 5 in: which operate 1 fisslfi fin 7-. The ,dielfiecarriesria' core .I8rof cylindrical; formation; while the-;.di-e :,I 'I carries a;

cored SI,1 one 'endcofgiwhichzisrcut'awayg' as shown at 20 toadefine. ;a.space-in:which: the lug I 2 is formed. It -.is eviden,t.:,that :whenathe dies.- I6 and 1 I1 are brought towards each other; and-:withxthe insu= latingmateriall a plastic .state positioned. about the cores I8 and I9, the insulating material .will be worked into. :the sleeveelikeu formation illustrated...

Referring now- ;.morewparticularly{to :Figure' 4;

alblanksof= metalfrom which the inner-conducting sleeve is formedsis identified inaitsentirety by the.

reference .characte r,-.-B; 4 The ;-:metal 1 employed in the manufacture of; atherinner conducting; sleeve should obviously be a :good conducting material. such as an appropriate copper alloy, which has the desired. properties; of springiness and resiliency; I

TheblankB. ist of. a gener ,1 rectangular formation presenting edges 2| and 22 which are formed:

substantially equi-distantly between their eX- tremities with notches 23 and 24. At one end the blank B is formed with a projection defined by a gradually inclined wall 25, and a sharp abrupt shoulder 26, and this projection is duplicated at the other extremity of the blank. It will be noted that the inclined walls 25 extend towards the free edge of the blank B, while the abrupt shoulderifitis \disposedtowards the central portion of the=blank"B.

The blank B with the notches 23 and 24 and the projections defined by the surfaces 25 and 26 may beformediina single stamping operation by employing appropriate dies in a well-known manner.

Aftervtheblank B has been fashioned, as shown in Figured, itlis bent into the formation depicted in Figure 5," in which it will be noted that the edgesdiland 22 are spaced apart. This deforming of the blank B is continued further until the blank assumes the. sleeve-likeformationidentified infisure 6-, and the inner;conn'ecting sleeve; is -nowh identifiedcbya the reference character S;

It ..will. .be noted that the notches 23 and 24- cooperate to define atrecess .designatedd'l, and that .at.one end theedges .2 I and .22 iaresl-ightly spaced: apart, .as indicated at 1.28. At the r other end,,how.ever, ,the. deformation. has .been carried furtherto provide an .overlappbetween the edges.

2 land-22, as shownatllia It 'isxevident that the portion of the sleeve S formed withtthe overlap" sertedinto the end of.. the sleeve I0-which .bears. the indicating nicks... The,.constricted diametrie cal .dimensionof theoverlapZB provides for the latter riding over. the lug I2..with. thebevel- I3 cooperatingin ,thislactionz.

When thesleeve Shas been inserted an -appropriate distancethe. lug .I 2 will bereceived. in the recess 21', andfan appropriate tool may now-be.

' availed offto expandjthatpportion ofth'esleeVe carryingth'e,overlap,29;. Theother extremity of the sleeves'lmayalsobe expanded by a tool to provide anoticeable advantage. This advantage is tied -up with'the ,factlth'at thesmaterial. employed. in the formation .ofthe "inner connecting sleeve S'h'asth'e .propertyof resiliency and springiness, toaa required iextent... When once formed into .the constrictedformation.shown, and later expanded,'i the metalfalways .exerts a! tendencyto return toits constrictedzcondition. Thus when a.

terminal such..asshown at'T is inserted into. the bore of Tthfe sleevesctheconicalformation of the nose of 'the terminalfwhich. is indicatedat 30 111. cause ,the terminals .toQride. past the incli'nedfsurfaces 25;. exertinga slight expanding.

action on the sleeves; v

However; when the projection defined'by the surfaces -'25and"26 'is positioned in the groove 3| form'edimtheterminal Tf the metal of the sleeve s'will =exert"a 'markeditendency to'grip the ter= terminal T in the-connecthrg sleevep It is -'notable that the groove 1 3 I may include a sharply inclined shouldersuch as shown at 32,

whichi-isdesigned;for=cooperation with the abrupt i above; desQri-bednexcept for. :three important 83m ace-mac tures. The modified form of insertmeans isprovided witha centrally disposed generally-rectangular cutout 33 of asize to. receive the lug l2. The longitudinal sides of the cutout are preferably disposed parallel :to the end-margins-v of the insert and the transverse ends of the cutoutgene erallyparallel toathe longitudinal edges of the insert means. The longitudinal edges of the insert means are preferably interrupted by a pair of transverse notches opposite the end mar gins of the cutout 33. By providing arelatively large cutout or recess 33 and the notches or slits 35, the blank maybe easily rolled or formed, preferably into the desired shape illustrated .;in Figure so as to provide substantially:corresponding terminal receptacles 36, which:are mo1 e or less independently operable of each other. In this modification or embodiment of the invention both of the terminal receptacles are preferably contracted. By this arrangement either end or extremity of the insert means may be inserted into an end of the insulator housing so that the recess formed by the cutout receives the lug l2, whereupon both of the receptacles 36 are expanded separately or simultaneously, thus looking the parts in assembly.

Accordingly, it will be apparent that in the modification of the invention illustrated in Figures 9 and 10, the recess is disposed in a different place, that both of the receptacles are contracted and subsequently expanded; and that either end of the insert means may be inserted into one end of the insulator housing.

The above described methods and construction of the parts provides a highly simplified construction of outer insulating sleeve and inner conducting sleeve respectively, together with a method for assembling these parts so as to positively insure of the sembled position.

Obviously slight changes might be made in the several steps of the method and formation of the particular parts without departing from the spirit of the invention as set forth in the appended claims.

I claim:

1. The method of assembl ng a connecting sleeve of the character described which consists in forming an outer insulating sleeve having a bore and carrying a lug extending into said bore, forming an inner conducting sleeve of a split construction with a recess intermediate the extremities thereof, constricting said inner sleeve at one end to a greater extent than at the other, and then inserting said constricted end into said outer sleeve, and passing the constricted end past the said lug to cause the latter to be received in said recess.

2. The method of assembling a connecting sleeve of the character described which consists in forming an outer insulating sleeve having a bore and carrying a lug extending into said bore, forming an inner conducting sleeve of a split construction with a recess itnermediate the extremities thereof, constricting said inner sleeve at one end to a greater extent than at the other, and then inserting said constricted end into said outer sleeve, passing the constricted end past the said lug to cause the latter to be received in said recess, and then expanding said constricted end portion.

3. The method of assembling an inner conducting sleeve with an outer insulating sleeve having a bore and carrying a lug extending into said bore which consists in first stamping a blank of parts maintaining their asmetal into substantially a rectangular formation with a notch in each side thereof, deforming said blank into-(a sleeve-like, formation with the said notches; defining atrecess, constricting one end of said sleeve-like formation to cause the meeting edges totoverlap, andthen passing said portionhaving-the overlapping, edges into said outer insulating -sleevepast said lug to cause the lug to be receivedinsaidrecess.

4. Theqmethod of. assembling an inner conducting sleeve ,with an outer insulating sleeve having-a boreand carrying a lug extending into said-bore which consists in first stamping. a blank of metal into. substantially a rectangular formationnvithza notch in each sidethereof, deformin said .LbIank into asleeve-like formation with the said notches defining a recess, constricting one end of said sleeve-like formation to cause the meeting edges to overlap, then passing said portion having the overlapping edges into said outer insulating sleeve past said lug to cause the lug to be received in said recess, and then expanding that portion of the sleeve having the overlapped edges.

5. The method of forming and assembling an inner conducting member with an outer insulating body having a cavity and carrying abutment means extending into said cavity which consists in providing notches in a blank of metal, deforming said blank into a pair of terminal receptacles with the said notches defining a recess, compressing a portion of one of the receptacles so that the portion overlaps another portion of the receptacle, and then passing said overlapped portion into said outer insulating body past said abutment means to cause the abutment means to be received in said recess.

6. The method of forming and assembling an inner conducting member with an outer insulating body having a chamber and carrying abutment means extending into said chamber which consists in providing notches in a blank of metal, deforming said blank into a pair of terminal receptacles with the said notches defining a recess, compressin at least a portion of one receptacle so that the portion overlaps another portion thereof, then passing said overlapped portion into said outer insulating body past said abutment means to cause the abutment means to be received in said recess and so that the overlapped portion may be expanded to lock the parts together.

7. The method of forming and assembling a contact with a chambered body of insulating material provided with a pair of abutment means, which consists in forming a blank of metal into a wire holding part and terminal receiving means and making a notch between the part and receiving means with the notch and an adjacent edge of the contact forming a recess, compressing at least a portion of the receiving means, and then inserting the contact into the chamber to a point substantially entirely within the confines of the body of insulating material so that at least a portion of the part and a portion of the receiving means are disposed side by side in offset overlapped relation in the chamber and the recess will receive one of the abutment means whereby to assist in holding the contact against movement in one direction and so that the compressed portion when expanded will engage the other abutment means to hold the contact against movement in another direction.

8. The method of forming and assembling conductor means with a tubular open-ended body of 2} insulating material of which a: portion thereof. may form lockingmeans; whiehconsist's in form-v inga cut-out in a blank: of metal; shaping the blank into a pair of 1 receptacles: adapted to r'e=-- ceiveconductors with: the cut-outand an adja-- cent; edge of the conductor mean-swarming a re:- cess between the receptacles; andthen'inserting the conductor meanssubstantially entirely into the body of insulating material to'engagethe-ree cess with the locking portion of said' body! 9. A method of fol-'ming and" assemb1in'g 'con:-' ductorrmeanswith a bodyi-offinsulating material having an opening: therein 1 ofwhichavportion of: the' body: may" constitute locking means; which consists in forming: azcut-out in ablank of mateirial; shaping the blankinto an pair: of condncl'm'.-

engagingrportionszwithathe cut out disposed'be tween-t the engaging. portions; and. then inserting the conduotor meansinto the opening'of :Ithe body of insulating material so that a portion of the bodyaisreceived' in the out-out wherebyv to lookttheparts'imassembly.

JESSE MLWHITEL REFERENCE-S CITED The fol-lowing"; references are: of i record 'in' the fiie: of this" patent:

UN STA'I'ES: PATENTS;

Number Name Date 1276?,80'8 N-ietmam June 24, 1930 235E003. Douglas May 9, 1939

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