Crimp connection

A crimp connection is achieved with a type of solderless electrical connector.

Crimp connectors are typically used to terminate stranded wire. They fulfill numerous uses, including allowing the wires to be easily terminated to screw terminals, fast-on / quick-disconnect / spade-foot type terminals, wire splices, various combinations of these. Crimp-on terminals are attached by inserting the stripped end of a stranded wire into a portion of the terminal, which is then mechanically deformed / compressed (crimped) tightly around the wire.^[1] The crimping is accomplished with a special crimping pliers. A key idea behind crimped connectors is that the finished connection is gas-tight.

Crimped connections fulfill similar roles, and may be thought of similarly to, soldered connections. There are complex considerations for determining which type is appropriate - crimp connections are sometimes preferred for these reasons:

• Easier, cheaper, and/or faster to reproduce reliable connections in large-scale production.
• Fewer dangerous, toxic and/or harmful processes involved in achieving the connection (soldered connections require aggressive cleaning, high heat, and possibly toxic solders).
• Potentially superior mechanical characteristics due to strain relief and lack of solder wicking.

Many classes of crimped connections exist. Some of the most common are:

Barrel

• Wire to be terminated is inserted into a cylindrical section of metal, then crimped, with the resultant shape somewhat of an oval.
• To the layperson, perhaps the most common type. Readily available at retail (Radio Shack, Home Depot, Frys, etc.).

Open-barrel

• refers to the pre-crimp crimp section having a U or V shape
• More robust connection than barrel-type and thus more common in industrial and automotive applications
• Simpler to automate since wire can be laid in the un-crimped connector versus barrel which requires funneling the wire into the barrel to prevent strands from catching.
• Types:
  • F crimp: Both wire and insulation (if optional insulation support is present) are crimped from U to B shape.
  • Weather-Pack/Metri-Pack: common brand-name crimp connectors designed for use in sealed housings. Wire is crimped from U to B shape, insulation from U to 'O' shape.

References

1. ^ Elliott, Brian (2007). Electromechanical devices & components illustrated sourcebook. McGraw-Hill. pp. 151. ISBN 9780071477529. 

External links

• Crimping-101 general info on types and motivations for crimps, with detailed pictures