Variable pressure insulation piercing crimp

Claim 1

A METHOD OF CRIMPING A METALLIC TERMINAL TO AN INSULATED WIRE IN A RANGE OF SIZES FROM A PREDETERMINED MINIMUM DIAMETER TO A PREDETERMINED MAXIMUM DIAMETER THROUGH CONTROLLING BULGING OF THE CRIMPED WIRE, COMPRISING THE STEPS OF FORMING A TERMINAL HAVING AT LEAST ONE INSULATION PIERCING PRONG AND CRIMPING MEANS AXIALLY SPACED ON EACH SIDE OF SAID PRONG, SAID PRONG HAVING A LENGTH WHICH IS GREATER THAN ONE-HALF THE DIAMETER OF THE BARE WIRE PLUS THE THICKNESS OF THE INSULATION ON ONE SIDE OF THE MAXIMUM DIAMETER WIRE BUT IS NO GREATER THAN THE DIAMETER OF THE BARE WIRE PLUS THE THICKNESS OF THE INSULATION PLUS THE INCREASE IN THICKNESS DUE TO BULGING OF THE MINIMUM DIAMETER WIRE, CRIMPING SAID TERMINAL TO THE WIRE WITH A RELATIVELY HIGH PRESSURE TO SECURE THE TERMINAL THEREON AND TO INDUCE THE INSULATION TO BULGE IN AN AREA OPPOSITE TO SAID PRONG, AND PRESSING SAID INSULATION IN SAID AREA WITH A CONTROLLED PRESSURE DIFFERENT FROM AND UNRELATED TO SAID HIGH PRESSURE TO CAUSE THE PRONG TO PIERCE THE INSULATION ONLY ON THE SIDE OPPOSITE TO SAID AREA AND TO PENETRATE MORE THAN HALF WAY THROUGH THE CORE OF THE WIRE TO MAKE GOOD ELECTRICAL CONTACT WITH THE CORE.

Claim 2

A METHOD OF CRIMPING A METALLIC TERMINAL TO AN INSULATED WIRE IN A RANGE OF SIZES FROM A PREDETERMINED MINIMUM DIAMETER TO A PREDETERMINED MAXIMUM DIAMETER THROUGH CONTROLLING BULGING OF THE CRIMPED WIRE, COMPRISING THE STEPS OF FORMING A TERMINAL HAVING AT LEAST ONE INSULATION PIERCING PRONG AND CRIMPING MEANS AXIALLY SPACED ON EACH SIDE OF SAID PRONG, SAID PRONG HAVING A LENGTH WHICH IS GREATER THAN ONE-HALF THE DIAMETER OF THE BARE WIRE PLUS THE THICKNESS OF THE INSULATION ON ONE SIDE OF THE MAXIMUM DIAMETER WIRE BUT IS NO GREATER THAN THE DIAMETER OF THE BARE WIRE PLUS THE THICKNESS OF THE INSULATION PLUS THE INCREASE IN THICKNESS DUE TO BULGING OF THE MINIMUM DIAMETER WIRE, CRIMPING SAID TERMINAL TO THE WIRE WITH A RELATIVELY HIGH PRESSURE TO SECURE THE TERMINAL THEREON AND TO INDUCE THE INSULATION TO BULGE IN AN AREA OPPOSITE TO SAID PRONG, AND PRESSING SAID INSULATION IN SAID AREA WITH A CONTROLLED PRESSURE DIFFERENT FROM AND UNRELATED TO SAID HIGH PRESSURE TO CAUSE THE PRONG TO PIERCE THE INSULATION ONLY ON THE SIDE OPPOSITE TO SAID AREA AND TO PENETRATE MORE THAN HALF WAY THROUGH THE CORE OF THE WIRE TO MAKE GOOD ELECTRICAL CONTACT WITH THE CORE.