US5097100A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Noble metal plated wire and terminal assembly, and method of making the same
Assignee: Honeywell International Inc
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Filing: 1991-01-25
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Granted: 1992-03-17
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Expires: 2011-01-25
Abstract
Abstract A lightweight, substantially corrosion-proof, conductive wire and terminal assembly (10) comprising a wire (12) laid on and welded to a terminal pad (18) at or near the end (16) of the wire. The wire (12) has an electrically conductive core (24) having a cylindrical surface. The cylindrical surface is substantially completely enveloped in a sheath of noble metal plating (26, 28). The terminal pad (18) has a noble metal surface where it is welded to the cylindrical surface of the wire (12), so the joint (22) formed by the weld is substantially sheathed in a noble metal, and thus is substantially as corrosion-proof as the noble metal sheath (26, 28) and terminal pad (18). The wire (12) is preferably covered with insulation (30) except at its end (16), which may be stripped. This invention has the advantage that the joint (22) does not require a post-plating operation after the wire and terminal pad (18) are welded together, yet the joint (22) is stronger than a joint between dissimilar metals such as copper wire (12) and a gold terminal pad (18) and substantially as corrosion-proof as the plating (26, 28). A method for forming the assembly (10) is also disclosed.
Inventors
- 👤 Jeffery E. Jackson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 09:14
CPC Classifications
H; H01; H01R; H01R13/00; H01R13/02; H01R13/03; H01R4/00; H01R4/02; H01R4/029; H01R43/00; H01R43/02; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49117; Y10T29/49124; Y10T29/49147; Y10T29/49149
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
161 words
A lightweight, substantially corrosion-proof, conductive wire and terminal assembly comprising: A. an electrically conductive, non-noble metal wire core having an elongated, generally cylindrical outer surface and a first end defining an end surface; B. an inner sheath of noble metal plating on said core completely covering the cylindrical outer surface of said core, said plating having an end substantially registered axially with the end surface of said core; C. an outer sheath of non-conductive insulation on said inner sheath, said outer sheath having an end which is recessed axially along said inner sheath from the ends of said inner sheath and core, whereby the ends of said inner sheath and core protrude from the end of said outer sheath to define a noble metal sheathed cylindrical stripped portion; and D. a terminal pad having a noble metal surface which is joined to said inner sheath along an axial line at said cylindrical stripped portion by a weld to form a joint.
Claim 2
Dependent Claim
161 words
A lightweight, substantially corrosion-proof, conductive wire and terminal assembly comprising: A. an electrically conductive, non-noble metal wire core having an elongated, generally cylindrical outer surface and a first end defining an end surface; B. an inner sheath of noble metal plating on said core completely covering the cylindrical outer surface of said core, said plating having an end substantially registered axially with the end surface of said core; C. an outer sheath of non-conductive insulation on said inner sheath, said outer sheath having an end which is recessed axially along said inner sheath from the ends of said inner sheath and core, whereby the ends of said inner sheath and core protrude from the end of said outer sheath to define a noble metal sheathed cylindrical stripped portion; and D. a terminal pad having a noble metal surface which is joined to said inner sheath along an axial line at said cylindrical stripped portion by a weld to form a joint.
Claim 3
Dependent Claim
20 words
The assembly of claim 1, wherein the diameter of said wire core is from about 44 to about 56 microns.
Claim 4
Dependent Claim
25 words
The assembly of claim 1, wherein said inner sheath is from about 0.00001 to about 0.0001 inch (from about 0.25 to about 2.5 microns) thick.
Claim 5
Dependent Claim
17 words
The assembly of claim 1, wherein said inner sheath is about 0.000050 inches (about 1.2 microns) thick.
Claim 6
Dependent Claim
26 words
The assembly of claim 1, wherein said noble metal is selected from the group consisting of gold, ruthenium, rhodium, palladium, osmium, iridium, platinum, and combinations thereof.
Claim 7
Dependent Claim
21 words
The assembly of claim 1, wherein said noble metal is selected from the group consisting of gold, palladium, and combinations thereof.
Claim 8
Dependent Claim
12 words
The assembly of claim 1, wherein said noble metal sheath is gold.
Claim 9
Dependent Claim
12 words
The assembly of claim 1, wherein said noble metal sheath is palladium.
Claim 10
Dependent Claim
22 words
The assembly of claim 1 wherein said noble metal sheath and said noble metal surface are made of substantially identical noble metals.
Claim 11
Dependent Claim
42 words
The wire and terminal assembly of claim 1, wherein the noble metal surface of said terminal pad is joined to said inner sheath only at a portion of said cylindrical stripped portion spaced axially inwardly from the end of said inner sheath.
Claim 12
Dependent Claim
42 words
The wire and terminal assembly of claim 10, wherein the noble metal surface of said terminal pad is joined to said inner sheath only at a portion of said cylindrical stripped portion spaced axially outwardly from the end of said outer sheath.
Claim 13
Independent Claim
135 words
A method for forming a substantially corrosion-proof wire and terminal assembly, comprising the steps of providing a parent wire made of non-noble metal and having an elongated cylindrical surface; plating the cylindrical surface of said parent wire with a substantially coextensive sheath of a noble metal; insulating said parent wire with a sheath of insulation after said plating step; severing said parent wire to form a severed first end, stripping said insulation from said wire along an end portion of said cylindrical surface adjacent to said first end; providing a terminal pad having a noble metal surface; laying said wire with the stripped portion of its cylindrical surface against said noble metal surface to form a joint, and welding said joint, wherein said non-noble metal wire remains unplated and uninsulated at said severed first end.
Claim 14
Independent Claim
135 words
A method for forming a substantially corrosion-proof wire and terminal assembly, comprising the steps of providing a parent wire made of non-noble metal and having an elongated cylindrical surface; plating the cylindrical surface of said parent wire with a substantially coextensive sheath of a noble metal; insulating said parent wire with a sheath of insulation after said plating step; severing said parent wire to form a severed first end, stripping said insulation from said wire along an end portion of said cylindrical surface adjacent to said first end; providing a terminal pad having a noble metal surface; laying said wire with the stripped portion of its cylindrical surface against said noble metal surface to form a joint, and welding said joint, wherein said non-noble metal wire remains unplated and uninsulated at said severed first end.
Claim 15
Dependent Claim
25 words
The method of claim 12, further comprising the step, following said plating step, of drawing said wire, thereby reducing the outside diameter of said sheath.
Claim 16
Dependent Claim
17 words
The method of claim 13, wherein said plating and drawing steps are repeated following said drawing step.
Claim 17
Dependent Claim
103 words
A lightweight, substantially corrosion-proof, conductive wire and terminal assembly comprising: A. an electrically conductive, elongated, non-noble metal, wire core having a generally cylindrical outer surface and an end surface; B. an inner sheath of noble metal plating on said core, said plating having an end located axially substantially at the end of said core, thereby leaving the end surface of said core unplated; and C. a terminal pad having a noble metal surface which is joined to the cylindrical surface of said sheath by a weld to form a joined in which the end of said core remains uncovered by said terminal pad.
Claim 18
Dependent Claim
103 words
A lightweight, substantially corrosion-proof, conductive wire and terminal assembly comprising: A. an electrically conductive, elongated, non-noble metal, wire core having a generally cylindrical outer surface and an end surface; B. an inner sheath of noble metal plating on said core, said plating having an end located axially substantially at the end of said core, thereby leaving the end surface of said core unplated; and C. a terminal pad having a noble metal surface which is joined to the cylindrical surface of said sheath by a weld to form a joined in which the end of said core remains uncovered by said terminal pad.
Claim 19
Dependent Claim
42 words
The wire and terminal assembly of claim 15, wherein the noble metal surface of said terminal pad is joined to said inner sheath only at a portion of said cylindrical outer surface spaced axially inwardly from the end of said inner sheath.
Claim 20
Dependent Claim
64 words
The wire and terminal assembly of claim 15, wherein said inner sheath and core are formed by providing a non-noble metal parent wire, plating said parent wire with a noble metal, and severing a portion of said plated parent wire comprising said inner sheath and said core from the remainder of said parent wire, thereby exposing the end of said core to ambient conditions.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-03-17 | 1995-09-16 | 1996-03-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-03-17 | 1999-09-16 | 2000-03-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-03-17 | 2003-09-16 | 2004-03-17 | $7700.00 | Window Closed / Lapsed |