Crimping assembly, tool and die design

1 . A die set to crimp a connector onto a conductor, the die set comprising:

a first die and a second die adapted to be removably coupled to a crimping tool in a crimping configuration;

the first die having a first working surface that faces toward the second die in the crimping configuration and the second die having a second working surface that faces toward the first die in the crimping configuration, to crimp the connector onto the conductor when the conductor and connector are positioned between the first die and the second die in the crimping configuration;

the second working surface including planar surfaces and being configured to receive the connector and the conductor in the crimping configuration with the connector and the conductor positioned between the planar surfaces; and

the first die further having an indenting member that projects from the first working surface of the first die to form an indentation in the connector to crimp the connector to the conductor, the indenting member having a plurality of non-planar faces that each include a concave portion.

2 . The die set of claim 1 , wherein the plurality of non-planar faces each further include a convex portion, the concave portion transitioning onto the convex portion.

3 . The die set of claim 2 , wherein the concave portions transition onto rims of the first die that project toward the second die in the crimping configuration.

4 . The die set of claim 2 , wherein the concave portions and the convex portions define at least part of a profile of the indentation in the connector, including convex portions of the profile that corresponds to the concave portions of the indenting member.

5 . The die set of claim 1 , wherein the working surface of the first die defines an apex; and

wherein the concave portions of the plurality of non-planar faces are adjacent to the apex.

6 . The die set of claim 5 , wherein the apex surface is square.

7 . The die set of claim 5 , wherein the non-planar faces extend from the apex to define edges between adjacent sets of the non-planar faces; and

wherein the concave portions extend to the edges of the corresponding non-planar faces.

8 . The die set of claim 5 , wherein the apex surface is rectangular.

9 . The die set of claim 1 , wherein the indenting member is bilaterally symmetric about one or more of a first axis of symmetry or a second axis of symmetry that is perpendicular to the first axis of symmetry.

10 . The die set of claim 9 , wherein the indenting member is bilaterally symmetric about each of the first axis of symmetry and the second axis of symmetry.

11 . A die set for use in a crimping tool to crimp a connector onto a conductor, the die set comprising a first die that includes:

a mating surface to selectively mate with the crimping tool; and

a working surface including an indenting member that projects away from the mating surface to form an indentation in the connector when the connector is crimped to the conductor by the crimping tool;

the indenting member having an apex and a plurality of non-planar faces that extend from the apex on opposing sides of the apex, each of the plurality of non-planar faces of the indenting member including a concave portion and a convex portion that transitions from the concave portion and are configured to form the indentation to have a plurality of non-planar faces, including a plurality of convex portions and a plurality of concave portions.

12 . The die set of claim 11 , wherein the apex is a square.

13 . The die set of claim 11 , wherein the apex is a rectangular portion.

14 . The die set of claim 11 , wherein the concave portions of the plurality of non-planar faces of the indenting member are adjacent to the apex.

15 . The die set of claim 11 , wherein the apex is at a distal end of the working surface, relative to the mating surface, and the convex portions extend at a proximal end of the working surface, relative to the mating surface.

16 . The die set of claim 11 , further comprising:

a second die that aligns with the first die to crimp the connector onto the conductor, the second die having a concave working surface to support the connector opposite the indenting member of the first die, including the concave portions of the plurality of non-planar faces of the indenting member.

17 . The die set of claim 11 , further comprising:

a second die that includes a second working surfaces with planar surfaces, the second die being configured to align with the first die to crimp the connector onto the conductor, with the connector and the conductor positioned between the planar surfaces.

18 . A method of forming a crimped connection between a connector and a conductor using a crimping tool, the method comprising:

aligning the connector and the conductor between a first die and a second die; and

moving the first die and the second die together so that:

a first working surface of a first die of the crimping tool, including an indenting member, and a second working surface of a second die of the crimping tool confront the connector; and

the connector is deformed by the first and second working surfaces into a crimped configuration to form the crimped connection, the crimped configuration including an indentation on the connector that includes a plurality of non-planar faces, including a plurality of concave portions and a plurality of convex portions, the plurality of convex portions including a convex contour formed by a corresponding concave contour on the indenting member of the first working surface.

19 . The method of claim 18 , wherein deforming the connector includes forming the indentation to include convex contours on opposing sides of the indentation.

20 . The method of claim 19 , wherein aligning the connector and the conductor includes positioning the connector and the conductor between planar surfaces of the second working surface.