WIRE AND METHODS FOR PREPARING A WIRE TO RECEIVE A CONTACT ELEMENT
A method is provided for preparing a wire for installation of a terminal. The method comprises removing an insulating layer from a conductor to expose a portion of a conductor. The method further includes attaching a conductive foil layer to a portion of the exposed portion of the conductor by applying pressure to the conductive foil layer. Terminated wires are also provided.
1 . A terminated wire comprising:
a wire comprising a conductor, the conductor comprising an exposed portion and being formed of an aluminum alloy;
a conductive layer formed of copper; and
a contact element formed of a copper alloy; wherein:
the conductive layer is joined to the exposed portion of the conductor; and
the contact element is secured to the exposed portion of the conductor and the conductive layer.
2 . The terminated wire of claim 1 wherein the conductor has a diameter, the conductive layer has a thickness, and the ratio of the diameter of the conductor to the thickness of the conductive layer is about 200:1.
3 . The terminated wire of claim 1 wherein the contact element comprises a crimped terminal.
4 . The terminated wire of claim 1 wherein the conductive layer comprises a ferrule.
5 . The terminated wire of claim 4 wherein a length of the exposed portion of the conductor and a length of the ferrule are substantially the same.
6 . The terminated wire of claim 1 wherein the exposed portion of the conductor and the conductive layer cooperate to form an amalgamated mass.
7 . The terminated wire of claim 1 wherein the wire further comprises an insulating layer circumferentially surrounding a portion of the conductor adjacent to the exposed portion.
8 . A vehicle comprising the terminated wire of claim 1 .