Wire and methods for preparing a wire to receive a contact element

Abstract

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.

What is claimed is: 
     
         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 .