Industrial Crimp Quality Handbook
Doc No: TM-640160065
Release Date: 00-00-02
UNCONTROLLED COPY
Page 6 of 27
Revision: C
Revision Date: 12-23-09
CUT-OFF TAB
LENGTH
CARRIER STRIP
terminal plating, one crimp height specification is
normally created.
*Consult individual terminal specification
requirements.
Crimp
It is the act of physically compressing (forming) a
connector or contact barrel around a cable in order
to make an electrical connection. On a crimped
terminal, a second crimp is often added to the
insulation area for added strain relief.
CSA
Canadian Standards Association is an independent
Canadian testing laboratory similar to UL
(Underwriters Laboratories Inc.).
Cut-off Tab Length
This material protrudes outside the end of the
terminal after the terminal is separated from the
carrier strip. As a rule, the cut-off tab should be
flush or .254mm (.010”) protruding outside the
housing sleeve. A cut-off tab, which is too long,
may expose a terminal outside the housing or it may
fail electrical spacing requirements. In most
situations, a tool is set-up to provide a cut-off tab
that is flush to one material thickness.
Dielectric Test
A test that uses the application of a voltage higher
than the rated voltage for a specific time for the
purpose of determining the adequacy against
breakdown of insulation materials and spacing under
normal conditions. This test is used to ensure the
crimping procedure did not puncture or destroy the
insulation material on the terminal.
Extrusions (Flash)
These small flares form on the bottom wire barrel
resulting from the clearance between the punch
and anvil tooling. If the anvil is worn or if the
terminal is over-crimped an excessive extrusion
results. An uneven extrusion may also result if the
punch and anvil being misaligned.
Ferrule
A short tube used to mate solderless connectors to
shielded or coaxial cable. It is used as an insulation
grip sleeve on solderless terminals.
Flash
It is an abnormal protrusion on the wire barrel,
(either insulation material or metal), which indicates
that the crimping tool is either misaligned or worn
and thus should not be used.
Funnel Entry
It is a crimped terminal or splice barrel, which opens
to facilitate quick and easy wire insertion.
Gas Tight Seal
A contact system that utilizes soft metals at high
contact pressures so that upon mating, metal is
upset and the resultant joint prevents contaminant
gases from entering the contact area.
Gauge
A method of measurement, often using “go” and “no-
go” pins or shapes to determine if an attribute is
within tolerance.
Harness
A group of wires or cables joined to form a circuit
network for electronic or electrical equipment. A
harness is usually an assembly of cables cut to the
proper length, terminated, and tied together prior to
being assembled in a piece of equipment.
Insulation Crimp (Strain Relief)
It is a crimp encompassing both the wire and
insulation. This helps to prevent the conductor
from being exposed due to the insulation receding
and offers additional resistance to vibration.
Insulation Crimp Height
Molex does not specify insulation crimp heights
because of the wide variety of insulation thickness,
material, and hardness. Most terminals are
designed to accommodate multiple wire ranges.
