Electrical connector

This application claims the benefit of U.S. Provisional Application No. 60/228,992 filed Aug. 30, 2000, the disclosures of which are incorporated herein by reference in their entirety as if set forth at length.

This invention relates generally to an electrical connector, and more particularly to a dual bladed terminal electrical connector for high power connectors of the type used in automotive vehicle batteries, power electronics, alternators, electric motors and the like.

High power electrical connectors are often made in-part by a machining process because the electrical contacts are made of a solid brass rod. Stamping, however, is the preferred manufacturing process because the electrical connectors can be made at reduced cost and higher volume. Rudoy et al. U.S. Pat. No. 5,588,884, incorporated herein by reference, discloses one such high power connector utilizing one elongated male terminal with dual blades extending axially and another S-shaped terminal, wherein the terminals mate from an axial direction. To improve electrical contact for high power applications, U-shaped inserts directly engage between the mating surfaces of the two terminals. The inserts have a series of twisted ribs having edges that resiliently engage the terminals.

The terminals in the Rudoy '884 reference can only be mated from one direction, thereby limiting versatility. More generally, present stamped terminals are expensive and difficult to manufacture often requiring special tools to assemble. What is needed is a terminal connector which lends itself to normal processing methods, can be made at a lower tooling cost, has a limited number of differing parts, and permits more convenient or multi-directional mating of the terminal parts with one another.

A high power electrical connector utilizing two elongated terminals each having dual contact blades extending laterally from an elongated support section forming a U-shaped cross section. A recess for each terminal is defined by the respective dual contact blades and support sections The first blade of the dual blades for the first terminal mates within the recess of the second terminal and the first blade of the dual blades for the second terminal mates within the recess of the first terminal. A laterally bisected S-shaped insert device engages electrically between the blades of the terminals. The insert device comprises a first and a second member each having a series of inward bent ribs acting as depressable leaf springs for engaging the adjacent blades. The ribs extend in the same direction as the mating movement of the opposing terminal. An arrangement of tangs and prongs of each member hold and lock the insert device within the recesses by engaging the leading and trailing edges of the blades of each terminal.

An advantage of the present invention is a high current, high power, electrical connector manufactured by a stamping process at high volume and low tooling cost.

Yet another advantage of the present invention is a versatile design providing consistent product performance with a reduction of differing parts.

Still further, an advantage of the present invention is a connector which does not require tools to assemble prior to mating.

The presently preferred embodiments of the invention are disclosed in the following description and accompanied drawings wherein:

FIG. 1 is an exploded perspective view of an electrical connector constructed in accordance with the invention;

FIG. 2 is a cross section view of the connector taken along line 2 — 2 viewing in the direction of the arrows of FIG. 1;

FIG. 3 is an enlarged perspective view of a member of the connector;

FIG. 4 is a blank view of the member;

FIG. 5 is an exploded perspective view of a second embodiment of an electrical connector; and

FIG. 6 is a cross section view of a third embodiment of an electrical connector.

Referring to FIGS. 1-4, an electrical connector 10 is shown having a dual bladed first terminal 12 and a substantially identical mating second terminal 14 . The dual blades of the first terminal 12 are identified as a first blade 16 and a second blade 18 , both projecting laterally outward with respect to the elongated first terminal 12 from an elongated support section 20 . Likewise, the second terminal 14 has first and second blade 22 , 24 which project laterally outward from a support section 26 . The first and second blades 16 , 18 of the first terminal 12 are substantially parallel to one another, and when combined with the support section 20 , define inwardly a recess 28 . Likewise, the first and second blades 22 , 24 of the second terminal 14 also form a recess 30 . When the terminals are mated, the first blade 16 of the first terminal 12 resides within the recess 30 of the second terminal 14 and the first blade 22 of the second blade 14 resides within the recess 28 of the first terminal 12 . At least one insulated wire 31 is engaged electrically or crimped at the trailing end of terminal 12 , and likewise, at least one insulated wire 33 is engaged to the trailing end of terminal 14 . Both wires 31 , 33 extend longitudinally with respect to the terminals 12 , 14 and in opposite directions to each other.

Electrically engaging directly between the blades of the first and second terminals 12 , 14 is a woven insert device 32 having a substantially S-shaped cross section, as best shown in FIG. 2 . Insert device 32 has a first leg 34 , an intermediate leg 36 and a second leg 38 all three disposed substantially parallel to one-another. The first leg 34 is engaged electrically between the second blade 18 of the first terminal 12 and the first blade 22 of the second terminal 14 . The intermediate leg 36 is engaged electrically between the first blade 22 of the second terminal 14 and the first blade 16 of the first terminal 12 . And, the second leg 38 of the insert device 32 is engaged electrically between the first blade 16 of the first terminal 12 and the second blade 24 of the second terminal 14 .

To simplify and reduce costs of manufacturing, the insert device 32 is divided into two substantially identical separate components, identified as first and second members 40 , 41 . During assembly, the first and second members are inserted and locked into their respective recesses 28 , 30 from a laterally direction 43 , as best shown in FIG. 1 . The first member 40 comprises the first leg 34 and an intermediate portion 42 of the intermediate leg 36 . The second member 44 of the insert device 32 comprises the second leg 38 and an intermediate portion 44 of the intermediate leg 36 . The two intermediate portions 42 , 44 are co-planar and substantially similar in dimensions, and together comprise the intermediate leg 36 . Connecting the first leg 34 to the intermediate portion 42 is a base 46 of the first member 40 . After assembly, the base 46 is disposed adjacent to and preferably electrically engages the support section 20 , and the outward side of the first leg 34 electrically engages an inward face 45 of the second blade 18 of the first terminal 12 . The second member 41 also has a base 48 engaged between the intermediate portion 44 and the second leg 38 . The base 48 electrically engages the support section 26 , and the outward side of the second leg 38 electrically engages an inward surface 47 of the second blade 24 of the second terminal 14 .

Referring to the first and second members 40 , 41 are elongated and substantially similar to one another, bending along the contours of the respective recess. The perimeter of each member 40 , 41 is substantially defined by connecting; intermediate edge 50 , end edge 52 , side edge 54 and opposite side edge 56 . Each member extends lengthwise from the intermediate edge 50 to the end edge 52 . The side edge 54 is disposed substantially parallel to the opposite side edge 56 and together generally define laterally each member 40 , 41 . The intermediate portions 42 , 44 of the respective members 40 , 41 project substantially transversely from the respective bases 46 , 48 to the intermediate edges 50 . The first and second legs 34 , 38 are defined longitudinally between the end edges 52 and the respective bases 46 , 48 of the first and second members 40 , 41 . The intermediate portions 42 , 44 and the first and second legs 34 , 38 have a series of ribs 58 which substantially extend laterally with respect to the member, or longitudinally with respect to the terminals 12 , 14 . A series of slits or slots 60 are aligned side-by-side, each slot alternating between each rib 58 . The ribs 58 are bent inwardly at the centers, thereby projecting slightly into the respective recesses 28 , 30 to improve the electrical engagement of the mating blades of the first and second terminals 12 , 14 . The positioning of the ribs 58 promote mating of the first and second terminals 12 , 14 because the longitude of the ribs 58 are substantially collinear with a mating direction 62 of the terminals.

Referring to FIGS. 1 and 2, to maximize electrical contact, the width of the first and second members 40 , 41 , or the distance between the side edge 54 and the opposite side edge 56 , is substantially equal to the width of the blades 16 , 18 , 22 , 24 , or distance between the leading edges 64 , 66 , 68 , 70 and the respective trailing edges 72 , 74 , 76 , 78 of the respective first and second blades 16 , 18 , 22 , 24 of the first and second terminals 12 , 14 . A longitudinal edge 80 extends between the leading edge 64 and the trailing edge 72 of the first blade 16 of the first terminal 12 , and a longitudinal edge 82 extends between the leading edge 66 and the trailing edge 74 also of the first terminal 12 . Defined between the longitudinal edges 80 , 82 is a longitudinal opening 84 to the recess 28 . Defined between the leading edges 64 , 66 is a leading opening 86 to the recess 28 . Likewise, defined between the trailing edges 72 , 74 is a trailing opening 88 to the recess 28 . The leading opening 86 is substantially parallel to the trailing opening 88 , and both are substantially perpendicular to the longitudinal opening 84 .

Like the first terminal, the longitudinal edge 90 of the first blade 22 of the second terminal 14 extends between the leading edge 68 and the trailing edge 76 . The longitudinal edge 92 extends between the leading edge 70 and the trailing edge 78 of the second blade 24 of the second terminal 14 . A longitudinal opening 94 is defined between the longitudinal edges 90 , 92 to the recess 30 . A leading opening 96 is defined between the leading edges 68 , 70 to the recess 30 , and a trailing opening 98 is defined between the trailing edges 76 , 78 to the recess 30 . During mating of the terminals 12 , 14 , the first blade 22 of the second terminal 14 moves through the leading opening 86 and into the recess 28 of the first terminal 12 . Incidentally, the first blade 16 of the first terminal 12 moves through the leading opening 96 of the second terminal 14 and into the recess 30 .

During assembly of the terminals, the first member 40 of the insert device 32 is inserted into the first terminal 12 from the lateral direction 43 and through the longitudinal opening 84 until the bases 46 , 48 are adjacent to the respective support sections 20 , 26 of the first and second terminals 12 , 14 . Each of the first and second member 40 , 41 have two tangs 100 , one projecting outward from the side edge 54 and engaged to the intermediate portion 42 and the other tang 100 is objecting outward from the opposite side edge 56 of the intermediate portion 42 as best shown in FIGS. 3 and 4. The tangs 100 are bent outward with respect to the first or second member 40 , 41 in order to engage the leading and trailing edges of the terminal blades. The tangs 100 of the first member 40 engage the leading and trailing edges 64 , 72 of the first blade 16 of the first terminal 12 and the tangs 100 of the second member 41 engage the leading and trailing edges 68 , 76 of the first blade 22 of the second terminal 14 . The tangs 100 thereby prevent movement of the insert device 32 in the longitudinal direction 62 during mating of the terminals.

The first and second legs 34 , 38 of the insert device 32 each have two tabs 102 projecting outward from the side edge 54 and opposite side edge 56 . Projecting transversely outward from the distal end of each tab 102 is a prong 104 . Each prong 104 extends laterally outward with respect to the terminal and away from the respective base 46 , 48 . A cantilevered end portion 105 of each prong 104 bends slightly inward toward the respective first and second legs 34 , 38 . When the first and second members 40 , 41 are inserted into the respective first and second terminals 12 , 14 , the end portions 105 of the resilient prongs 104 are forced outward as they slide along the respective leading and trailing edges 66 , 74 of the first terminal 12 and leading edge 70 and trailing edge 78 of the second blade 24 of the second terminal 14 , until the prongs 104 snap into notches 106 defined by the leading edges 64 , 66 , 68 , 70 and the trailing edges 72 , 74 , 76 , 78 . Each notch 106 extends into each respective blade and thereby forms a shelf surface 108 which faces the respective support section of the first and second terminals 12 , 14 . The prongs 104 assure that the first and second members 40 , 41 will not separate from their respective first and second terminals 12 , 14 .

A flap 120 of each first and second member 40 , 41 protects the longitudinal edge 84 , 92 of the respective first and second terminal 12 , 14 . The flap 120 extends unitarily from the end edge 82 , 84 of the respective first and second members 40 , 41 , and projecting outward therefrom, substantially covering the longitudinal edges 84 , 92 .

Referring to FIG. 5, a second embodiment of an insert device 32 ′ of the present invention is shown wherein an electrical connector 10 ′, utilizing the same terminals 12 , 14 as the first embodiment, mates not from the longitudinal direction 62 as in the first embodiment but from the lateral direction 43 . Consequently, a series of ribs 58 ′ of the insert device 32 ′ extend in the lateral direction 43 or longitudinally with respect to the first and second members 40 ′, 41 ′ and not laterally as in the first embodiment. Unlike the first embodiment, the first and second members 40 ′, 41 ′ are not identical to one-another but are substantial mirror images of one-another and can be manufactured from identical planar stampings. Intermediate portions 42 ′, 44 ′ are substantially divided longitudinally into an inner segment 112 and a substantially larger outer segment 114 . The inner segments 112 longitudinally extend between an inner portion 116 of an intermediate edge 50 ′ and the respective bases 46 ′, 48 ′. The outer segments 114 extend longitudinally between an outer portion 118 of each intermediate edge 50 ′ and the respective base 46 ′, 48 ′ and. The inner and outer portions 116 , 118 of the intermediate edge 50 ′ are substantially parallel to one-another. The inner portion 116 of the first member 40 ′ and the inner portion 116 of the second member 41 ′ face one-another when the terminals 12 , 14 are mated. The outward convex surface of flaps 120 ′ of the first and second member 40 ′, 41 ′ and the outward convex surface of the respective base 48 ′ 46 ′ of the second and first member 41 ′, 40 ′ guide the first blade 22 , 16 of the second and first terminal 14 , 12 into the respective recess 28 , 30 .

The outer portion 118 has a flap 122 which extends laterally outward and protects or covers a substantial portion of the longitudinal edge 82 , 90 of the first blade 16 , 22 of the first and second terminal 12 , 14 .

A tang 100 ′ projects from an opposite side edge 56 ′ of the first member 40 ′ from the inner segment 112 of the intermediate portion 42 ′. The tang 100 ′ engages the leading edge 64 of the first blade 16 of the first terminal 12 . Unlike the first embodiment, a side edge 54 ′ of the first member 40 ′ has a tab 102 ′ and a prong 104 ′ projecting therefrom at the outer segment 114 of the intermediate portion 42 ′. The prong 104 ′ engages the trailing edge 72 of the first blade 16 of the first terminal 12 . The second member 41 ′ also has a tang 100 ′ protruding from the inner segment 112 and engaging the leading edge 68 of the first blade 22 of the second terminal 14 . The outer segment 114 of the second member 114 ′ has a tab 102 ′ and a prong 104 ′ projecting from the opposite side edge 56 ′. The prong 104 ′ thereby engages a trailing edge 76 of the first blade 22 of the second terminal 14 .

Referring now to FIG. 6, a third embodiment of the present invention is shown wherein the first terminal 12 ″ does not have the second blade 18 of the first and second embodiments. Instead, a series of support sections 20 ″ project transversely from a face 45 ″. A first blade 16 ″ projects from the distal ends of the support sections 20 ″ so that the first blade 16 ″ is disposed parallel to the face 45 ″. A recess 28 ″ is carried between the first blade 16 ″ and the face 45 ″. A series of second terminals 14 ″ mate to the series of first terminals 12 ″ similar to that of the first embodiment.

Although the preferred embodiments of the present invention are disclosed, various changes and modifications may be made thereto to one skilled in the art without departing from the scope and spirit of the invention as set forth in the appended claims. Furthermore it is understood that the terms used herein are merely descriptive rather than limiting and various changes may be made without departing from the scope and spirit of the invention.