Abstract:
An 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 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.

Description:
[0001]    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. 
     
    
     
       TECHNICAL FIELD  
         [0002]    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.  
         BACKGROUND OF THE INVENTION  
         [0003]    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.  
           [0004]    The terminals in the Rudoy &#39;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.  
         SUMMARY OF THE INVENTION  
         [0005]    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.  
           [0006]    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.  
           [0007]    Yet another advantage of the present invention is a versatile design providing consistent product performance with a reduction of differing parts.  
           [0008]    Still further, an advantage of the present invention is a connector which does not require tools to assemble prior to mating. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    The presently preferred embodiments of the invention are disclosed in the following description and accompanied drawings wherein:  
         [0010]    [0010]FIG. 1 is an exploded perspective view of an electrical connector constructed in accordance with the invention;  
         [0011]    [0011]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;  
         [0012]    [0012]FIG. 3 is an enlarged perspective view of a member of the connector;  
         [0013]    [0013]FIG. 4 is a blank view of the member;  
         [0014]    [0014]FIG. 5 is an exploded perspective view of a second embodiment of an electrical connector; and  
         [0015]    [0015]FIG. 6 is a cross section view of a third embodiment of an electrical connector.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0016]    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 .  
         [0017]    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 .  
         [0018]    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 coplanar 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 .  
         [0019]    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.  
         [0020]    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 .  
         [0021]    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 .  
         [0022]    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.  
         [0023]    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 member s  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 .  
         [0024]    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 .  
         [0025]    Referring to FIG. 5, a second embodiment an insert device  32 ′ of the present invention is shown wherein an electrical connector  10 ′ mates, not from the longitudinal direction  62  as in the first embodiment but from the lateral direction  43 . Consequently, a series of ribs  58 ′ extend 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 .  
         [0026]    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 .  
         [0027]    A tang  110 ′ 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, an 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  110  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 .  
         [0028]    Referring now to FIG. 6, a third embodiment of the present invention is shown wherein the first terminal  12 ″ does not have a second blade  18  as does 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 formed thereby between the first blade  16 ″ and the face  45 ″. A series of second members  14 ″ mate to the series of first terminals  12 ″ similar to that of the first embodiment.  
         [0029]    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.