Embodiments herein are directed to a wire spring terminal including a main contact body having a base and a set of sidewalls defining a central cavity, a first spring contact extending from the base into the central cavity, and a second spring contact extending from one of the sidewalls into the central cavity, wherein the first and second spring contacts are configured to engage a wire inserted into the main contact body. In some embodiments, the wire spring terminal includes a third spring contact extending from the base into the central cavity, and a fourth spring contact extending from another one of the set of sidewalls into the central cavity, the third and fourth spring contacts configured to engage a wire. The first and third spring contacts may be arranged side-by-side, separated by a slot. The second and fourth spring contacts are also arranged side-by-side, separated by another slot.

FIELD

The present invention relates generally to electrical contact terminals and, more particularly, to a one-piece push-in electrical spring contact terminal.

BACKGROUND

Wire connection terminals are mainly used to connect the electrical wires between electronic components or to connect the wire contacts of the electronic components onto a circuit board. The electronic components may include resistors, capacitors, inductors, LEDs, transformers, liquid crystal panels, touch panels, etc. Accordingly, the wire connection terminal serves to transmit power or electronic signals to facilitate layout and service of the internal circuit boards and electronic components of the electronic products and apparatuses.

There are many different types of electrical connectors for use in lighting fixtures that are capable of being easily connected and disconnected. Electrical connectors may have a terminal assembly for making an electrical connection via push-in termination with a conductor of a stripped end of a wire. Such electrical connectors may provide a connection to one or more additional conductors of stripped ends of wires, a printed circuit board, and/or another electrical apparatus.

Many electrical connectors permit safely de-energizing or removing an electrical component from a circuit (power or ground) so that it may be serviced. During removal, tension on the wire(s) instead of the connector may weaken the connection between the wire and the electrical contact within the connector. In some cases, the wire is therefore soldered or crimped to the contact. In other cases the wire is simply inserted into an insulation displacement contact or pushed into the connector. Such separation of the wire from the contact terminal may render the connector unusable, leading to increased material and labor costs.

With respect to these and other considerations the present disclosure is provided.

BRIEF SUMMARY

A wire spring terminal according to a first embodiment of the present disclosure may include a main contact body having a base and a set of sidewalls defining a central cavity, the sidewalls oriented substantially perpendicularly to the base. The wire spring terminal may further include a first spring contact extending from the base into the central cavity, and a second spring contact extending from one of the set of sidewalls into the central cavity, wherein the first and second spring contacts are configured to engage a wire inserted into the central cavity.

A wire spring terminal according to a second embodiment of the present disclosure may include a main contact body having a base and a set of sidewalls defining a central cavity, the sidewalls oriented substantially perpendicularly to the base. The wire spring terminal may further include a first spring contact extending from the base into the central cavity, and a second spring contact extending directly from an upper end of one of the set of sidewalls into the central cavity, wherein the first and second spring contacts are configured to engage a wire inserted into the central cavity.

A wire spring terminal for an electrical connector according to a third embodiment of the present disclosure may include a main contact body having a base and a set of sidewalls defining a central cavity, the sidewalls oriented substantially perpendicularly to the base. The wire spring terminal may further include a first spring contact extending from the base into the central cavity, and a second spring contact extending from one of the set of sidewalls into the central cavity. The first and second spring contacts are configured to engage a wire inserted into the central cavity, wherein the second spring contact includes a shoulder region extending from the upper end of the one of the set of sidewalls, and an upper wall extending from the one of the set of sidewalls. The upper wall may be oriented substantially parallel to the base of the main contact body, and substantially perpendicular to the one of the set of sidewalls. The second contact spring further includes a free end portion cantilevered from the upper wall at an angle into the central cavity.

DETAILED DESCRIPTION

The present embodiments will now be described more fully hereinafter with reference to the accompanying drawings, where some embodiments are shown. The subject matter of the present disclosure may be embodied in many different forms and are not to be construed as limited to the embodiments set forth herein. These embodiments are provided so this disclosure will be thorough and complete, and will fully convey the scope of the subject matter to those skilled in the art. In the drawings, like numbers refer to like elements throughout.

As used herein, an element or operation recited in the singular and proceeded with the word “a” or “an” are understood as possibly including plural elements or operations, except as otherwise indicated. Furthermore, various embodiments herein have been described in the context of one or more elements or components. An element or component may comprise any structure arranged to perform certain operations. Although an embodiment may be described with a limited number of elements in a certain topology by way of example, the embodiment may include more or less elements in alternate topologies as desired for a given implementation. Note any reference to “one embodiment” or “an embodiment” means a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrases “in one embodiment,” “in some embodiments,” and “in various embodiments” in various places in the specification are not necessarily all referring to the same embodiment.

Embodiments described and/or illustrated herein may provide electrical spring contacts of a terminal having a wire interface that can be disengaged from an electrical wire. The embodiments described and/or illustrated herein may provide electrical spring contacts that enable an electrical wire to be inserted into and/or removed from a receptacle multiple times without damaging the electrical wire and/or the electrical contact. The embodiments described and/or illustrated herein may provide electrical spring contacts that can accommodate a greater range of different wire sizes than at least some known wire spring terminals.

Described herein are improvements over current art contact springs and terminals, which are made of two separate parts. Current art approaches employ three (3) holes in the front of the terminal for insertion of different size wires (18 ga-12 ga) therein. Current art approaches also have three (3) cantilever springs at an opposite side, each of the springs bending down on the terminal to grip hold wires on the terminal. The wire spring terminal of the present disclosure is generally manufactured from a single piece of electrically conductive material, and may be generally punched out from a larger sheet of material, and then rolled or bent or otherwise configured into the desired shape. The spring terminal has a pin or a receptacle at one end. At an opposite end, the spring terminal has springs contacts, which bend up for from a base of a main contact body, and springs that extend from an upper part of the sidewalls defining the main contact body. Each of the spring is cantilevered, and arranged to engage opposite sides of a wire (e.g., 10 ga) inserted therebetween.

The present embodiments are directed a wire spring terminal including a main contact body having a base and a set of sidewalls defining a central cavity, a first spring contact extending from the base into the central cavity, and a second spring contact extending from one of the set of sidewalls into the central cavity, wherein the first and second spring contacts are configured to engage a wire inserted into the main contact body. In some embodiments, the wire spring terminal includes a third spring contact extending from the base into the central cavity, and a fourth spring contact extending from another one of the set of sidewalls into the central cavity, the third and fourth spring contacts configured to an additional wire, which may have a different gauge, inserted into the main contact body. The first and third spring contacts may be arranged side-by-side, separated by a slot or gap. The second and fourth spring contacts are also arranged side-by-side, separated by another slot or gap. As configured, the wire spring terminal is a unitary, one-piece push-in electrical spring contact terminal suitable to accept and retain wires in the range of 18 ga-10 ga.

The spring contacts are of resilient construction, such as in the form of a spring member, and are configured so that when compressed by the wire inserted into the main contact body, the spring contacts allow for insertion of the conductor with reduced insertion force. Once the wire is fully inserted within the internal cavity of the main contact body, the spring contacts engage opposite sides/surfaces of an exposed portion of the wire, such that removal of the wire is resisted.

Referring now toFIGS. 1-4, an example wire spring terminal (hereinafter “terminal”)100will be described in greater detail. As shown, the terminal100may be an electrical contact terminal for an electrical connector used for coupling modular electrical wiring to an electrical fixture. The terminal100may be made from a unitary piece of electrically conductive material, and includes one or more pairs of spring contacts110A-B and112A-B that angle towards one another to engage and retain a wire (not shown) therebetween, as will be described in greater detail below. The terminal100is generally made of a metal material having electrical conductivity.

As shown, the terminal100includes a main contact body102and a set of opposing sidewalls104,106extending perpendicularly from a base108. The base108and the set of opposing sidewalls104,106may form the shape of a rectangular box, which defines a central cavity114and an end opening118for receiving a wire therein. In some embodiments, the opposing sidewalls104,106may extend a length of the main contact body102, between a first end120and a second end122. The opposing sidewalls104,106may be spaced apart by a distance such that multiple wires can be inserted into the central cavity114. In some embodiments, the terminal may accept and retain wires in the range of 10 ga-18 ga.

The main contact body102and the pairs of spring contacts110A-B and112A-B may each be fabricated from copper, gold, silver, aluminum, nickel, platinum, stainless steel, and/or the like. Optionally, the main contact body102and/or the pairs of spring contacts110A-B,112A-B may include a base material that is coated (e.g., plated and/or the like) with one or more different materials. For example, fabricating the pairs of spring contacts110A-B,112A-B and/or other portions of the main contact body from one or more metallic materials may prevent damage to the from heat or extended operation.

As further shown, the terminal100includes a first spring contact110A extending from the base108into the central cavity114, and a second spring contact110B extending from sidewall104into the central cavity114. Similarly, a third spring contact112A extends from the base108into the central cavity114, and a fourth spring contact112B extends from sidewall106. In some embodiments, the first spring contact110A and the third spring contact112A are arranged side-by-side, separated by a first slot126, which may be a gap or opening. The first spring contact110A and the third spring contact112A may extend generally along the same plane, as shown, or may extend at different angles towards the base108relative to one another to accommodate for different wire sizes and or varied gripping force. The second spring contact110B and the fourth spring contact112B are similarly arranged side-by-side, and separated by a second slot128, which may be a gap or opening. The second spring contact110B and the fourth spring contact112B may extend generally along the same plane, as shown, or may extend at different angles into the central cavity114relative to one another. The first and second slots126,128permit individual movement/operation of each pair of spring contacts110A-B and112A-B. In some embodiments, each of the pairs of spring contacts110A-B and112A-B is generally flat and has a uniform thickness. In other embodiments, one or more contacts from the pairs of spring contacts110A-B and112A-B may be curved and/or have a varied geometry.

As further shown, the second and fourth spring contacts110B,112B extend from respective shoulder sections132,134of the opposing sidewalls104,106. In some embodiments, the second and fourth spring contacts110B,112B include respective upper walls138,140extending from the shoulder sections132,134. The upper walls138,140extend towards a centerline ‘CL,’ and are oriented parallel, or substantially parallel, to the base108of the main contact body102. The upper walls138,140are oriented perpendicular, or substantially perpendicular, to the opposing sidewalls104,106. As shown, the upper walls138,140meet centrally between the opposing sidewalls104and106, partially defining the second slot128.

The second and fourth spring contacts110B,112B further include respective free ends144,146extending from the upper walls138,140. As shown, the free ends144,146extend at an angle into the central cavity114and towards the first and third spring contacts110A,112A. In some embodiments, the free ends144,146are cantilevered with respect to the upper walls138,140and the opposing sidewalls104,106. Each of the second and fourth spring contacts110B,112B is elastically deformable and configured to provide a downward force to a wire inserted into the central cavity114.

The first and third spring contacts110A,112A extend upward from a central section of the base108towards shoulder sections132,134. Specifically, free ends152,154of respective first and third spring contacts110A,112A extend into the central cavity114at an angle relative to the base108. In some embodiments, the free ends144,146are cantilevered with respect to the base108. Each of the first and third spring contacts110A,112A is elastically deformable and configured to provide an upward force to a wire inserted into the central cavity114.

As shown, the first and third spring contacts110A,112A may extend from an edge156of an opening158formed through the base108of the main contact body102. In one embodiment, the opening158includes a pair of notches164,166(FIG. 4) formed adjacent respective lower shoulders168,170of the opposing sidewalls104,106. The notches164,166may be part of a slot extending between opposing sidewalls104,106, wherein the slot is machined as part of a process to form a series of slits in the base108having appropriate lengths to form the first and third spring contacts110A,112A by a subsequent machining step (e.g., mechanical punching).

The terminal100further includes a connection member171extending outwardly from the second end122of the main contact body102. In various embodiments, the connection member171may be a pin member or a terminal connector. In the embodiment shown, the connection member represents a pin member. For example, the connection member171may include a tubular section172extending along centerline ‘CL,’ and a neck region173connecting the tubular section172to a tongue174. In some embodiments, the connection member171represents a pin that may be inserted into a socket (not shown). The tubular section172may include first and second sides172A-B bent towards each other. For example, the first and second sides172A-B may be curved so as to meet along intersection175. As further shown, the connection member171may include an end cap176disposed at the tip of the tubular section172. In some embodiments, the end cap176includes three (3) complementary triangular sections arranged together to form a circular dome shape. In yet other embodiments, the tubular section172does not include an end cap. Instead, the tubular section172is open along each end, and represents a terminal connector.

The tubular section172is joined to the tongue174by the neck region173, which widens at an intersection with the tongue174. In some embodiments, as better shown inFIGS. 3-4, the tongue174may include a first section177adjacent the neck region173, and a second region178adjacent the base108. As shown, the second region178may include one or more side cutouts179,180to relieve strain and to enable bending or curving of the second region178. In some embodiments, the stepped second region178causes the first section177to extend along a plane that is offset but parallel to a plane defined by an upper surface of the base108of the main contact body102.

In some embodiments, the connection member171may further include a support member182extending between the tubular section172and the tongue174. The support member182provides strength and rigidity to the neck region173and the tubular section172. As shown, the support member182may include a stiffening feature such as a ridge183extending from the first section177, across the neck region173, and into to the tubular section172. In some embodiments, the ridge183extends outwardly (e.g., upwards in the orientation ofFIG. 3) from a top surface of each of the first section177, the neck region173, and the tubular section172. Along an underside of the connection member171, the ridge183may extend into the first section177and the tubular section172to form a recess or trough therein. In some embodiments, the ridge183may be stamped into the terminal100. It will be appreciated however, that various other types of stiffening features may alternatively be used to provide structural support between the main contact body102and the connection member171.

Turning now toFIG. 5, operation of the terminal100will be described in greater detail. As shown, the pair of spring contacts112A-B may contact opposite sides of an uninsulated/exposed portion of the wire185that is inserted in a direction along arrow ‘A’ through the end opening118and towards the second end122of the main contact body102. As oriented inFIG. 5, the third spring contact112A extends upwards at an angle, while the fourth spring member112B extends downwards at an angle, thus forming an opening between the pair of spring contacts112A-B. In the embodiment shown, the spring contacts112A-B extend at an angle towards the second end122of the main contact body102to permit the wire185to be more easily inserted therebetween. The opening between the pair of spring contacts112A-B has a dimension that is slightly smaller than the diameter of the uninsulated/exposed portion of the wire185so that as the wire185is inserted, the pair of spring contacts112A-B are forced apart. Once the wire185is inserted, the return bias force of each spring contact112A-B locks the wire185in place so that the wire185cannot be easily disengaged from the main contact body102. In some embodiments, each spring contact112A and112B may have an angled or sharpened edge to better grip or dig into the wire185.

Referring now toFIG. 6, an example wire spring terminal200will be described in greater detail. As shown, the terminal200may be an electrical contact terminal for an electrical connector used for coupling modular electrical wiring to an electrical fixture. The terminal200may be made from a unitary piece of electrically conductive material, and includes one or more pairs of spring contacts210A-B and212A-B that angle towards one another to engage and retain a wire (not shown) therebetween, as will be described in greater detail below. As shown, the terminal200includes many or all of the features previously described in relation to the terminal100ofFIGS. 1-5. As such, just certain aspects of the terminal200will hereinafter be described for the sake of brevity.

As shown, the terminal200includes a first spring contact210A extending from the base208into the central cavity214, and a second spring contact210B extending from sidewall204into the central cavity214. Similarly, a third spring contact212A extends from the base208into the central cavity214, and a fourth spring contact212B extends from sidewall206. In some embodiments, the first spring contact210A and the third spring contact212A are arranged side-by-side, separated by a first slot226. The first spring contact210A and the third spring contact212A may extend generally along the same plane, as shown, or may extend at different angles towards the base208relative to one another to accommodate for different wire sizes and or varied gripping force. The second spring contact210B and the fourth spring contact212B are similarly arranged side-by-side, and separated by a second slot228. The second spring contact210B and the fourth spring contact212B may extend generally along the same plane, as shown, or may extend at different angles into the central cavity214relative to one another. The first and second slots226,228permit individual movement/operation of each pair of spring contacts210A-B and212A-B.

In some embodiments, each of the pairs of spring contacts210A-B and212A-B is generally flat and has a uniform thickness. In other embodiments, one or more contacts from the pairs of spring contacts210A-B and212A-B may be curved and/or have a varied geometry. In yet other embodiments, one or more contacts from the pairs of spring contacts210A-B and212A-B has a different length to accommodate for multiple wires of varying thicknesses. For example, as shown, the second contact spring210B is longer than the fourth contact spring212B. As a result, the distance between the free end252of the second contact spring210B and the first contact spring210A is reduced, rendering the opening for the wire to pass through smaller than the opening between the second pair of contact springs212A-B. During use, wires with a smaller diameter may be inserted through the first pair of spring contacts210A-B, while wires with a larger diameter may be inserted through the second pair of spring contacts212A-B.

Referring now toFIG. 7, an example wire spring terminal300will be described in greater detail. As shown, the terminal300may be an electrical contact terminal for an electrical connector used for coupling modular electrical wiring to an electrical fixture. The terminal300includes many or all of the features previously described above in relation to terminals100and200. As such, just certain aspects of the terminal300will hereinafter be described for the sake of brevity.

As shown, the terminal300includes a first spring contact310A extending from the base308into the central cavity314, and a second spring contact310B extending from sidewall304into the central cavity314. Similarly, a third spring contact312A extends from the base308into the central cavity314, and a fourth spring contact312B extends from sidewall306. In some embodiments, the first spring contact310A and the third spring contact312A are arranged side-by-side, separated by a first slot326. The first spring contact310A and the third spring contact312A may extend generally along the same plane, as shown, or may extend at different angles towards the base308relative to one another to accommodate for different wire sizes and or varied gripping force. The second spring contact310B and the fourth spring contact312B are similarly arranged side-by-side, and separated by a second slot328. The second spring contact310B and the fourth spring contact312B may extend generally along the same plane, as shown, or may extend at different angles into the central cavity314relative to one another. The first and second slots326,328permit individual movement/operation of each pair of spring contacts310A-B and312A-B.

In this embodiment, the second and fourth spring contacts310B,312B extend from an upper wall341, which may be a contiguous component or piece of material extending from the shoulder section332of the sidewall304towards the sidewall306. As shown, the second and fourth spring contacts310B,312B may extend downwards from an inner edge343of the upper wall341, wherein free ends344,346are cantilevered with respect to the upper wall341. In the non-limiting embodiment shown, the second slot328extends between the inner edge343and the respective free ends344and346of second and fourth spring contacts310B and312B. By extending the second slot328only to the inner edge343, as opposed to entirely through the upper wall341, the second and fourth spring contacts310B,312B may have increased rigidity. In some embodiments, as shown, a third slot348may be provided between a free end349of the upper wall341and the upper shoulder334of the sidewall306, wherein the third slot348may represent a space or gap. The upper wall341and the fourth spring contact312B are not in direct physical contact with the sidewall306. Instead, the upper wall341may be cantilevered from the shoulder section332.

Referring now toFIG. 8, an example wire spring terminal400will be described in greater detail. As shown, the terminal400may be an electrical contact terminal for an electrical connector used for coupling modular electrical wiring to an electrical fixture. The terminal400includes many or all of the features previously described in relation to the terminals100,200, and300. As such, just certain aspects of the terminal400will hereinafter be described for the sake of brevity.

As shown, the terminal400includes a first spring contact410A extending from the base408into the central cavity414, and a second spring contact410B extending from sidewall404into the central cavity414. Similarly, a third spring contact412A extends from the base408into the central cavity414, and a fourth spring contact412B extends from sidewall406. In some embodiments, the first spring contact410A and the third spring contact412A are arranged side-by-side, separated by a first slot426. The first spring contact410A and the third spring contact412A may extend generally along the same plane, as shown, or may extend at different angles towards the base408relative to one another to accommodate for different wire sizes and or varied gripping force. The second spring contact410B and the fourth spring contact412B are similarly arranged side-by-side, and separated by a second slot428. The second spring contact410B and the fourth spring contact412B may extend generally along the same plane, as shown, or may extend at different angles into the central cavity414relative to one another. The first and second slots426,428permit individual movement/operation of each pair of spring contacts410A-B and412A-B.

In this embodiment, the second and fourth spring contacts410B,412B extend from respective upper walls438,440, which may extend from shoulder sections432,434of the opposing sidewalls404,406. As shown, the second and fourth spring contacts410B,412B may extend downwards from upper walls438,440, wherein free ends444,446are cantilevered with respect to the upper walls438,440and/or shoulder sections432,434. In the non-limiting embodiment shown, the free ends444,446may have a serrated edge and/or a sharpened surface to increase a gripping force on a wire inserted between the pairs of spring contacts410A-B and412A-B.

Although not shown, the embodiments described and/or illustrated herein may provide electrical spring connectors having an actuator for securing and/or releasing the wire from the electrical spring contacts. The embodiments described and/or illustrated herein may provide electrical spring connectors having an actuator for releasing an electrical wire from an electrical contact, wherein the actuator can be actuated using a tool (e.g., an instrument, a pen, a wire, a rod, and/or the like), using a body part (e.g., a person's finger, thumb, and/or the like), and/or the like.