Electrical terminal for high current applications

A mass terminated connector is provided for conducting electrical current. The connector preferably comprises a plurality of U-shaped conductive assemblies and a conductive contact or terminal having a plurality of slots for receiving the conductive assemblies. According to the preferred embodiment, each assembly is manufactured from flat metal stock which is folded into a "U" shape and which includes a series of barbs for penetrating the insulation on the multiple wires of a power cable. The folded metal stock assemblies with connnected wires are received within the associated U-shaped slots in the contact or terminal.

FIELD OF THE INVENTION 
This invention relates in general to electrical connectors, and more 
particularly to the mass termination of a multiplicity of wires to a 
single point for the purpose of handling high current in an electrical 
connector. 
BACKGROUND OF THE INVENTION 
A common problem in high current applications such as battery charging and 
DC power distribution, is the termination of high current carrying 
conductors to a connector. For such high current applications, the 
conductors often comprise a plurality of wires rather than a single high 
current carrying cable (e.g. 16 number 14AWG twisted pair wires with an 
overall shield). 
According to the prior art, the multiple wires which comprise a power 
conductor are soldered, crimped or welded to the connector after the 
insulation has been physically stripped from the individual wires. This 
technique is extremely labour and time intensive. 
SUMMARY OF THE INVENTION 
According to one aspect of the present invention, a mass terminated 
connector is provided for conducting high current. The connector as 
exemplified by a preferred embodiment of the invention, comprises one or 
more connector contacts for receiving a plurality of U-shaped conductive 
assemblies. Each connector contact or terminal comprises a plurality of 
slots for receiving the conductive assemblies. According to the preferred 
embodiment, each assembly is manufactured from flat metal stock which is 
folded into a "U" shape and which includes a series of barbs for 
penetrating the insulation on the multiple wires of the power cable. The 
folded metal stock assemblies with connected wires are received within the 
associated U-shaped slots in the connector body.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
FIG. 1 shows plus (+) and minus (-) connectors 1 and 3, each in accordance 
with the present invention, terminating the wire ends of a power cable 5. 
A cross sectional view is provided in FIG. 2. In the illustrated preferred 
embodiment, each connector comprises a pair of U-shaped conductive 
assemblies 7 and 9 which are received within respective U-shaped slots 11 
and 13, of a contact or terminal 15, as shown best in FIGS. 2 and 7. 
According to the preferred embodiment, each assembly 7 and 9 is fabricated 
from a piece of flat, highly conductive and ductile metal stock 17 (FIG. 
3). The metal stock 17 is preferably punched and formed to create a 
plurality of barbs 19 on one half and V-shaped grooves 21 on the other 
half. FIG. 4 shows the stock 17 folded over such that the protruding barbs 
19 are lined up internally with respective ones of the V-shaped grooves 
21. 
In FIG. 5, the individual cable wires 22 are shown laying in respective 
ones of the V-shaped grooves 21 (each wire 22 consisting of a central 
conductor 23 surrounded by insulation 25). As shown in FIG. 5, the 
insulation 25 is not stripped prior to being laid in the V-shaped grooves 
21. 
The assembly 7 (and 9) is then mechanically compressed such that the barbs 
19 pierce the insulation 25 of each wire 22 and are embedded in the 
respective central conductors 23, thereby providing good electrical 
connection and mechanical retention of the wires 22. 
As discussed briefly above, FIG. 7 shows the assemblies 7 and 9 prior to 
being force fit into the U-shaped slots 11 and 13, respectively, of the 
contact terminal 15, while FIG. 2 shows the completed connector 1. Force 
fitting of the assemblies 7 and 9 into slots 11 and 13 can be effected 
using a mechanical tool, in a well known manner, and results in a good 
electrical as well as mechanical connection. 
According to the invention, the wires 22 need not be cut to length prior to 
installation in the assembly 7 (or 9), but can be gang sheared after 
termination. 
A person understanding the principles of the present invention may conceive 
of alternative embodiments or variations thereof. For example, the flat 
metal stock 17 can be selected from a number of suitable conductive 
materials capable of being stamped and formed. The number of barbs 19 per 
V-shaped groove 21 depends on the required conductivity, although at least 
one barb must be provided per groove. The number of rows of grooves 21 
(and barbs 19) is related to the number of wires 22 to be terminated. In 
FIGS. 1, 2 and 7, each connector is shown with eight such rows of barbs 19 
and grooves 21 for receiving eight wires 22, while the illustrative 
example of the assembly shown in FIGS. 3 to 6 shows four such rows of 
barbs 19 and grooves 21 for receiving four wires 22. Furthermore, it is 
contemplated that the grooves 21 can be U-shaped or any other suitable 
shape for receiving the wires 22. Indeed, it is also contemplated that 
where a suitably ductile metal is used for the flat metal stock 17, it may 
be possible to omit preforming of the grooves 21 altogether. Instead, 
according to this embodiment, the metal stock 17 is punched to form barbs 
19, folded over such that the barbs 19 line up with the wires 22, and then 
compressed so that the barbs 19 pierce the insulation of the wires and the 
ductile metal stock 17 forms around the wires 22 (i.e. "packing" the wires 
22 against the metal stock 17). In fact, the material 17 (less barbs and 
grooves), can be folded and compressed so that all wires 22 lay in 
parallel and the creation of barbs 19 and subsequent piercing of the wires 
22 by the barbs 19 can be effected via a separate punching operation. All 
such embodiments and variations are believed to be within the sphere and 
scope of the invention as set forth in the claims appended hereto.