Push-in electrical terminal with insulation contact

An electrical terminal includes a terminal base. A mate portion is attached to the terminal base. The mate portion is adapted to mate with a corresponding electrical terminal. The electrical terminal includes a conductor contact portion. The conductor contact portion includes a box attached to the terminal base. A lever extends from one wall of the box. The lever is curved to extend toward the terminal base. The lever is adapted to engage a conductor of a wire inserted into the box. The electrical terminal also includes an insulation contact portion. The insulation contact portion is attached to the terminal base. The insulation contact portion is adapted to engage an insulation of the wire.

BACKGROUND OF THE INVENTION

This invention relates to an electrical terminal. More specifically, this invention relates to an electrical terminal with a push-in connection for an electrical wire.

Electrical terminals are normally used in matching pairs in order to allow electrical connections to be made between electrical wires or electrical devices. A typical electrical terminal is made of an electrically-conductive material and includes a mate portion that engages the matching electrical terminal and a contact portion that engages the electrical wire. In order to provide a desired flow of electrical current between the wire and the electrical terminal, the contact portion provides an electrical connection between the electrical terminal and a conductor portion of the electrical wire. Additionally, in order to prevent the wire from pulling away from the electrical terminal, the contact portion maintains a physical connection with the electrical wire.

Common types of connections used in the contact portion include crimped, welded, or push-in connections. It would be advantageous to have an alternative electrical terminal with a push-in connection.

SUMMARY OF THE INVENTION

The invention relates to an electrical terminal. The electrical terminal includes a terminal base. A mate portion is attached to the terminal base. The mate portion is adapted to mate with a corresponding electrical terminal. The electrical terminal includes a conductor contact portion. The conductor contact portion includes a box attached to the terminal base. A lever extends from one wall of the box. The lever is curved to extend toward the terminal base. The lever is adapted to engage a conductor of a wire inserted into the box. The electrical terminal also includes an insulation contact portion. The insulation contact portion is attached to the terminal base. The insulation contact portion is adapted to engage an insulation of the wire.

In another embodiment, the electrical terminal includes a terminal base with a mate portion attached to the terminal base. The mate portion is adapted to mate with a corresponding electrical terminal. A conductor contact portion is also attached to the terminal base. The conductor contact portion is adapted to engage a conductor of a wire. An insulation contact portion is also attached to the terminal base. The insulation contact portion is adapted to engage an insulation of the wire. The insulation contact portion includes a wire contact with a fixed end that is attached to the terminal base and a free end that is movable relative to the terminal base.

Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, there is illustrated inFIG. 1a perspective view of a first embodiment of an electrical terminal in accordance with the invention, indicated generally at10. The illustrated electrical terminal10is made from a single sheet of metal, stamped and folded into the configuration shown. However, the electrical terminal10may be made from any desired material and by any desired process.FIG. 2is a view similar toFIG. 1showing the electrical terminal10connected to an insulated wire12.

The electrical terminal10includes a mate portion14that is configured to be mated with a corresponding electrical terminal (not shown). The illustrated mate portion14is a two-armed female terminal that is configured to mate with a male pin-type terminal inserted along a terminal axis16. However, the mate portion14may be any desired type of connection.

The electrical terminal10also includes a contact portion, indicated generally at18, that is configured to engage the wire12. The contact portion18includes a conductor contact portion20, which is configured to engage a conductor22of the wire12to provide electrical contact between the electrical terminal10and the conductor22. The contact portion18also includes an insulation contact portion24that is configured to engage an insulator26of the wire12. The contact portion18is a push-in type connector and will be described in greater detail below. The illustrated insulation contact portion24is configured to be crimped onto the wire12, but may be any desired type of connection.

FIG. 3is a cross-sectional view of the electrical terminal10taken along the line3-3ofFIG. 1, andFIG. 4is a cross-sectional view of the electrical terminal10taken along the line4-4ofFIG. 1, perpendicular to the view shown inFIG. 3.FIG. 5is a view similar toFIG. 4taken along the line5-5ofFIG. 2and showing the electrical terminal10connected to the wire12.

The electrical terminal10includes a terminal base28. The illustrated terminal base28is a continuous piece that extends from the mate portion14through the conductor contact portion20to the insulation contact portion24. The mate portion14includes two terminal arms30that extend from the terminal base28and are located on opposed sides of the terminal axis16.

The conductor contact portion20includes a box32that extends from the terminal base28. The box32defines an interior space, indicated generally at34. The illustrated box32is positioned so that the terminal axis16extends through the interior space34. The illustrated box32includes an outer wall36that is located on an opposed side of the interior space34from the terminal base28. Two side walls38are located on opposed sides of the interior space34and extend from the terminal base28to the outer wall36. In the illustrated embodiment, one of the side walls38includes a dovetail lock40(best shown inFIGS. 1 and 2). The dovetail lock40helps retain the box32in its assembled state. However, the box32may be held together by any desired connector or mechanism.

The conductor contact portion20also includes a front wall42that is located between the interior space34and the mate portion14. In the illustrated embodiment, the front wall42is made from pieces of material that are folded from the outer wall36toward the terminal base28. However, the front wall42may extend from any desired part of the electrical terminal10. The box32includes an open side44which allows for insertion of the wire12into the interior space34, as will be described below. In the illustrated embodiment, the open side44is located opposite the front wall42, but may be on any desired portion of the box32.

The conductor contact portion20includes a lever46that serves to engage the wire12, as will be described below. The illustrated lever46is stamped from the same piece of material as the rest of the electrical terminal10, but the lever46may be a separate component if desired. The illustrated lever46extends from the outer wall36of the box32but may extend from any desired part of the electrical terminal10. The lever46extends from the box32, and at least a portion of the lever46is located outside the interior space34of the box32. The lever46extends through the open side44of the box32into the interior space34. The lever46includes a curve portion48where the lever46is bent so that the extended portion of the outer wall36extends into the interior space34. The curve portion48may have any desired size or curvature.

The lever46extends from the outer wall36toward the opposed side of the box32. In the illustrated embodiment, the lever46extends from the outer wall36toward the terminal base28. However, the lever46may extend toward any desired part of the electrical terminal10. The lever46includes an engagement edge50, which is the part of the lever46that is nearest the terminal base28. The engagement edge50is the part of the lever46that engages the wire12, as will be described the below. In the illustrated embodiment, the engagement edge50is a distal end of the lever46, but may be any desired part of the lever46. The engagement edge50of the lever46is located in the interior space34of the box32.

The lever46and the terminal base28define an insertion channel, indicated generally at52, therebetween. The insertion channel52extends from the engagement edge50of the lever46toward the open side44of the box32. The illustrated insertion channel52is wedge-shaped, being widest at the open side44and narrowest at the engagement edge50, although such is not required.

As shown in theFIG. 5, the wire12includes an exposed end54where a portion of the conductor22is exposed by removal of a portion of the insulator26from the wire12. To attach the electrical terminal10to the wire12, the wire12is initially positioned on the terminal axis16and is then moved relative to the electrical terminal10in an insertion direction56parallel to the terminal axis16. The exposed end54of the conductor22is thus moved through the open side44of the box32into the insertion channel52. The conductor22engages the lever46and pushes the lever46away from the terminal base28. The wire12is moved farther in the insertion direction56until the conductor22engages a wire stop58on the box32, which prevents further movement of the conductor22in the insertion direction56. In the illustrated embodiment, the wire stop58is a portion of the front wall42.

Once attached, the conductor22of the wire12is located between the lever46and the terminal base28. The engagement edge50of the lever46engages the conductor22, and the resilient lever46presses against the conductor22. The lever46also presses the conductor22against the terminal base28. The illustrated lever46includes a conductor notch60on the engagement edge50. The illustrated conductor notch60is a cut-out portion of the engagement edge50of the lever46that has a generally semi-circular shape, as best seen inFIG. 3. The conductor22is located partially in the conductor notch60, which increases the contact area between the lever46and the conductor22. The engagement of the conductor22with the lever46and the terminal base28provides an electrical connection between the conductor22and the electrical terminal10.

The engagement of the conductor22with the lever46and the terminal base28also resists the wire12being removed from the electrical terminal10. If a force is applied to move the wire12opposite the insertion direction56relative to the electrical terminal10, the lever46will be pulled opposite the insertion direction56and will pinch the conductor22between the lever46and the terminal base28.

The insulation contact portion24also resists the wire12being removed from the electrical terminal10. The illustrated insulation contact portion24includes two crimp arms62that extend from the terminal base28. The illustrated crimp arms62are attached to a portion of the wire12by ultrasonic welding. However, the crimp arms62may be attached to the wire12using any desired method.

In the illustrated embodiment, the distance between the terminal axis16and the terminal base28is different at different parts of the electrical terminal10. The terminal base28includes a mate offset64that is located between the mate portion14and the conductor contact portion20. In the conductor contact portion20, the terminal base28is closer to the terminal axis16than it is in the mate portion14. Additionally, the terminal base28includes a contact offset66that is located between the conductor contact portion20and the insulation contact portion24. In the conductor contact portion20, the terminal base28is closer to the terminal axis16than it is in the insulation contact portion20. The offsets64and66allow the wire12to be positioned on the terminal base28while being coaxial with the terminal axis16. The particular size of the offsets64and66can be selected depending on the relative sizes of the terminal arms30, the conductor22, and the insulator26.

Referring toFIG. 6, there is shown a perspective view of a second embodiment of an electrical terminal in accordance with the invention, indicated generally at110. The illustrated electrical terminal110is made from a single sheet of metal, stamped and folded into the configuration shown. However, the electrical terminal110may be made from any desired material and by any desired process. The electrical terminal110includes a mate portion114and a conductor contact portion120that are substantially the same as the previously-described electrical terminal10. These parts of the electrical terminal110will not be described in detail, but similar components are identified on the drawings by the same reference number increased by 100. The electrical terminal110includes an insulation contact portion124that will be described in greater detail.

The electrical terminal110includes a terminal base128that extends from the conductor contact portion120to the insulation contact portion124. The terminal base128includes an offset that is166located between the conductor contact portion120and the insulation contact portion124. In the conductor contact portion120, the terminal base128is closer to a terminal axis116than it is in the insulation contact portion124. The insulation contact portion124extends from the offset166to an insertion end168of the electrical terminal110.

The insulation contact portion124includes two struts170that extend between the offset166and the insertion end168. The illustrated struts170are mirror-images of each other, but may have different shapes if desired. Each strut includes a guide channel172. The guide channels172are C-shaped paths that open facing toward each other. Each of the guide channels172is defined by part of the material of the respective strut170that is folded inwardly. Each of the guide channels172extends parallel to the terminal axis116.

The electrical terminal110includes a terminal wall174at the insertion end168that is attached to the struts170. The illustrated terminal wall174is generally perpendicular to the terminal axis116, but may have any desired orientation. An insertion opening176is located in the terminal wall174, and the terminal axis116passes through the insertion opening176. The illustrated insertion opening176has a circular shape, but may have any desired shape. The insulation contact portion124includes two side walls178that are connected to the terminal wall174and are located on opposed sides of the terminal axis116. Each of the side walls178is connected to the one of the struts170and provides increased strength to the insulation contact portion124.

The insulation contact portion124includes a resilient, V-shaped wire contact180. The wire contact180includes a fixed end182, a free end184, and an intermediate peak186. Some features of the wire contact180are best seen inFIG. 7, which is a cross-sectional view taken along the line7-7ofFIG. 6.

The fixed end182of the wire contact180is attached to the struts170near the insertion end168of the electrical terminal110. The fixed end182is located between the two side walls178, and a first wing188of the wire contact180extends from the fixed end182between the two side walls178to the peak186.

The free end184of the wire contact180includes two guide tabs190(only one is shown inFIG. 6) that extend from opposed sides of the free end184. Each of the guide tabs190is located in one of the guide channels172. The guide tabs190are not fixed to the struts170and, thus, are able to move in the respective guide channel172relative to the struts170in a direction generally parallel to the terminal axis116. A second wing192of the wire contact180extends from the free end184to the peak186.

The peak186is a curved portion of the wire contact180located where the first wing188and the second wing192meet. In the illustrated embodiment, the peak186and the terminal base128are located on opposed sides of the terminal axis116. The peak186may have any desired shape or orientation.

The wire contact180includes a first wire contact opening194that extends through the first wing188. The first wire contact opening194has an elliptical shape, but may have any desired shape. The terminal axis116passes through the center of the illustrated first wire contact opening194, but the first wire contact opening194may be in any desired position. The wire contact180also includes a second wire contact opening196that extends through the second wing192. The second wire contact opening196has an elliptical shape, but may have any desired shape. The terminal axis116passes through the center of the illustrated second wire contact opening196, but the second wire contact opening196may be in any desired position.

FIG. 8is a view similar toFIG. 7, with a wire112shown in an inserted position on the electrical terminal110. The wire112is an insulated wire and includes a conductor122and an insulation126. The wire112includes an exposed end154where a portion of the conductor122is exposed. The wire112is moved into the inserted position by moving the exposed end154of the wire112relative to the electrical terminal110through the insertion opening176, through the first wire contact opening194, through the second wire contact opening196, and into the conductor contact portion120. The conductor122is connected to the conductor contact portion120similarly to the way the conductor22is connected to the previously-described conductor contact portion20, and will not be described in detail.

FIG. 9is a view similar toFIG. 8, with the electrical terminal110shown in a seated position in a housing, indicated generally at198. The illustrated housing198includes a terminal support200, which is engaged with a portion of the terminal base128, and a wire lock202, which is engaged with a portion of the wire contact180. The illustrated terminal support200and wire lock202are located on opposed sides of the terminal axis116, but may have any desired relative positions.

The wire lock202engages the peak186of the wire contact180and pushes the peak186toward the terminal base128. As a result, the free end154of the wire contact180is pushed away from the insertion end168of the electrical terminal110. The guide tabs190located in the guide channels172restrict how far the free end154is able to move away from the terminal axis116. In the illustrated embodiment, when the wire112is in the inserted position, the portions of the wire112in the wire contact openings194and196include the insulation126. When the electrical terminal110is in the seated position, the first wing188and the second wing192are moved so that a first engagement edge204and a second engagement edge206are pushed into the insulation126of the wire112. The engagement edges204and206are the portions of the wings188and192defining the sides of the wire contact openings194and196, nearest the peak186. The wire contact180is made of a harder material than the insulation126, and the insulation126is displaced by the engagement edges204and206.

When the electrical terminal110is in the seated position, the insulation contact portion124resists the wire112being removed from the electrical terminal110. A force applied to move the wire112away from the electrical terminal110will be resisted by the engagement of the wire contact180with the insulation126of the wire112. If desired, the wire contact180may engage with the conductor120of the wire112.

The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiments. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.