ELECTRICAL TERMINAL FOR ELECTRICAL CONNECTOR ASSEMBLY

An electrical terminal for use in an electrical connector assembly includes a receptacle portion and a spring portion. The receptacle portion is formed from an electrically conductive material and includes an engagement arm having a support surface that defines a receptacle space. The spring portion is supported on the support surface of the engagement arm of the receptacle portion and is formed from an electrically conductive material. The spring portion includes a first end portion, a second end portion, and an intermediate portion extending between the first end portion and the second end portion. The intermediate portion includes a corrugation having alternating raised and lowered regions between the first and second end portions.

BACKGROUND OF THE INVENTION

This invention relates in general to electrical connector assemblies that provide mechanical and electrical connections between electrically operated devices in electrical systems. In particular, this invention relates to an improved structure for an electrical terminal for such an electrical connector assembly that is well suited for conducting relatively high magnitudes of currents therethrough without undesirably affecting the amount of force needed to connect the electrical terminal to a mating electrical terminal.

Many electrical systems are known in the art that include one or more electrically operated devices. For example, most automobiles and other vehicles are provided with a variety of electrically operated devices for the comfort and convenience of a driver or occupant. Typically, each of these electrically operated devices is connected to a source of electrical energy (and/or other components of the electrical system) by one or more electrical conductors. In many instances, an electrical connector assembly is provided on either or both ends of each electrical conductor to facilitate the installation, removal, and service of the electrically operated devices.

A typical electrical connector assembly includes a housing (which is typically formed from an electrically non-conductive material) that supports an electrical terminal (which is typically formed from an electrically conductive material). The housing of the electrical connector assembly may also support an end of an electrical conductor that is connected to the electrical terminal to facilitate both mechanical and electrical connections with the other components of the electrical system. A wide variety of electrical connector assemblies are known in the art and have functioned satisfactorily for many years.

However, it is known that when an electrical connector assembly is used to conduct relatively high magnitudes of currents, the heat generated by such relatively high-magnitude currents may cause undesirable dimensional changes in the electrical terminal, which can adversely affect the performance of the electrical terminal assembly. Thus, it would be desirable to provide an improved structure for an electrical terminal for such an electrical connector assembly that is well suited for conducting relatively high magnitudes of currents therethrough without undesirably affecting the amount of force needed to connect the electrical terminal to a mating electrical terminal.

SUMMARY OF THE INVENTION

This invention relates to an improved structure for an electrical terminal for such an electrical connector assembly that is well suited for conducting relatively high magnitudes of currents therethrough without undesirably affecting the amount of force needed to connect the electrical terminal to a mating electrical terminal. The electrical terminal includes a receptacle portion and a spring portion. The receptacle portion is formed from an electrically conductive material and includes an engagement arm having a support surface that defines a receptacle space. The spring portion is supported on the support surface of the engagement arm of the receptacle portion and is formed from an electrically conductive material. The spring portion includes a first end portion, a second end portion, and an intermediate portion extending between the first end portion and the second end portion. The intermediate portion includes a corrugation having alternating raised and lowered regions between the first and second end portions.

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 inFIGS.1through6a first embodiment of an electrical terminal, indicated generally at10, for use in an electrical connector assembly in accordance with this invention. The illustrated electrical terminal10is a female electrical terminal that includes a receptacle portion, indicated generally at11, which is structured and configured to receive a conventional male electrical terminal (not illustrated) as described below, and a connection portion, indicated generally at12, which is structured and configured to be connected to a conventional electrical conductor (not illustrated). However, it will be appreciated that this invention may be used in conjunction with any other type of electrical terminals.

The receptacle portion11of the illustrated electrical terminal10includes a first engagement arm13having a support surface13afrom which one or more support protrusions13bextend. In the illustrated embodiment, the support surface13ais generally flat and planar in shape and has four generally cylindrically-shaped support protrusions13bextending therefrom, although such is not required. Similarly, the illustrated receptacle portion11also includes a second engagement arm14having a support surface14afrom which one or more support protrusions14bextend. In the illustrated embodiment, the support surface14ais also generally flat and planar in shape and has four generally cylindrically-shaped support protrusions14bextending therefrom, although again such is not required. The first and second support surfaces13aand14aare spaced apart from one another so as to define a receptacle space therebetween.

In the illustrated embodiment, the receptacle portion11of the electrical terminal10is formed from a single piece of an electrically conductive material that is bent or otherwise deformed to a desired configuration that includes some or all of the structures discussed above. To accomplish this, the receptacle portion11of the electrical terminal10may include one or more bridging portions15that extend between the first engagement arm13and the second engagement arm14to facilitate the manufacture thereof. However, the receptacle portion11may be formed from any desired number of pieces of material and in any desired manner.

The receptacle portion11of the illustrated electrical terminal10also includes a first spring, indicated generally at16, that is supported on the first engagement arm13. The first spring16is formed from an electrically conductive material and includes first end portion16ahaving a pair of openings extending therethrough, a second end portion16bhaving a pair of openings extending therethrough, and an intermediate portion16cextending between the first and second end portions16aand16b. As best shown inFIG.2, the illustrated intermediate portion16cincludes nine separate corrugations, each of which is shaped having alternating raised and lowered regions between the first and second end portions16aand16b. As a result, each of the plurality of corrugated intermediate portions16cdefines one or more first contact points16dthat face toward the support surface13aof the first engagement arm13and one or more second contact points16ethat face toward the support surface14aof the second engagement arm14. However, the intermediate portion16cmay be formed having a greater or lesser number of such corrugations having any desired shape or combination of shapes.

Referring back toFIG.2, it can be seen that the corrugated intermediate portions16cof the illustrated first spring16are arranged such that the first contact points16dand the second contact points16ealternate throughout both the length (i.e., in a first direction extending between the first and second end portions16aand16b) and the width (i.e., in a second direction extending perpendicular to the first direction) of the first spring16. However, the corrugated intermediate portions16cof the first spring16may be shaped in any other desired manner.

As best shown inFIGS.3through6, the pair of openings extending through the first end portion16aof the first spring16are sized and positioned to be received upon a first pair of the support protrusions13bprovided on the support surface13aof the first engagement arm13. Similarly, the pair of openings extending through the second end portion16bof the first spring16are sized and positioned to be received upon a second pair of the support protrusions13bprovided on the support surface13aof the first engagement arm13. Thus, the first spring16can be supported on the first engagement arm13by inserting initially moving the first spring16within the receptacle space defined between the first and second engagement arms13and14, and then moving the first spring16laterally such that the openings extending through the first and second end portions16aand16bare respectively received on the support protrusions13b.

The receptacle portion11of the illustrated terminal10also includes a second spring, indicated generally at17, that is supported on the second engagement arm14. The second spring17is formed from an electrically conductive material and includes first end portion17ahaving a pair of openings extending therethrough, a second end portion17bhaving a pair of openings extending therethrough, and an intermediate portion17cextending between the first and second end portions17aand17b. As best shown inFIG.2, the illustrated intermediate portion17cincludes nine separate corrugations, each of which is shaped having alternating raised and lowered regions between the first and second end portions17aand17b. As a result, each of the plurality of corrugated intermediate portions17cdefines one or more first contact points17dthat face toward the support surface14aof the second engagement arm14and one or more second contact points17ethat face toward the support surface13aof the first engagement arm13. However, the intermediate portion17cmay be formed having a greater or lesser number of such corrugations having any desired shape or combination of shapes.

Referring back toFIG.2, it can be seen that the corrugated intermediate portions17cof the illustrated second spring17are arranged such that the first contact points17dand the second contact points17ealternate throughout both the length (i.e., in a first direction extending between the first and second end portions17aand17b) and the width (i.e., in a second direction extending perpendicular to the first direction) of the second spring17). However, the corrugated intermediate portions17cof the second spring17may be shaped in any other desired manner.

As best shown inFIGS.3through6, the pair of openings extending through the first end portion17aof the second spring17are sized and positioned to be received upon a first pair of the support protrusions14bprovided on the support surface14aof the second engagement arm14. Similarly, the pair of openings extending through the second end portion17bof the second spring17are sized and positioned to be received upon a second pair of the support protrusions14bprovided on the support surface14aof the second engagement arm14. Thus, the second spring17can be supported on the second engagement arm14by inserting initially moving the second spring17within the receptacle space defined between the first and second engagement arms13and14, and then moving the second spring17laterally such that the openings extending through the first and second end portions17aand17bare respectively received on the support protrusions14b.

FIGS.3and5illustrate how a male blade terminal, indicated generally at20, or similar electrical conductor can be connected to the first embodiment of the electrical terminal10. Initially, as shown inFIG.3, an end portion of the male blade terminal20is aligned with the receptacle space defined between the first and second engagement arms13and14. Then, as shown inFIG.5, the male blade terminal20is inserted into the receptacle space between the first and second springs16and17. During such insertion, the male blade terminal20engages the second contact points16eand17eof the first and second springs16and17, thereby compressing the first and second springs so as to exert respective retention forces on opposite sides of the male blade terminal20. The staggered, multiple point contact of the male blade terminal20with the first and second springs16and17advantageously reduces the amount of resistance to the insertion of the male blade terminal into the electrical terminal10. At the same time, the magnitude of such resistance is advantageously stable throughout the insertion process. Thus, the electrical terminal10is particularly well suited for conducting relatively high-magnitude electrical currents in the electrical system.

As mentioned above, the first embodiment of the electrical connector10may be supported within a housing (not shown) that is formed from an electrically non-conductive material so as to provide an electrical connector assembly. The housing of the electrical connector assembly may include one or more portions that mechanically engage and support an end of an electrical conductor to facilitate its connection (both mechanical and electrical) with the other components of the electrical system. If desired, a watertight seal may extend be provided on the housing of the electrical connector assembly for sealingly engaging the electrical conductor and the electrical terminal10supported therein.

Referring now toFIGS.7,8, and9, there is illustrated a second embodiment of an electrical terminal, indicated generally at30, in accordance with this invention. The illustrated electrical terminal30is a female electrical terminal that includes a receptacle portion, indicated generally at31, which is structured and configured to receive a conventional male electrical terminal (not illustrated) as described below, and a connection portion, indicated generally at32, which is structured and configured to be connected to a conventional electrical conductor (not illustrated). However, it will be appreciated that this invention may be used in conjunction with male electrical terminals and with many other types of electrical terminals.

The receptacle portion31of the illustrated electrical terminal30includes a hollow cylindrical engagement arm33having an inner cylindrical support surface33a. In the illustrated embodiment, the receptacle portion31of the electrical terminal30is formed from a single piece of an electrically conductive material that is bent or otherwise deformed to a desired configuration that includes some or all of the structures discussed above.

The receptacle portion31of the illustrated terminal30also includes a spring, indicated generally at34, that is supported on the inner cylindrical support surface33athereof. The spring34is formed from an electrically conductive material and is generally hollow and cylindrical in shape, including a first end portion34a, a second end portion34b, and an intermediate portion34cextending between the first and second end portions34aand34b. As best shown inFIG.8, the illustrated intermediate portion34cincludes sixteen separate corrugations, each of which is shaped having alternating raised and lowered regions between the first and second end portions34aand34b. As a result, each of the plurality of corrugated intermediate portions34cdefines one or more first contact points34dthat face outwardly toward the support surface33aof the first engagement arm33and one or more second contact points34ethat face inwardly away from the support surface33aof the second engagement arm14. However, the intermediate portion16cmay be formed having a greater or lesser number of such corrugations having any desired shape or combination of shapes. If desired, the spring34may include an axially-extending split35so that the spring34can resiliently engage the inner cylindrical support surface33aof the engagement arm33in a known manner.

As best shown inFIG.9, it can be seen that the corrugated intermediate portions34cof the illustrated spring34are arranged such that the first contact points34dand the second contact points34ealternate throughout both the axial length and the radial extent of the spring34). However, the corrugated intermediate portions34cof the spring34may be shaped in any other desired manner. A male pin terminal (not shown) may be connected to the second embodiment of the electrical terminal30in a manner that is similar to the male blade terminal20described above. The staggered, multiple point contact of the male pin terminal with the spring34advantageously reduces the amount of resistance to the insertion of the male pin terminal into the electrical terminal10. At the same time, the magnitude of such resistance is advantageously stable throughout the insertion process. Thus, the electrical terminal10is also particularly well suited for conducting relatively high-magnitude electrical currents in the electrical system.

The second embodiment of the electrical connector30may be supported within a housing (not shown) that is formed from an electrically non-conductive material so as to provide an electrical connector assembly. The housing of the electrical connector assembly may include one or more portions that mechanically engage and support an end of an electrical conductor to facilitate its connection (both mechanical and electrical) with the other components of the electrical system. A watertight seal may extend be provided on the housing of the electrical connector assembly for sealingly engaging the electrical conductor and the electrical terminal30supported therein.

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.