Male pin terminal

Abstract: A two piece male terminal (10) includes a contact member (12) and an attachment member (14). The contact member (12) has a round solid pin (16) at its forward end portion, an integral collar (22) defining a radially extending abutment (22) at its midportion and a round clamping portion (26) behind the collar (20) and a flattened rearward end portion (28). The attachment member (14) has an attachment portion (50) at its forward end portion that is tightly clamped around the clamping portion (26) of the contact member (12) and a cable attachment means (46-58) at the rearward end portion which receives the flattened rearward end portion (28) of the contact member (12) so that the flattened end portion (28) engages the cable (30) at its core (30) when the two-piece terminal (10) is attached to the cable (30). In addition, the clamping portion (26) of the contact member (12) is swedged to define a post (72) extending radially outwardly of the outer surface of the clamping portion (26) and the attachment member (14) has a slot (80) which receives the post (72) when it is rolled onto the clamping portion (26). The post (72) is coined to define a flange (84) which engages the attachment member (14) at locations surrounding the slot (80) to securely retain the attachment member (14) to the contact member (12).

Description: The present invention relates to male pin terminals, more specifically to a two piece male pin terminal comprising a contact member having an upset collar for locking behind a flex finger on a connector housing and a cable attachment member which is crimped onto a cable and the contact member and which has a slot for receiving a swaged post on the contact member to securely retain the two members together. US-A-5,348,498, a division of US-A-5,252,088, discloses a two piece male pin terminal which includes a contact member and an attachment member both made of electrically conductive material such as brass. The contact member has a round solid pin at one end and has a round point to facilitate insertion of the male terminal into terminal cavities of a connector and through sealing hole and membrane of an insert. The medial portion of the contact member includes an integral collar and the opposite end a round clamping section behind the collar and a flattened dished end. The integral collar and clamping section secure the contact member and the attachment member together. The attachment member is formed from a sheet metal stamped blank having a generally rectangular attachment portion at one end, a medial transition neck and a conventional core and insulation crimp portion at the other end. The attachment portion is rolled into a cylinder having a hollow circular rib at one end formed around the collar and a hollow circular rib at the other end spaced from the hollow circular rib to form a circular groove used to lock the male terminal in the connector body, the connector body having a deflectable finger which is received within the circular groove. The section of the rolled attachment portion between the hollow ribs, clamps around the clamping section of the contact member tightly. The core and insulation crimp portion of the blank is formed as an open U-shape channel. The flattened dish end of the contact member lies in the bottom of the channel when the attachment member is crimped to the contact member so that the core of an electric cable is pressed against an upper surface of the flattened dished end when the channel is crimped about the cable. Although the two piece male terminal of the aforementioned application has been highly satisfactory, it requires that the attachment member be roll-formed around the collar of the pin. This requires complicated tooling and makes it more difficult to hold close tolerance limitations in the collar area. The present invention seeks to provide an improved male pin terminal. A male pin terminal in accordance with the present invention is characterised over US-A-5252088 by the features specified in the characterising portion of claim 1. A preferred embodiment provides a two piece male terminal in which a cylindrically shaped male contact member has an upset collar to define a radially extending rearward facing abutment surface and a cylindrical clamping portion adjacent the radially extending abutment surface which is swaged to define a depression extending radially inwardly from its outer surface and with the material from the swaged depression forming a post extending radially outwardly of the outer surface. The attachment member preferably has a cylindrical attachment portion which is rolled around the clamping portion of the contact member and which has aligned notches defining a slot which receives the post on the clamping portion of the contact member. The post is thereafter coined down to provide a flange for engaging the rolled attachment portion at locations surrounding the slot to securely retain the attachment member to the contact member. Preferably, the rolled cylindrical attachment portion is spaced from the upset collar of the contact member so that the full radial extent of the upset collar can be used as an abutment surface for engaging a flexible finger in a connector housing to aid in retaining the male pin terminal in the connector housing. The advantages of the preferred two piece male terminal are that it can increase terminal retention, can require less complicated tooling to form the terminal in making the terminal, can require less material for the contact portion of the attachment member and can enable the contact member to have a collar which can be more readily formed within tighter tolerance limitations. An embodiment of the present invention is described below, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a side elevational view of an embodiment of two-piece male pin terminal; Figure 2 is a plan view of the two-piece male terminal of Figure 1; Figure 3 is an end elevational view of the two-piece male terminal assembly of Figure 1; Figure 4 is an enlarged cross-sectional view of the two piece male terminal taken along line 4-4 of Figure 1; Figure 5 is a fragmentary cross-sectional view of the two piece male terminal taken along line 5-5 of Figure 4; Figures 6 and 7 are, respectively, plan and side elevational views of the contact member of the two piece male terminal of Figure 1; Figure 8 is a plan view of the metal blank for forming the attachment member of the two-piece terminal of Figure 1; Figure 9 is a side elevational view of the two piece male pin terminal of Figure 1 connected to an insulated connector housing and to a core and insulation of a conductor cable; and Figure 10 is a side elevational view of an alternative contact member for the two piece male terminal. Referring to the drawings, a male terminal 10 of two-piece construction comprises a contact member 12 and an attachment member 14, both of which are made of an electrically conductive material, such as brass. The contact member 12 has a round or cylindrically shaped solid pin 16 along its forward portion. The pin has a round point 16a at its forward end to facilitate insertion of the male terminal 10 into a terminal cavity and through sealing holes and membranes of an insert, as will be hereinafter more fully described. The contact member 12 at a medial portion is upset to define an integral collar 20. The collar 20 is disc shaped and has a radially extending abutment surface 22 at its rearward side and a radially extending surface 24 at its forward side. Both surfaces 22, 24 are perpendicular to the axis of the pin 16. The contact member 12 also has a cylindrically shaped clamping portion 26 intermediate its ends and located adjacent the radially extending abutment surface 22 of the collar 20 and a flattened and dished end 28 that is knurled on its upper surface 28a along its rearward portion 28b. Although the rearward end portion 28b is flattened, it is also slightly arcuate in shape, as shown in Figure 3. The flattened and dished end 28 is used to establish good electrical contact between the contact member 12 and a conductive core 30 of an electrical conductor cable when the male terminal 10 is attached to the core 30 of an insulation end 32 of the cable, as shown in Figure 9. The attachment member 14 is made from a sheet metal blank 40 stamped to the configuration shown in Figure 8. The stamped blank 40 has a generally rectangular attachment portion 42 at its forward end, a medial transition connect portion 44 and a conventional core and insulation crimp portions 46, 48 at its other or rearward end. The attachment blank 40 is rolled into a cylinder 50 at its forward end that is formed around the clamping portion 26 of the contact member 12 at a location spaced rearwardly from the radially extending abutment surface 22 of the collar 20 of the contact member 12 and is also rolled so as to form a hollow circular, radially extending rib 52 spaced from the collar 20 and which defines with the collar 20 a circular groove 54 used to lock the male terminal 10 in a connector body, as hereafter more fully described. The rolled cylindrical attachment portion 50 at the forward end is located between the collar 20 and the rib 52 and clamps tightly around the clamping section 26 of the contact member 12. The core and insulation crimping portions 46, 48 of the blank 40 are bent to form conventional, open U-shaped channels 56, 58, as shown in Figure 3. The flattened dished end 28 of the contact member 12 lies in the bottom of the channels 56 when the attachment member 14 is attached to the contact member 12 so that the core 30 of an electrical cable 32 is pressed against the upper knurled surface 28a of the flattened dished end 28 when the channels 56, 58 are crimped onto the core 30 and the insulation of the cable 32, as shown in Figure 9. An important feature of the described embodiment is the manner in which the attachment member 14 is retained on the contact member 12. As best shown in Figures 5 and 6, the clamping portion 26 of the contact member 12 is swaged or swedged, so as to define an annular depression 70 extending radially inwardly from the outer cylindrical surface of the clamping portion 26. The material swaged from the depression 70 is pushed and extends radially outwardly from the outer cylindrical surface of the clamping portion 26 to form a post 72 located centrally of the annular depression 70. The post 72 is preferably tapered so that its transverse dimension or diameter progressively decreases proceeding from its end adjacent the clamping portion 26 toward its outer free end. In addition, the attachment portion 42 of the attachment member blank 40 has a pair of rectangular notches 80. The attachment portion 42 when rolled to form the cylinder 50 defines a seam 81 at its adjacent axially extending side edges and the notches 80 are aligned with each other to define a slot 82 which receives the post 72 on the clamping portion 26 of the contact member 12 when the cylinder 50 is rolled onto and clamped to the clamping portion 26. After the attachment member 12 is rolled onto the clamping portion 26 of the contact member 12, the post 72 is coined or swaged down to form a flange 84 which engages the cylinder 50 of the attachment member 14 at locations surrounding the slot 82 to securely retain the attachment member 14 to the clamping portion 26 of the contact member 12. This securely holds the attachment member 14 onto the contact member 12 in addition to any clamping forces resulting from crimping the core 30 of the electric conductor. This stabilises the connection between the contact member 12 and the attachment member 14 axially and in all directions. As best shown in Figure 9, the two piece male terminal 10 is adapted to be connected to a connector housing 85 having a terminal cavity 86 defined in part by a deflectable finger 87. The connector housing 85 has a plurality of through cavities 86 therethrough and with the deflectable fingers 87 being located in a side wall adjacent the cavities 86. The two piece male terminal 10 is connected to the connector housing by insertion from right to left, as viewed in Figure 9. As the terminal 10 is inserted, the forward portion of the lock collar 20 will cam the flexible finger 87 radially outwardly until it passes the finger 87 whereupon the flexible finger will be deflected into the annular groove 54 between the collar 20 and the rib 52. It should be noted that the finger 87 can engage for the full radial extent of the lock collar 20 so that the pull out force rearward or to the right is maximised due to the larger engagement between the finger 87 and the collar 20. In the embodiment shown in Figure 9, an insert 90 is connected to the connector housing 85 with the insert having a forwardly extending portion 91 which holds the adjacent fingers 87 apart to prevent removal of the two piece male terminal 10 from either direction, and in a manner fully described in US-A-5,348,498 and US-A-5,252,088 which may be referred to for a full description. In addition, the connector housing has a membrane seal 93 having button portions 94 whose openings 95 have a smaller diameter than the diameter of the pin 16 to sealingly engage the male terminals 10. From the foregoing, it should be apparent that the two-piece electrical terminal has tolerance limits on the upset collar which can be closely maintained, permits maximum engagement between the flexible finger 87 and the collar 20 and has an attached member which does not require as much material as the attachment member shown and described in the aforementioned US-A-5,348,498 and in which the swedged retention means between the attachment member 14 and the contact member 12 ensures a good tight connection between the attachment member 14 and the contact member 12, which connection also minimises the ability of the flattened dish shaped end 28 of the contact member 12 to move radially out of position with respect to the bottom of the U-shaped crimp wings 46 as compared to the two piece terminal design of the aforementioned US-A-5,348,498. Figure 10 shows an alternative embodiment of a contact member 12' for the two piece male terminal. The contact member 12' differs from the contact member 12 in that it has a collar 20' which has a forwardly facing taper which progressively increases from the pin 16' to the outer diameter of the collar to define a ramp 96, which facilitates a smoother and lower engage force against the finger 87 when the contact member 12' of the terminal 10' is inserted in the cavity 86 of the connector.

Claims: A male pin terminal comprising an electrically conductive contact member (12) and an attachment member (14); the contact member including a solid pin (16) at a first end thereof, an integral collar (20) forming a radially extending abutment at an intermediate portion of the member, a rounded clamping portion (26) located at an opposite side to the collar relative to the pin and a flattened second end (28); the attachment member (14) including a rolled cylindrically shaped attachment portion (42) at a first end thereof clamped around the clamping portion (26) of the contact member, the attachment portion including a seam (81) along adjacent edges thereof, and a cable attachment means (46-58) at a second end thereof operative to receive the second end (28) of the contact member (12) so that the second end can engage a core of a cable when a cable is attached to the terminal; characterised in that the clamping portion (26) includes a post (72) extending radially beyond a surface of the clamping portion; in that the seam (81) has notch means (80) forming a slot (82) for receiving the post; and in that a flange (84) is formed on the free end of the post, the flange engaging the attachment portion (14) at a location surrounding the slot so to as securely retain the attachment member on the contact member. A male pin terminal according to claim 1, wherein the attachment member (14) is made from an electrically conductive material. A male pin terminal according to claim 1 or 2, wherein the pin (16) is substantially cylindrical. A male pin terminal according to any preceding claim, wherein the pin (16) is substantially circular in axial cross-section. A male pin terminal according to any preceding claim, wherein the post (72) is swaged from the clamping portion (26).

Inventors: BUNGO EDWARD MARTIN, MORELLO JOHN RAYMOND, NICHOLS THOMAS R, BUNGO, EDWARD MARTIN, MORELLO, JOHN RAYMOND, NICHOLS, THOMAS R.
Applicants: GEN MOTORS CORP, SOLID STATE STAMPING INC, GENERAL MOTORS CORPORATION
Application year: 1995
Main classification: H01R13
IPC codes: H01R13, H01R4, H01R43