Abstract:
An electrical clip connector has a terminal clip which is electrically mated to a ground stud by hand. The terminal clip is protected by an erogonomically friendly housing which supports the functional requirements of the terminal clip. The housing has a hoop portion which defines a through hole orientated concentrically to a bore defined by a resilient barrel segment of the terminal clip. Communicating transversely with the rough hole is a channel carried by a first portion of the housing which encases a first arm of the terminal clip engaged to a circumferential first end of the barrel segment. A second or activation arm of the terminal clip extends from an opposite end of the barrel segment and crosses over the first arm so that compression of the arms toward one-another causes the loop segment to enlarge for receipt of the ground stud. The second arm is encased by a second portion of the housing which is preferably hinged to the first portion near the hoop portion. When the clip connector is fully compressed, contact between the first and second portions prevent damage or deformation of the terminal clip which could degrade the electrical connection.

Description:
TECHNICAL FIELD  
       [0001]     The present invention relates to an electrical clip connector and more particularly to a ground electrical clip connector for an automotive ground stud.  
       BACKGROUND OF THE INVENTION  
       [0002]     Conventional electrical grounding methods within the automotive industry include a connection having a ring terminal held to a threaded stud with a threaded nut. The electrical contact is created between the ring terminal and the body sheet metal by applying torque to the nut which applies an axial force upon the ring terminal. Thus a reliable connection is dependent upon the amount of torque applied to the nut. Because this is controlled in the power nut driver used at the assembly plant, frequent calibration of the nut driver is required to assure compliance to the torque specification. Unfortunately, inadvertent mis-alignment of the nut to the threaded stud can cause cross-threading between the nut and the stud which will cause a false torque reading and potentially a bad connection. Moreover, tools such as a nut driver are cumbersome within a manufacturing environment and lead to increase maintenance and labor expenses.  
         [0003]     However, a hand pluggable ground connection or terminal clip such as that disclosed in Hurdoy, U.S. Pat. No. 5,788,543, issued Aug. 4, 1998, do not require the cumbersome and costly use of calibrated tools. The disclosed terminal clip has a barrel portion sized to fit over a stud having a prescribed diameter. To mate with the stud, the terminal clip also has an activation arm which when depressed expands the barrel portion to a diameter that is larger than the diameter of the stud and therefore capable of fitting over the stud. In this expanded state the terminal is slid down the length of the stud until the top of the stud extends above the barrel portion of the terminal clip. Once aligned axially to the stud, the activation arm is released causing the barrel portion of the terminal to exert a spring induced radial force upon the stud as it tightens around the stud circumference.  
         [0004]     Unfortunately, the exposed state of the metallic terminal clip leaves it prone to damage from adjacent obstacles. Moreover, the sharp edges and snagging interfaces of the terminal clip can snag adjacent wires causing wire insulation chaffing or which may prevent the activation arm from fully releasing after being depressed. Moreover, if the activation arm is depressed to far, the terminal clip may be inadvertently damaged via plastic deformation, loosing some of its resiliency necessary to provide a reliable electrical connection. Yet further, the activation arm is not ergonomically friendly to the user in the assembly plant and in its exposed condition is susceptible to damage due to shipping and handling.  
       SUMMARY OF THE INVENTION  
       [0005]     An electrical clip connector has a terminal clip which is electrically mated to a ground stud by hand. The terminal clip is protected by an erogonomically friendly housing which supports the functional requirements of the terminal clip. The housing has a hoop portion which defines a through hole orientated concentrically to a bore defined by a resilient barrel segment of the terminal clip. Communicating transversely with the through hole is a channel carried by a first portion of the housing which encases a first arm of the terminal clip engaged to a circumferential first end of the barrel segment. A second or activation arm of the terminal clip extends from an opposite end of the barrel segment and crosses over the first arm so that compression of the arms toward one-another causes the barrel segment to enlarge for receipt of the ground stud. The second arm is encased by a second portion of the housing which is preferably hinged to the first portion near the hoop portion. When the clip connector is fully compressed, contact between the first and second portions prevent damage or deformation of the terminal clip which could degrade the electrical connection.  
         [0006]     Advantages of the present invention include a clip connector having a novel housing which protects a terminal clip from inadvertent damage due to over deflection, provides consistent deflection regardless of wire gauge size, protects surrounding wires from insulation chaffing, and enhances the ergonomics making the connector user friendly in the assembly plant.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]     The presently preferred embodiments of the invention are disclosed in the following description and in the accompanied drawings, wherein:  
         [0008]      FIG. 1  is in an exploded perspective view of an electrical clip connector of the present invention;  
         [0009]      FIG. 2  is a perspective view of the electrical clip connector shown in a released state and in a compressed state which is illustrated in phantom;  
         [0010]      FIG. 3  is a cross section of the electrical clip connector taken along line  3 - 3  of  FIG. 2 ;  
         [0011]      FIG. 4  is a partial cross section of the electrical clip connector taken along line  4 - 4  of  FIG. 3 ; and  
         [0012]      FIG. 5  is a perspective view of a second embodiment of an electrical clip connector. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0013]     Referring now to the drawings,  FIGS. 1-3  illustrate an electrical clip connector  10  capable of securing electrically to a protruding ground stud  12  preferably within an automotive environment. The clip connector  10  has a housing  14  which substantially encases a terminal clip  16  capable of repeated matings to the ground stud  12 , with a repeating predefined normal force, by hand and without the use of tools. The terminal clip  16  has a barrel segment  18  which wraps circumferentially about the stud  12  at slightly less than three hundred and sixty degrees to electrically engage the stud. A first end  20  of the barrel segment  18  engages unitarily to a radially outward projecting first arm  22  that engage electrically to an insulated wire  24 . A second or activation arm  26  projects substantially tangentially from the barrel segment  18  and outward from a second end  28  of the barrel segment  18 , thus crossing under the first arm  22  at an intersection or crossing point  30  located radially outward from a central axis  32  of a void or open ended bore  34  defined by the barrel segment for receiving the stud  12 . When the first and second arms  22 ,  26  are compressed toward one another, the void  34  expands radially outward with respect to the central axis  32  in order for the barrel segment  18  to slip over the stud  12  during mating of the connector  10 .  
         [0014]     Substantially encasing and protecting the elongated first and second arms  22 ,  26  and the barrel segment  18  of the terminal clip  16  are respective elongated first and second portions  36 ,  38  and a hoop or shoe-horn portion  40  of the housing  14 . The housing  14  is preferably made of a one-piece injected molded plastic which provides an electrically insulating barrier. The first portion  36  is generally open ended and hollow defining a generally square cross-sectioned channel  42  which communicates longitudinally between an open base end  44  and an open distal end  46  of the first portion  36 , and extends radially outward with respect to the central axis  32 . The base end  44  engages unitarily to the shoe-horn portion of the housing which defines a generally round through hole  48  that co-extends with the bore  34  and shares the common central axis  32  when the connector  10  is assembled and mated. The channel  42  communicates transversely with the through hole  48 . During assembly of the connector  10 , the barrel segment  18  of the terminal clip  16  is first inserted through the open distal end  46  of the first portion  36 , through the channel  42 , through the base end  44 , and into the through hole  48 . Once inserted, the shoe-horn portion  40  substantially houses and concentrically aligns the barrel segment  18  to the central axis  32 , and the first portion  36  substantially houses the first arm  22  of the terminal clip  16 . The wire  24  projects from the first arm  22  and through the open distal end  46  of the first portion  36  of the housing  14 .  
         [0015]     Referring to  FIGS. 2 and 4 , the through hole  48  is sized radially to accept the barrel segment  18  when the first and second arms  22 ,  26  are in a fully depressed state  50 . Thus, when the first and second arms  22 ,  26  are in a fully released state  52 , a radial clearance  54  exists between the barrel segment  18  of the terminal clip  16  and the shoe-horn portion  40  of the housing  14  accounting for the reduced diametric size of the terminal clip bore  34 . The barrel segment  18  is in-part held axially within the through hole  48  by top and bottom circumferential shoulders  56 ,  58  which project radially inward into the through hole. Each shoulder  56 ,  58  carries a substantially annular face  60  which substantially covers and directly opposes respective top and bottom edges  62 ,  64  of the terminal clip  16  located at the barrel segment  18 . Therefore, the shoulders  56 ,  58 , in addition to aligning the barrel segment  18  axially, also protect the edges  62 ,  64  of the barrel segment from possible damage created by external forces. Because the clip connector  10  can receive the stud  12  from either above or below, disposed opposite each annular face  60  is a circumferential bevel or chamfer  66  which helps concentrically align the stud  12  to the through hole  48 .  
         [0016]     The substantially square shape of the traversing cross-section of the channel  42  of the first portion  36  of the housing  14  is generally defined by a top wall  68 , a bottom wall  70 , a clockwise orientated or inward sidewall  72 , and an opposite counter-clockwise orientated or outward sidewall  74 . The inward sidewall  72  has a slot  76  which communicates laterally with the channel  42  and extends longitudinally from the base end  44  and through the open distal end  46 . The slot  76  provides the necessary clearance for the second arm  26  of the terminal clip  16 , permitting the first arm  22  to be slid radially inward into the channel  42  as previously described.  
         [0017]     To assemble, the terminal clip  16  inserts into the channel  42  of the first portion  36  of the housing  14  until it snap locks radially to the housing. The terminal clip  16  is thus held radially with respect to the central axis  32  between the hoop portion  40  of the housing and a cantilevered lock arm  78  of the top wall  68  which projects radially inward toward and slightly beyond the base end  44  from a mid-part of the top wall. The lock arm  78  also projects at a slight angle into the channel  42  so that during insertion of the terminal clip  16  into the channel  42 , the top edge  62  of the barrel segment  18  engages the angled lock arm  78  causing it to resiliently flex upward out of the channel  42 . Continued insertion of the terminal clip  16  orientates the second end  28  of the barrel segment  18  radially inward of and adjacent to a distal head  80  of the lock arm  78 , at which point the lock arm  78  snaps back into the channel  42  placing the distal head  80  in radial contact with the second end  28  of the barrel segment  18 .  
         [0018]     Preferably, and prior to insertion of the terminal clip  16  into the channel  42 , a non-ferrous core  82  at a distal end of the insulated wire  24  is engaged electrically to a circumferential outward side  84  of the first arm  22 , and an insulation jacket  86  of the wire  24  adjacent to the distal end is crimped to a distal end of the first arm  22  of the terminal clip  16  via crimp wings  88  of the first arm. The electrical engagement of the core  82  can be accomplished via sonic welding, soldering or any conventional type of electrical connection. The crimp wings  88  are sized to accept a wide range of wire gauges, and likewise the first portion  36  of the housing  14  is designed to adjustably accept a similar if not wider range of wire gauges.  
         [0019]     The outward sidewall  74  of the first portion  36  of the housing  14  is generally a cantilevered member projecting radially outward from the base end  44 . The cantilevered outward sidewall  74  flexes to accept a wide range of wire gauges and is thus not engaged directly to either the top or bottom walls  68 ,  70  but instead projects radially outward from the base end  44 . The cantilevered outward wall  74  resiliently flexes in a circumferential counter-clockwise direction, thus increasing the cross section of the channel, to accept larger wire gauge sizes pre-crimped to the distal end of the first arm  22 .  
         [0020]     When the terminal clip  16  is moved between the compressed and released states  50 ,  52 , the second portion  38  of the housing  14  must move substantially with the activation or second arm  26  of the terminal clip  16  for which it encases. An elongated barrier wall  90  of the second portion  38  engages pivotally to the base end  44  of the first portion  36  at the inward sidewall  72  via a resilient hinge  92 . The hinge  92  is disposed radially inward from and adjacent to the end of the slot of the first portion  36 . Preferably, the hinge  92  is unitary to both the first and second portions  36 ,  38  so that the housing  14  is a one piece injection plastic molded part. The barrier wall  90  of the second portion  38  projects radially outward with respect to a pivoting axis  94  of the hinge  92  and generally away from the central axis  32 . The barrier wall  90  extends laterally in a vertical direction which as illustrated is parallel to the pivoting axis  94  of the hinge  92 . The pivoting axis  94  is disposed substantially parallel to the central axis  32 . Because the pivoting axis  94  is spaced circumferentially from the crossing point  30  of the first and second arms  22 ,  26  of the terminal clip  16  with respect to the central axis  32 , a circumferential outward side  96  of the second arm  26  slides directly against the barrier wall  90  as the terminal clip  16  moves between the compressed and released states  50 ,  52 .  
         [0021]     The second arm  26  is disposed operatively within an alcove  98  of the second portion  38  of the housing  14  defined circumferentially by the barrier wall  90 , and axially between a clockwise projecting horizontal top flap  100 , and a clockwise projecting horizontal bottom flap  102  of the second portion  38 . The barrier wall  90  extends laterally between the top and bottom flaps  100 ,  102 . Because the top flap  100  is disposed adjacent to and above the top wall  68  of the first portion  36  and the parallel bottom flap  102  is disposed adjacent to and below the bottom wall  70  of the first portion  36 , the first portion moves increasingly into the alcove  98  as the clip connector  10  moves from the released state  52  into the compressed state  50 .  
         [0022]     To stabilize the pivoting action of the second portion  38  with respect to the first portion  36  of the housing  14  each flap  100 ,  102  carries a close ended groove  104  which extends circumferentially with respect to the pivoting axis  94 . When the clip connector  10  is assembled, the groove  104  of the top flap  100  is in receipt of a pin  106  of the first portion  36  which projects upward from the top wall  68  and the groove  104  of the bottom flap  102  is in receipt of an opposite pin  106  of the first portion  36  which projects downward from the bottom wall  70 . The pins travel within their respective grooves  104  as the clip connector  10  moves between the compressed and released states  50 ,  52 . Although not illustrated, the housing  14  of the clip connector  10  is capable of functioning without the resilient hinge  92 , however, this is not preferred since it would produce a two-part housing and sacrifice some stability of the overall connector.  
         [0023]     A rib  108  of the second portion  38  contacts the inward sidewall  72  of the first portion  36  when the clip connector  10  is in the fully compressed state  50 . This contact prevents over compression and permanent deformation of the activation arm  26  which could limit expansion of the barrel segment, thus impairing receipt of the stud during the mating process. The rib contact also prevents over expansion and plastic deformation of the barrel segment  18  which would impair electrical continuity between the stud  12  and the terminal clip  16  by reducing the normal force that the resiliency or bias of the barrel segment  18  places on the stud  12 . The elongated rib  108  projects laterally outward from the barrier wall  90  into the alcove  98  in a counter clockwise direction and extends longitudinally parallel to the activation arm  26 . The rib  108  is disposed above the activation arm  26  and is aligned axially above the slot  76  of the first portion  36  through which the activation arm  26  projects. This alignment orientates the rib  108  axially to the inward sidewall  72  of the first portion  36  to achieve contact to the sidewall above the slot  76 .  
         [0024]     The cantilevered outward sidewall  74  of the first portion  36  of the housing  14  and the barrier wall  90  of the second portion  38  are both contoured to include grasping tabs or pads  110  which assist the user in mating and un-mating the clip connector by hand to the stud  12 . To mate and un-mate the connection, the operator&#39;s finger and thumb are in contact with respective pads  110 , located at easily identifiable end points of the first and second portions  36 ,  38  of the housing  14  for maximum leverage. As the operator applies a squeezing force the barrel segment  18  of the terminal clip  16  expands creating a clearance between the clip  16  and the stud  12 .  
         [0025]     When the clip connector clip is assembled, the top and bottom flaps  100 ,  102  of the second portion  38  of the housing  14  prevent the ingress of obstacles between the first and second arms  22 ,  26  of the terminal clip  16  which could impair compression of the clip. Moveover, rounded corners and edges of the housing are less likely to chaff the insulation jackets of surrounding wires.  
         [0026]     Referring to  FIG. 5 , a second embodiment of the connector clip  10 ′ is illustrated having a variety of alternative features. For instance, a top wall or lid  68 ′ of a first portion  36 ′ of a housing  14 ′ is hinged to an outward wall  74 ′ of the first portion  36 ′. In this arrangement, a terminal clip  16 ′ is inserted laterally into a channel  42 ′ of the first portion  36 ′ prior to snap locking the lid  68 ′ closed. Contrary to the first embodiment, the lid  68 ′ does not have a lock arm to hold the terminal clip  16 ′ radially in place. Instead, a hoop portion  40 ′ of the housing  14 ′ circumferentially surrounds a barrel segment  18 ′ of the terminal clip  16 ′ by greater than one hundred and eighty degrees, thus preventing the terminal clip from moving radially outward and longitudinally along the channel  42 ′.  
         [0027]     While the forms of the invention herein disclosed constitute presently preferred embodiments, many others are possible. For instance, the second arm  26  of the terminal clip can be engaged electrically to a second clip wire, in a fashion similar to the first arm. It is not limited herein to mention all the possible equivalent forms or ramifications of the invention. It is understood that the terms used herein are merely descriptive rather than limiting and that various changes may be made without departing from the spirit or scope of the invention.