Abstract:
A terminal is provided with a body sized to be received within a receptacle. A distal region extends lengthwise from the body in a receptacle direction. At least one portion of the distal region extends centrally inward into the receptacle to receive a pin to deform and maintain contact with the received pin. A lengthwise extending proximal region is connected to the body and spaced apart from the distal region. At least one portion of the proximal region extends radially outward to engage a side wall of the receptacle to enhance contact of the terminal with the receptacle. A receptacle assembly is provided for receiving one or a plurality of terminals.

Description:
TECHNICAL FIELD 
     Various embodiments relate to electrical terminals for facilitating electrical connectivity, and receptacle assemblies comprising electrical terminals. 
     BACKGROUND 
     Electrical terminals are used in a number of applications to facilitate electrical connecting of one element to another. Some electrical terminals may be configured to facilitate use with a removable connector of the type that may be repeatedly inserted and removed or otherwise configured to repeatedly engage and disengage the electrical terminal. The ability of the electrical terminal to facilitate electrical connectivity with such a removable connector can be problematic if an electrical connection area between the terminal and connector has poor connectivity, particularly when tolerance variations or degradation from repeated use causes a mating arrangement between the components to become loose or otherwise insecure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic of a charging system utilizing a charging connector assembly according to an embodiment; 
         FIG. 2  is a partially disassembled perspective view of the charging connector assembly of  FIG. 1 , utilizing a plurality of receptacle assemblies; 
         FIG. 3  is a side perspective view of one of the receptacle assemblies of  FIG. 2 ; 
         FIG. 4  is a side section view of the receptacle assembly of  FIG. 3 ; 
         FIG. 5  is a side perspective view of a terminal of the receptacle assembly of  FIG. 3 ; 
         FIG. 6  is a side perspective view of a receptacle assembly of  FIG. 2  according to another embodiment; 
         FIG. 7  is a side perspective view of a terminal of the receptacle assembly of  FIG. 6 ; 
         FIG. 8  is a side elevation view of a terminal according to another embodiment; 
         FIG. 9  is a side elevation view of a terminal according to yet another embodiment; 
         FIG. 10  is a side perspective view of a receptacle assembly of  FIG. 2  according to yet another embodiment; 
         FIG. 11  is a side perspective view of a terminal of the receptacle assembly of  FIG. 10 ; 
         FIG. 12  is a side perspective view of a terminal according to another embodiment; 
         FIG. 13  is a partial section view of a receptacle assembly of  FIG. 2  according to another embodiment; and 
         FIG. 14  is a partial side elevation view of a terminal of the receptacle assembly of  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION 
     As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. 
       FIG. 1  illustrates a charging system  20  operable to facilitate charging of a vehicle charging system  22  with energy provided from a wall outlet or charging station  24  as contemplated according to an embodiment. The system  20  may include a cordset  26  having plurality of conducting wires and/or other conducting elements to facilitate delivering current between the charging station  24  and the vehicle charging system  22 . One end of the cordset  26  may include a connector assembly  28  configured to be received within a charging receptacle  30  associated with the vehicle charging system. The connector assembly  28  may be of the type described in U.S. Pat. No. 7,878,866 to Kwasny et al., the disclosure of which is hereby incorporated by reference in its entirety. 
     The charging receptacle  30  may be configured to facilitate establishment of an electrical connection between a plurality of electrically conducting elements of the vehicle charging system  22  and the charging station  24 . The charging receptacle  30  may facilitate the desired electrical connection by providing interconnecting conducting elements and/or by guiding the vehicle charging system  22  and conducting elements of the connector assembly  28  into a mating arrangement with each other. The charging receptacle  30  may be configured to support a multiple pin or port connection methodology for facilitating electrically interconnecting the vehicle charging system  22  and the conducting elements of the connector assembly  28 , including but not limited to that specified in Society of Automotive Engineer (SAE) J1772 and International Electrotechnical Commission (IEC) 51851. 
       FIG. 2  illustrates the connector assembly  28  with a male charging connector  32  for receipt within the receptacle  30 . The illustrated charging connector  32  may be configured to facilitate electrically interconnecting vehicle charging system conducting elements with conducting elements of the cordset  26  by guiding the elements into engagement with each other. The charging connector assembly  28  may include a plurality of female receptacle assemblies  34  for receiving pins their within the charging receptacle  30 . The receptacle assemblies  34  are oriented within a cavity  36  of the connector  32  and may be configured to facilitate interconnecting of pins within the charging receptacle  30  with wires included within the cordset  26 . 
     The charging system  20  and the particular components disclosed in  FIGS. 1 and 2  are for example only and depict one embodiment for utilizing the receptacle assemblies  34 . Of course, the receptacle assemblies  34  may be employed at any electrical connection wherein a female receptacle receives a pin. 
     Referring now to  FIGS. 3 and 4 , the receptacle assembly  34  is illustrated with a receptacle housing  38 . The receptacle housing  38  may be similar to an embodiment disclosed in U.S. patent application Ser. No. 13/214,376 filed on Aug. 22, 2011 by Mott et al., which is incorporated by reference herein. The receptacle housing  38  has a bore or receptacle  40  formed therein. The receptacle  40  has an opening  42  and a blind depth end  44 . The receptacle housing  38  may be generally hollow and cylindrical in shape. Of course, the housing  38  may have any suitable shape, such as a reduced diameter, and is not limited to having a blind depth. The housing  38  may be formed of any suitable material, such as a conductive material that is adequately rigid. According to another embodiment, the receptacle housing  38  may be insulated on its exterior. 
     An electrically conductive terminal  46  is received within the receptacle  40 . In the depicted embodiment, the terminal  46  contacts the receptacle  40  for providing an electrical connection between the terminal  46  and the receptacle  40 . The terminal  46  is illustrated removed from the receptacle housing  38  in  FIG. 5 . 
     Referring now to  FIGS. 3-5 , the terminal  46  has a generally cylindrical body  48  that is received within the receptacle  40 . The terminal  46  may be formed of an electrically conductive spring metal, such as a spring tempered alloy or a binary metal such as copper clad steel. The body  48  has a lengthwise slit  50  formed through the body  48 . In the depicted embodiment a proximal region  52  of the body  48  of the terminal  46  is installed against the blind depth end  44  of the receptacle  40 . Additionally, the terminal  46  may be bonded to the receptacle housing  38  by sonic welding or any suitable manufacturing process. 
     The terminal  46  has a distal region  54  with a plurality of beams or leaf springs  56  oriented generally in a radial array and extending lengthwise from the body  48  toward the receptacle opening  42 . Each leaf spring  56  has a first angled portion  58  that extends centrally inward and longitudinally away from the body  48 . Additionally, each leaf spring  56  has a second angled portion extending radially outward from the first angled portion  58  and extending toward the receptacle opening  42 . The leaf springs  56  are spaced apart circumferentially with gaps  62  between consecutive leaf springs  56 . Although the first and second angled portions  58 ,  60  are illustrated and described, any suitable geometry, such as curved leaf springs may be utilized. 
     The receptacle assembly  34  also includes a retainer  64  secured to the receptacle opening  42  for reducing a diameter of the receptacle opening  42 . The retainer  64  may be similar to an embodiment disclosed in U.S. patent application Ser. No. 13/214,376 filed on Aug. 22, 2011 by Mott et al., which is incorporated by reference herein. The retainer  64  may be insulated to prevent inadvertent electrical communication with the opening end of the receptacle housing  38 . The retainer  64  has a shoulder  66  abutting the opening  42 . The retainer  64  also has a body  68  extending into the receptacle  40  with a tapered surface  70  which may extends centrally within the second angled portions  60  of the leaf springs  56 . The retainer  64  has a reduced inner diameter  72  and a leading-edge  74  for guiding a pin (not shown) into the receptacle  44  in engagement with the leaf springs  56  of the terminal  46 . 
     The proximal region  52  also includes a radial array of leaf springs  76  extending in a lengthwise direction from the body  48  toward the blind depth end  44  of the receptacle  40 . The leaf springs  76  extend radially outward for engaging a side wall  78  of the receptacle  40 . Each leaf spring  76  has a lengthwise extending portion  80  and an angled portion  82 . The angled portion  82  extends along an external side of the lengthwise portion  80  to thereby increase an outer diameter of the proximal region  52  of the terminal  46 . The outer diameter of the proximal region exceeds an inner diameter of the receptacle  40  so that the angled portions  82  of the leaf springs  76  are each forced into contact with the receptacle due to deformation of the lengthwise portions  80  during installation of the terminal  46  into the receptacle  40 . The reaction force of the leaf springs  76  maintains the leaf springs  76  in contact with the receptacle  40 . The individual leaf springs  76  create contact point redundancy and improve reliability of the contacts between the terminal  46  and the receptacle housing  38 . Additionally, the proximal location of the contact points at the angled portions  82  of the leaf springs  76  shortens the current length along the receptacle housing  38  as opposed to a contact along the body  48 . 
     The terminal  46  may be formed integrally from a single sheet of stamped spring tempered alloy or binary metal. The sheet of material may have a length from the proximal region  52  of the terminal body  48  to the distal end of the pin contact leaf springs  56 . The sheet of material may also have a thickness. The sheet of material may have a width terminating at lateral ends  84 ,  86  that are formed together to collectively provide the slit  50 . The sheet of material may be rolled about a lengthwise or central axis of the terminal  46 . In order to prevent the body  48  from expanding, and to thereby constrain the body  48  to a particular outer diameter, a pair of interlocking features for the interlocking the lateral ends  84 ,  86  of the body  48 . In the depicted embodiment the interlocking features include a pair of trapezoidal recesses  88  formed into the lateral end  84 . A corresponding pair of trapezoidal tabs  90  extend from the lateral end  86  and are received into the trapezoidal recesses  88  for interlocking the lateral ends  84 ,  86  of the body  48 . 
     The terminal  46  may be utilized in the connector assemblies  28  for vehicle charging systems  22 . Such systems often employ high-voltage charging, which is most effective if contact of electrical connections is optimized. Additionally, such vehicle charging systems  22  are exposed to harsh environments and undergo multiple mating cycles. The terminal  46  improves contact of the receptacle housing  38  with the terminal  46  as well as contact of the terminal  46  with the pin  76 . These improved contacts improve the durability of the terminal  46  and consequently the durability of the receptacle housings  38  and the connector assembly  28 . 
     The leaf springs  76  of the proximal region are spaced apart circumferentially with gaps  92  in between sequential leaf springs  76 . The gaps  92  may be generally equivalent in width to that of the corresponding leaf springs  76 . The gaps  92  provide clearance to permit the lengthwise portions  80  converge. 
     As stated above, the terminal  46  may be formed from a copper clad stainless steel. In such an example, a copper layer  94  is provided on an interior surface of the terminal  46  for enhanced conductivity with the pin. Copper is more conductive that stainless steel, which provides a rigid and flexible structure for the terminal  46 . By angling the angled portion  82  of the leaf springs  76  of the proximal region  52 , the copper layer  94  is in direct contact with the receptacle housing  38 . Therefore, the electrical connection can be conveyed from the pin, through the copper layer  94 , directly to the receptacle housing  38  without passing through the less conductive stainless steel. 
       FIG. 6  illustrates a receptacle assembly  96  according to another embodiment. The receptacle assembly  96  includes a receptacle housing  38  and a retainer  64  as disclosed in the prior embodiment. The receptacle assembly  96  also includes a terminal  98  that is similar to the prior embodiment. The terminal  98  is also illustrated in  FIG. 7  and has a body  100  formed from a sleeve with lateral ends  102 ,  104  interconnected at a slit  106 . A radial array of leaf springs  108  extend from the body  100  at a distal region  110  with first and second angled portions  112 ,  114  for engaging a pin received within the receptacle  40 . A second radial array of leaf springs  116  extend from the body  100  at a proximal region  118  with lengthwise portions  120  and angled portions  122  for engaging the side wall  78  of the receptacle  40 . The leaf springs  116  are spaced circumferentially by gaps  124 . The difference from the prior embodiment is that the lateral ends  102 ,  104  have an alternative interlocking configuration. The lateral end  102  has a pair of semi-circular recesses  126  formed therethrough; and the other lateral end  104  has a corresponding pair of semi-circular tabs  128  interlocked into the recesses  126 . Of course, any suitable interlocking configuration may be employed. 
       FIG. 8  illustrates a terminal  130  according to another embodiment. The terminal  130  has a body  132  formed from a sleeve with lateral ends  134 ,  136  interconnected at a slit  138  by a pair of trapezoidal tabs  140  received in a pair of trapezoidal recesses  142 . A radial array of leaf springs  144  extend from the body  132  at a distal region  146  with first and second angled portions  148 ,  150  for engaging a pin received within the receptacle  40 . A second radial array of leaf springs  152  extend from the body  132  at a proximal region  154  with lengthwise portions  156  and angled portions  158  for engaging the side wall  78  of the receptacle  40 . The leaf springs  152  are spaced circumferentially by slits  160 . In comparison to the prior embodiments, the slits  160  permit more leaf springs  152  and consequently more contact points between the terminal  130  and the receptacle housing  38 . 
       FIG. 9  illustrates a terminal  162  according to another embodiment. The terminal  162  has a body  164  formed from a sleeve with lateral ends  166 ,  168  interconnected at a slit  170  by a pair of semi-circular tabs  172  received in a pair of semi-circular recesses  174 . A radial array of leaf springs  176  extend from the body  164  at a distal region  178  with first and second angled portions  180 ,  182  for engaging a pin received within the receptacle  40 . A second radial array of leaf springs  184  extend from the body  164  at a proximal region  186  with lengthwise portions  188  and angled portions  190  for engaging the side wall  78  of the receptacle  40 . The leaf springs  184  are spaced circumferentially by slits  192  for optimizing a quantity of leaf springs  184  and consequently maximizing contact points between the terminal  162  and the receptacle housing  38 . 
       FIG. 10  illustrates a receptacle assembly  194  according to another embodiment. The receptacle assembly  194  includes a receptacle housing  38  and a retainer  64  as disclosed in prior embodiments. The receptacle assembly  194  also includes a terminal  196  that is similar to prior embodiments. The terminal  196  is also illustrated in  FIG. 11  and has a body  198  formed from a sleeve with lateral ends  200 ,  202  interconnected at a slit  204  by a fastener, such as laser-spot welding  206 . A radial array of leaf springs  208  extend from the body  198  at a distal region  210  with first and second angled portions  212 ,  214  for engaging a pin received within the receptacle  40 . A second radial array of leaf springs  216  are formed into the body  198  at a proximal region  218  thereof, with lengthwise portions  220  and angled portions  222  for engaging the side wall  78  of the receptacle  40 . The leaf springs  216  are spaced circumferentially about the body  198 . By orienting the leaf springs  216  about the body  198 , the proximal region  218  and the body  198  are combined, thereby minimizing materials while optimizing conductivity. 
       FIG. 12  illustrates a terminal  224  according to another embodiment. The terminal  224  has a body  226  formed from a sleeve. A radial array of leaf springs  228  extend from the body  226  at a distal region  230  with first and second angled portions  232 ,  234  for engaging a pin received within the receptacle  40 . A second radial array of leaf springs  236  are formed into the body  226  at a proximal region  238  thereof, with lengthwise portions  240 , first angled portions  242  and second angled portions  244  for engaging the side wall  78  of the receptacle  40 . The leaf springs  236  are spaced circumferentially about the body  226 . By orienting the leaf springs  236  about the body  226 , the proximal region  238  and the body  226  are combined, thereby minimizing materials while optimizing conductivity. 
       FIG. 13  illustrates a receptacle assembly  246  according to another embodiment. The receptacle assembly  246  includes a receptacle housing  248  with a receptacle  250  formed to a blind depth end  252 . A groove  254  is formed adjacent the blind depth end  252 . The receptacle assembly  246  also includes a terminal  256  that is similar to prior embodiments. The terminal  256  is also illustrated in  FIG. 14  and has a body  258  formed from a sleeve. A radial array of leaf springs  260  extend from the body  258  at a proximal region  262  with lengthwise portions  264 , first angled portions  266  and second angled portions  268  for engaging the groove  254  of the receptacle  250  thereby providing additional contact points between the terminal  256  and the receptacle housing  248 . The second angled portions  268  abut the lengthwise portions  264 . 
     While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.