Patent Publication Number: US-10320129-B2

Title: Low profile terminal assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is the National Stage of International Patent Application No. PCT/US2015/020143, filed on Mar. 12, 2015, which is hereby expressly incorporated herein by reference in its entirety. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to terminal assemblies for vehicles and, more particularly to, a low profile terminal assembly for holding a fuse for a vehicle. 
     2. Description of the Related Art 
     It is known to provide a fuse holder for a removable electrical fuse. The fuse holder typically is in-line with a wire connected to a load and an unprotected wire connected to an eyelet, which is connected to a terminal of a battery. The fuse holder includes a housing and a cover pivotally attached to the housing, and configured to carry the electrical fuse. The fuse electrically interconnects the wires. 
     One disadvantage of the above fuse holder is that the fuse holder is spliced into the wiring harness and/or the electrical cable. Another disadvantage of the above fuse holder is that there is an unprotected wire between the fuse holder and the terminal for connection to the battery. Therefore, there is a need in the art to provide a new terminal assembly coupled to an electrical cable for engaging an electrical component to hold a fuse without requiring disassembly or alteration of the terminal assembly. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention provides a terminal assembly for serviceably housing an electrical fuse. The terminal assembly includes a first terminal having a mounting end and a first fuse contacting end with the mounting end adapted for receiving a stud, a second terminal having a wire contacting end and a second fuse contacting end with the wire contacting end adapted for receiving an electrical cable, and a terminal housing securing the first terminal and the second terminal together. The terminal housing defines a cavity adapted for receiving a fuse. The first fuse contacting end of the first terminal and the second fuse contacting end of the second terminal extend into the cavity. The fuse is adapted to be inserted into the cavity and is disposed atop the first terminal and the second terminal without requiring disassembly or alteration of the terminal assembly. 
     One advantage of the present invention is that a new terminal assembly is provided for a vehicle that holds an electrical fuse therein. Another advantage of the present invention is that the terminal assembly is coupled to an electrical cable to hold an electrical fuse for engaging an electrical component. Yet another advantage of the present invention is that the terminal assembly does not require added splices to integrate into a wire harness. Still another advantage of the present invention is that the terminal assembly holds an electrical fuse without requiring disassembly or alteration of the terminal assembly. A further advantage of the present invention is that the terminal assembly serviceably houses slow blow cartridge type electrical fuses having a low profile configuration. Yet a further advantage of the present invention is that the terminal assembly holds an electrical fuse and is secured by a stud. Still a further advantage of the present invention is that the terminal assembly eliminates an unprotected “up stream” wire. Another advantage of the present invention is that the terminal assembly is smaller and less expensive than some fuse holders. 
     Other features and advantages of the present invention will be readily appreciated, as the same becomes better understood, after reading the subsequent description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a low profile terminal assembly, according to one embodiment of the present invention. 
         FIG. 2  is a fragmentary elevational view of the low profile terminal assembly of  FIG. 1 . 
         FIG. 3  is a perspective view of another embodiment, according to the present invention, of the low profile terminal assembly of  FIGS. 1 and 2 . 
         FIG. 4  is plan view of the low profile terminal assembly of  FIG. 3 . 
         FIG. 5  is an elevational view of the low profile terminal assembly of  FIG. 3 . 
         FIG. 6  is an exploded view of the low profile terminal assembly of  FIG. 3 . 
         FIG. 7  is diagrammatic view of a prior art in-line fuse holder illustrated in operational relationship with an energized power stud. 
         FIG. 8  a diagrammatic view of the low profile terminal assembly of  FIGS. 1 and 2  illustrated in operational relationship with an energized power stud. 
         FIG. 9  is a fragmentary view of the low profile terminal assembly of  FIGS. 1 and 2  illustrated in operational relationship with a power source. 
         FIG. 10  is a fragmentary view of another embodiment, according to the present invention, of the low profile terminal assembly of  FIGS. 1 and 2  illustrated in operational relationship with a power source. 
         FIG. 11  is a fragmentary view of yet another embodiment, according to the present invention, of the low profile terminal assembly of  FIGS. 1 and 2  illustrated in operational relationship with a power source. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT(S) 
     As disclosed in the  FIGS. 1 and 2 , one embodiment of a low profile terminal assembly  10 , according to the present invention, is shown for serviceably housing an electrical fuse  12 . In one embodiment, the terminal assembly  10  is coupled between an electrical cable  14  and an energized power stud  16  extending from an electrical component (not shown) of a vehicle (not shown), such as an alternator or battery. It should be appreciated that the terminal assembly  10  may be used in other embodiments for the vehicle other than the electrical cable  14  and stud  16 . 
     As illustrated in  FIGS. 1 and 2 , the terminal assembly  10  includes a first terminal  18  for coupling the terminal assembly  10  to the stud  16  and a second terminal  20  for coupling the terminal assembly  10  to the electrical cable  14 . The terminal assembly  10  further includes a terminal housing  22  for securing the first and second terminals  18 ,  20  together and for receiving the fuse  12 . It should be appreciated that the terminals  18 ,  20 , as illustrated, extend in opposite directions from the terminal housing  22 . 
     The fuse  12  includes a fuse housing  24  having a pair of fuse terminals  26  and a fuse element  28  disposed therein. The fuse housing  24  is generally rectangular in shape, but may have any suitable shape. The fuse terminals  26  extend generally parallel from the fuse housing  24 . The pair of fuse terminals  26  electrically couple the fuse element  28  between the first and second terminals  18 ,  20  as the fuse  12  is inserted into the terminal housing  22 . The fuse terminals  26  are made of an electrically conductive material such as metal. It should be appreciated that the fuse  12  is preferably a slow blow cartridge type having a low-profile configuration. 
     The first terminal  18  includes a mounting end  30  having an aperture  32  for receiving the stud  16 . The aperture  32  may be open ended, generally circular in shape, or may have any suitable shape. If the aperture  32  is closed, i.e. circular, then the mounting end  30  could be in the shape of an eyelet. The first terminal  18  also includes a first fuse contacting end  34  for coupling the first terminal  18  to one of the fuse terminals  26 . In the embodiment illustrated, the first terminal  18  has a substantially L-shaped configuration such that an angle defined between the mounting end  30  and the first fuse contacting end  34  is approximately 90 degrees. In another embodiment, the first terminal  18  has a straight configuration between the mounting end  30  and the first fuse contacting end  34 . In other embodiments, the first terminal  18  may have a multiple bend configuration between the mounting end  30  and the first fuse contacting end  34  to allow for various orientations. The mounting end  30  is directly connected to the first fuse contacting end  34 . The first terminal  18  is made of an electrically conductive material such as metal. It should be appreciated that the first fuse contacting end  34  is generally planar. It should also be appreciated that the mounting end  30  of the first terminal  18  is directly adjacent the terminal housing  22 . 
     The second terminal  20  includes a wire contacting end  36  for coupling the second terminal  20  to the electrical cable  14 . The wire contacting end  36  is generally arcuate in shape for receiving the electrical cable  14 . The second terminal  20  also includes a second fuse contacting end  38  for coupling the second terminal  20  to the other one of the fuse terminals  26 . The second terminal  20  has a substantially L-shaped configuration such that an angle defined between the wire contacting end  36  and the second fuse contacting end  38  is approximately 90 degrees. The second terminal  20  is made of an electrically conductive material such as metal. The second fuse contacting end  38  is generally planar. It should be appreciated that the wire contacting end  36  is secured to the electrical cable  14  by a suitable mechanism such as crimping or welding. 
     The terminal housing  22  includes a first slot  40  for receiving the first terminal  18  and a second slot  42  for receiving the second terminal  20 . The terminal housing  22  also includes a cavity portion  43  defining a cavity  44  for receiving the fuse  12 . The first terminal  18  is disposed through the first slot  40  such that the first fuse contacting end  34  extends into the cavity  44 . The second terminal  20  is disposed through the second slot  42  such that the second fuse contacting end  38  extends into the cavity  44 . The first terminal  18  is spaced from the second terminal  20  while disposed within the terminal housing  22  such that the first and second terminals  18 ,  20  are electrically disconnected when the fuse  12  is not installed. Within the cavity  44 , the first fuse contacting end  34  is disposed substantially parallel to the second fuse contacting end  38 . Furthermore, the mounting end  30  of the first terminal  18  is substantially planar with the wire contacting end  36  of the second terminal  20 . It should be appreciated that first fuse contacting end  34  is spaced from the second fuse contacting end  38  with the first fuse contacting end  34  and second fuse contacting end  38  being adapted to be electrically connected solely through the fuse  12 . 
     The terminal housing  22  is generally rectangular in shape, but may be any suitable shape. The terminal housing  22  is made of a non-conductive material such as plastic. The terminal housing  22  may be formed as integral, unitary, and one-piece or as two pieces snapped together. In one embodiment, the terminal housing  22  is molded over the first terminal  18  and second terminal  20 . It should be appreciated that the terminal housing  22  is typically molded by injection molding, but may be molded by any suitable process. 
     In operation of the terminal assembly  10 , the fuse  12  is inserted into the cavity  44  of the terminal housing  22  and is disposed atop the first and second terminals  18 ,  20 . Specifically, as the fuse  12  enters the cavity  44 , the pair of fuse terminals  26  electrically couple to the first and second fuse contacting ends  34 ,  38 . As such, electrical current may pass between the first and second terminals  18 ,  20  because the fuse  12  electrically connects the first and second terminals  18 ,  20  through the fuse element  28 . It should be appreciated that the fuse  12  is secured within the cavity  44  of the terminal housing  22  by a suitable mechanism such as a friction fit. 
     Referring to  FIGS. 3 through 6 , another embodiment, according to the present invention, of the terminal assembly  10  is shown. Like parts of the terminal assembly  10  have like reference numerals increased by one hundred (100). As illustrated in  FIGS. 3 through 6 , the terminal assembly  110  includes a first terminal  118  for coupling the terminal assembly  110  to the stud  16  and a second terminal  120  for coupling the terminal assembly  110  to the electrical cable  14 . The terminal assembly  110  also includes a terminal housing  122  for securing the first and second terminals  118 ,  120  together and for receiving the fuse  12 . It should be appreciated that the terminals  118 ,  120 , as illustrated, extend in opposite directions from the terminal housing  22 . 
     The first terminal  118  includes a mounting end  130  having an aperture  132  for receiving the stud  16 . The aperture  132  may be open ended, generally circular in shape, or may have any suitable shape. If the aperture  132  is closed, i.e. circular, then the mounting end  130  could be in the shape of an eyelet. The first terminal  118  also includes a first fuse contacting end  134  for coupling the first terminal  118  to one of the fuse terminals  26 . In the embodiment illustrated, the first terminal  118  has a substantially L-shaped configuration such that an angle defined between the mounting end  130  and the first fuse contacting end  134  is approximately 90 degrees. In another embodiment, the first terminal  118  has a straight configuration between the mounting end  130  and the first fuse contacting end  134 . In other embodiments, the first terminal  118  may have a multiple bend configuration between the mounting end  130  and the first fuse contacting end  134  to allow for various orientations. The mounting end  130  is directly connected to the first fuse contacting end  134 . The first terminal  118  is made of an electrically conductive material such as metal. It should be appreciated that the first fuse contacting end  134  is generally planar. It should also be appreciated that the mounting end  130  of the first terminal  118  is directly adjacent the terminal housing  122 . 
     The second terminal  120  includes a wire contacting end  136  for coupling the second terminal  120  to the electrical cable  14 . The wire contacting end  136  is generally arcuate in shape for receiving the electrical cable  14 . The second terminal  120  also includes a second fuse contacting end  138  for coupling to the second terminal  120  to the other one of the fuse terminals  26 . The second terminal  120  has a substantially L-shaped configuration such that an angle defined between the wire contacting end  136  and the second fuse contacting end  138  is approximately 90 degrees. The second terminal  120  is made of an electrically conductive material such as metal. The second fuse contacting end  138  is generally planar. It should be appreciated that the wire contacting end  136  is secured to the electrical cable  14  by a suitable mechanism such as crimping or welding. 
     The terminal housing  122  includes a first slot  140  for receiving the first terminal  118  and a second slot  142  for receiving the second terminal  120 . The terminal housing  122  also includes a cavity portion  143  defining a cavity  144  for receiving the fuse  12 . The terminal housing  22  further includes a flange  146  extending outwardly and a pair of protrusions  148  opposing one another and spaced below the flange  146 . The first terminal  118  is disposed through the first slot  140  such that the first fuse contacting end  134  extends into the cavity  144 . The second terminal  120  is disposed through the second slot  142  such that the second fuse contacting end  138  extends into the cavity  144 . The first terminal  118  is spaced from the second terminal  120  while disposed within the terminal housing  122  such that the first and second terminals  118 ,  120  are electrically disconnected when the fuse  12  is not installed. Within the cavity  144 , the first fuse contacting end  134  is disposed substantially parallel to the second fuse contacting end  138 . Furthermore, the mounting end  130  of the first terminal  118  is substantially planar with the wire contacting end  136  of the second terminal  120 . It should be appreciated that first fuse contacting end  134  is spaced from the second fuse contacting end  138  with the first fuse contacting end  134  and second fuse contacting end  38  being adapted to be electrically connected solely through the fuse  12 . 
     The terminal housing  122  is generally rectangular in shape, but may be any suitable shape. The terminal housing  122  is made of a non-conductive material such as plastic. The terminal housing  122  may be formed as integral, unitary, and one-piece or as two pieces snapped together. In one embodiment, the terminal housing  122  is molded over the first terminal  118  and second terminal  120 . It should be appreciated that the terminal housing  122  is typically molded by injection molding, but may be molded by any suitable process. 
     The terminal assembly  110  also includes a seal  150  disposed about the cavity portion  143  of the terminal housing  122 . The seal  150  includes a ring shaped body  152  having a generally rectangular shape, but may be any suitable shape. The seal  150  has one or more ribs  154  extending outwardly from the body  152  and spaced from each other. The seal  150  is disposed about the cavity portion  143  of the terminal housing  122  and adjacent the flange  146 . The seal  150  is made of an elastomeric material such that the ribs  154  flex to form a seal with a cover  156  to be described. 
     The terminal assembly  110  further includes a cover  156  cooperating with the terminal housing  122 . The cover  156  is generally rectangular in shape, but may be any suitable shape, to be disposed over the cavity portion  143  of the terminal housing  122 . The cover  156  has a cavity (not shown) to receive the cavity portion  143  of the terminal housing  122 . The cover  156  has one or more latches  160  to removably secure the cover  156  to the terminal housing  122 . In one embodiment, the latches  160  are disposed on opposed sides and are movable to engage and disengage the corresponding protrusions  148  on the terminal housing  122 . The cover  156  may include a tether  162  that engages a recess  164  in the terminal housing  122  to keep the cover  156  attached to the terminal housing  122 . It should be appreciated that the cover  156  is removable from the terminal housing  122  via the latches  160 . It should also be appreciated that the ribs  154  of the seal  150  engage the inside of the cover  156 . 
     In operation of the terminal assembly  110 , the fuse  12  is inserted into the cavity  144  of the terminal housing  122  and is disposed atop the first and second terminals  118 ,  120 . Specifically, as the fuse  12  enters the cavity  144 , the pair of fuse terminals  26  electrically couple to the first and second fuse contacting ends  134 ,  138 . The seal  150  is disposed about the cavity portion  143  of the terminal housing  122 . The cover  156  is disposed over the cavity portion  143  of the terminal housing  122  and the latches  160  engage the protrusions  148  in the terminal housing  122  to secure the cover  156  to the terminal housing  122 . It should be appreciated that electrical current may pass between the first and second terminals  118 ,  120  because the fuse  12  electrically connects the first and second terminals  118 ,  120  through the fuse element  28 . 
     Referring to  FIG. 7 , a prior art in-line fuse holder  170  is generally shown for serviceably housing an electrical fuse (not shown). The fuse holder  170  is coupled between a first electrical cable  14  and a second electrical cable  15 . The first electrical cable  14  is connected to a mounting  172  having an aperture (not shown) for receiving an energized power stud  16  extending from an electrical component (not shown) of a vehicle (not shown), such as an alternator or battery. The second electrical cable  15  is connected to a load  174  such as an electrical component of the vehicle. The load  174  is connected by an electrical ground wire  176  to ground  178  of the vehicle. It should be appreciated that current flows from the energized power stud  16  through the first electrical cable  14 , in-line fuse holder  170 , second electrical cable  15 , the load  174 , and ground wire  176  to ground  178 . It should also be appreciated that the first electrical cable  14  is unprotected for the in-line fuse holder  170  is unprotected. 
     Referring to  FIG. 8 , the terminal assembly  10 ,  110  is generally shown for serviceably housing the electrical fuse  12  previously described. The terminal assembly  10 ,  110  includes the first terminal  18 ,  118  having the mounting end  30 ,  130  with an aperture  32 ,  132  for receiving the energized power stud  16  extending from an electrical component (not shown) of a vehicle (not shown), such as an alternator or battery. The terminal assembly  10 ,  110  includes the second terminal  120  connected to one end of the electrical cable  14 . The electrical cable  14  has another end connected to the load  174  such as an electrical component of the vehicle. The load  174  is connected by the electrical ground wire  176  to ground  178  of the vehicle. It should be appreciated that current flows from the energized power stud  16  through the mounting end  30 ,  130 , the terminal assembly  10 ,  110 , the electrical cable  14 , the load  174 , and ground wire  176  to ground  178 . It should also be appreciated that the terminal assembly  10 ,  110  eliminates an unprotected wire at the mounting end  30 ,  130 . 
     Referring to  FIG. 9 , the terminal assembly  10 ,  110  is shown in operational relationship with a power source  180  such as a battery. The power source  180  includes the energized power stud  16 . As illustrated, the first terminal  18 ,  118  and second terminal  20 ,  120  may be configured at approximately ninety degrees (90°). The first terminal  18 ,  118  has the mounting end  30 ,  130  connected to the energized power stud  16  and the second terminal  20 ,  120  is connected to the electrical cable  14 . It should be appreciated that the terminal assembly  10 ,  110  houses the fuse  12 . 
     Referring to  FIG. 10 , another embodiment, according to the present invention, of the terminal assembly  10 ,  110  is shown in operational relationship with a power source  180  such as a battery. The power source  180  includes the energized power stud  16 . Like parts of the terminal assembly  10  have like reference numerals increased by two hundred (200) and like parts of the terminal assembly  110  have like reference numerals increased by one hundred (100). As illustrated, the terminal assembly  210  includes a first terminal  218  for coupling the terminal assembly  210  to the energized power stud  16  and a second terminal  220  for coupling the terminal assembly  210  to the electrical cable  14 . As illustrated, the first terminal  218  may be straight and the second terminal  220  may be configured at approximately ninety degrees (90°). The first terminal  218  has the mounting end  230  connected to the energized power stud  16  and the second terminal  220  is connected to the electrical cable  14 . It should be appreciated that the terminal assembly  210  houses the fuse  12 . 
     Referring to  FIG. 11 , yet another embodiment, according to the present invention, of the terminal assembly  10 ,  110  is shown in operational relationship with a power source  180  such as a battery. The power source  180  includes the energized power stud  16 . Like parts of the terminal assembly  10  have like reference numerals increased by three hundred (300) and like parts of the terminal assembly  110  have like reference numerals increased by two hundred (200). As illustrated, the terminal assembly  310  includes a first terminal  318  for coupling the terminal assembly  310  to the energized power stud  16  and a second terminal  320  for coupling the terminal assembly  310  to the electrical cable  14 . As illustrated, the first terminal  318  may have one or more bends  386  to form a generally “Z” shaped configuration and the second terminal  320  may be configured at approximately ninety degrees (90°). The first terminal  318  has the mounting end  330  connected to the energized power stud  16  and the second terminal  320  is connected to the electrical cable  14 . It should be appreciated that the terminal assembly  310  houses the fuse  12 . 
     Accordingly, in the present invention, the terminal assembly  10 ,  110 ,  210 ,  310  advantageously provides circuit protection to the electrical cable  14  without requiring substantial manipulation of the electrical cable  14  to incorporate the fuse  12 . Furthermore, the terminal assembly  10 ,  110 ,  210 ,  310  eliminates an unprotected wire at the mounting end  30 ,  130 ,  230 ,  330 . It should be appreciated that the fuse  12  is readily accessible and components of the terminal assembly  10 ,  110 ,  210 ,  310  remain fixed and need not be altered to access and/or replace the fuse  12 . 
     The present invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. 
     Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, the present invention may be practiced other than as specifically described.