Patent Publication Number: US-2022239027-A1

Title: Electrical terminal for mating with two coplanar tabs

Description:
FIELD OF THE INVENTION 
     The present invention is directed to an electrical terminal for mating with two coplanar tabs. In particular, the invention is directed to an electrical terminal which properly positions and mates with tabs with minimal pitch. 
     BACKGROUND OF THE INVENTION 
     There are many terminals known in the industry for quickly mating with tabs of a mating connector or device. However, the geometry of known terminals does not affect a reliable electrical connection with mating tabs as the size of the mating tabs is reduced. 
     It would, therefore, be desirable to provide an electrical terminal and connector which properly positions and mates with mating tabs of minimal pitch. It would also be beneficial to provide an electrical terminal which applies sufficient mating force to the mating terminals to affect and maintain a proper electrical connection. 
     SUMMARY OF THE INVENTION 
     An embodiment is directed to an electrical terminal having a base section, a first contact leg and a second contact leg. The first contact leg extends from the base section. The first contact leg has a first generally planar portion. A first curved resilient contact portion extends from a first side of the first planar portion, and a first positioning wall extending from a second side of the first planar portion. The first side of the first planar portion is opposed to the second side of the first planar portion. The second contact leg extends from the base section. The second contact leg has a second generally planar portion. A second curved resilient contact portion extends from a first side of the second planar portion, and a second positioning wall extends from a second side of the second planar portion. The first side of the second planar portion is opposed to the second side of the second planar portion. 
     An embodiment is directed to an electrical connector having a housing with a base portion with a first terminal receiving portion and a second terminal receiving portion extending therefrom. An electrical terminal is positioned in the housing. The electrical terminal has a base section positioned in the base portion of the housing. A first contact leg is positioned in the first terminal receiving portion. The first contact leg has a first planar portion, a first curved resilient contact portion, and a first positioning wall. A second contact leg is positioned in the second terminal receiving portion. The second contact leg has a second planar portion, a second curved resilient contact portion, and a second positioning wall. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the illustrative embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative embodiment of an electrical terminal of the present invention. 
         FIG. 2  is an enlarged perspective view of a contact arm of the electrical terminal shown in area  2  of  FIG. 1 . 
         FIG. 3  is a cross-sectional view taken along line  3 - 3  of  FIG. 2 . 
         FIG. 4  is a cross-sectional view taken along line  4 - 4  of  FIG. 2 . 
         FIG. 5  is a perspective view of in illustrative embodiment of a housing for use with the electrical terminal of  FIG. 1 . 
         FIG. 6  is a perspective view of the electrical terminal prior to being inserted into the housing. 
         FIG. 7  is a perspective view of an electrical connector assembly with the electrical terminal fully inserted into the housing. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. 
     Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the invention expressly should not be limited to such embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features, the scope of the invention being defined by the claims appended hereto. 
     As shown in  FIGS. 1 through 4 , an electrical terminal  10  includes a base section  12 , a first contact leg  14  and a second contact leg  16 . The first contact leg  14  extends from the base section  12 . The first contact leg  14  has a first generally planar portion  20 , a first curved resilient contact portion  22  which extends from a first side  24  of the first planar portion  20 , and a first positioning wall  26  which extends from a second side  28  of the first planar portion  20 . The first side  24  of the first planar portion  20  is opposed to the second side  28  of the first planar portion  20 . 
     The second contact leg  16  extends from the base section  12 . The second contact leg  16  has a second generally planar portion  30 , a second curved resilient contact portion  32  which extends from a first side  34  of the second planar portion  30 , and a second positioning wall  36  which extends from a second side  38  of the second planar portion  30 . The first side  34  of the second planar portion  30  is opposed to the second side  38  of the second planar portion  30 . 
     The first positioning wall  26  extends substantially angled from the first planar portion  20  of the first contact leg  14 . The second positioning wall  36  extends substantially angled from the second planar portion  30  of the second contact leg  16 . In an embodiment, the substantial angles of the extensions of the first positioning wall  26  and the second positioning wall  36  are substantially identical. In an embodiment, the substantial angles are greater than zero (0) degrees, and less than or equal to ninety (90) degrees, i.e., substantially perpendicular to the respective planar portions ( 20 ,  30 ) or less. In some embodiment, one or both the first positioning wall  26  and the second positioning wall  36  are substantially flat. In some other embodiments, one or both the first positioning wall  26  and the second positioning wall  36  are non-flat. 
     The second side  28  of the first planar portion  20  and the second side  38  of the second planar portion  30  are positioned adjacent each other, with or without touching each other. The first positioning wall  26  and the second positioning wall  36  extend between the first curved resilient contact arm  22  and the second resilient contact arm  32 . As shown in  FIG. 2 , the first positioning wall  26  and the second positioning wall  36  may have tapered ends  37  which may have lead-in surfaces  39  provided thereon. 
     In an embodiment as shown in  FIG. 1 , a longitudinal axis  40  of the first contact leg  14  is substantially parallel to a longitudinal axis  42  of the second contact leg  16 . The longitudinal axis  40  of the first contact leg  14  and the longitudinal axis  42  of the second contact leg  16  are substantially perpendicular to a longitudinal axis  44  of the base section  12 . In some embodiment, the longitudinal axis  40  and the longitudinal axis  42  may be non-parallel. In some embodiment, they may be non-perpendicular to the longitudinal axis  44 . 
     A push-in installation surface  46  is provided on the base section  12 . The push-in installation surface  46  extends substantially perpendicular to a base planar portion  48  of the base section  12 . 
     The first curved resilient contact portion  22  has a first arcuate section  50  which extends from the first planar portion  20  and a first tab engaging section  52  which extends from a free end of the first arcuate section  50 . The second curved resilient contact portion  32  has a second arcuate section  54  which extends from the second planar portion  30  and a second tab engaging section  56  which extends from a free end of the second arcuate section  54 . 
     As shown in  FIGS. 1 through 4 , the first planar portion  20  of the first contact leg  14  has a first resilient contact arm  60  formed thereon. The first resilient contact arm  60  has a first free end  62  which extends toward the first tab engaging section  52 . As shown in  FIG. 1 , the second planar portion  30  of the second contact leg  16  has a second resilient contact arm  64  formed therein. The second resilient contact arm  64  has a second free end  66  which extends toward the second tab engaging section  56 . 
     Projections  68  are formed in the first resilient contact arm  60  and the second resilient contact arm  64 . The projections  68  extend from the first resilient contact arm  60  and the second resilient contact arm  64  in a direction toward the first tab engaging section  52  and the second tab engaging section  56 . 
     A housing  70 , as shown in  FIGS. 5 through 7  is provided to receive the electrical terminal  10  therein. The housing  70  has a base portion  72  with a first terminal receiving portion  74  and a second terminal receiving portion  76  extending from the base portion  72 . The first terminal receiving portion  74  and the second terminal receiving portion  76  are separated by a cavity or slot  78 . A cover  80  is hingedly attached to the base portion  72 . 
     The base portion  72  has a base receiving cavity  82 . The base receiving cavity  82  is dimensioned to receive the base section  12  of the electrical terminal  10  therein. Latching projections  81  extend from the base portion  72 . A positioning member  83  also extends from the base portion  72 . In the illustrative embodiment shown, the positioning member  83  is positioned between the latching projections  81 , however, other configurations can be used. 
     The first terminal receiving portion  74  has a first terminal receiving cavity  84  in which the first contact leg  14  of the electrical terminal  10  is positioned. The first terminal receiving cavity  84  extends from the base receiving cavity  82 . The first terminal receiving cavity  84  is configured to receive a first mating contact (not shown) therein. 
     The second terminal receiving portion  76  has a second terminal receiving cavity  86  in which the second contact leg  16  of the electrical terminal  10  is positioned. The second terminal receiving cavity  86  extends from the base receiving cavity  82 . The second terminal receiving cavity  86  is configured to receive a first mating contact (not shown) therein. 
     The cover  80  has terminal engaging projections  88  which are configured to cooperate with the push-in installation surface  46  of the terminal  10 , as will be more fully described. Latches  89  extend from the cover  80 . 
     During assembly, the terminal  10  is inserted into the housing  70  through the base portion  72 . When properly positioned: the first contact leg  14  of the terminal  10  is positioned in the first terminal receiving cavity  84  of the first terminal receiving portion  74 ; the second contact leg  16  of the terminal  10  is positioned in the second terminal receiving cavity  86  of the second terminal receiving portion  76 ; and the base section  12  of the terminal  10  is positioned in the base receiving cavity  82  of the base portion  72 . 
     With the electrical terminal  10  properly positioned in the housing  70  the cover  80  is rotated to close the base portion  72  of the housing  70 . As this occurs, the terminal engaging projections  88  of the cover  80  engage the push-in installation surface  46  of the base section  12  of the terminal  10 . The engagement of the terminal engaging projections  88  of the cover  80  engage the push-in installation surface  46  causes the terminal  10  to be pushed forward in the housing  70 , thereby ensuring that the first contact leg  14  and the second contact leg  16  are properly positioned in the housing  70 . With the cover  80  properly rotated, the latches  89  cooperate with the latch projections  81  to secure the cover  80  in the closed position. 
     With the terminal  10  properly inserted and retained in the housing  70 , the connector assembly  90  can be mated to mating terminals or tabs  92  ( FIG. 7 ). The mating tabs  92  are coplanar tabs that extend from a device or are positioned in a mating connector (not shown). The mating tabs  92  have a minimal pitch or size. 
     As the connector assembly  90  is moved onto the mating tabs  92 , free ends  94  of the mating tabs  92  are move into engagement with the first contact leg  14  and the second contact leg  16 . As this occurs, the lead-in surfaces  39  of the tapered ends  37  of the first positioning wall  26  and the second positioning engage the free ends  94  to cause the free ends  94  and the mating tabs  92  to properly positioned relative to the first curved resilient contact portion  22  and the second resilient contact portion  32 . 
     As insertion of the connector assembly  90  onto the mating tabs  92  continues, the first positioning wall  26  and the second positioning wall  36  continue to cooperate with the mating tabs  92  to properly position the mating tabs  92  in the first contact leg  14  and the second contact leg  16 . This ensures that the first tab engaging section  50  and the second tab engaging section  56  are positioned inline with the mating tabs  92 . 
     As the spacing between the first tab engaging section  50  and the projection  68  of the first resilient contact arm  60  is less than the thickness of the mating tab  92 , the first tab engaging section  50  and the projection  68  engage the mating tab  92  to mechanically and electrically connect the first tab engaging section  50  and the projection  68  to the mating tab  92 . This causes the first arcuate section  50  and the first resilient contact arm  60  to be moved to a stressed position, which in turn causes the first tab engaging section  50  and the projection  68  to exert a normal force on the mating tab  92 . The normal force allows the first tab engaging section  50  and the projection  68  to maintain engagement with the mating tab  92  over time and over many cycles. In addition, the normal force allows the first tab engaging section  50  and the projection  68  to wipe the mating tab  92  as insertion continues to eliminate any contaminants in the engagement area. 
     Similarly, the spacing between the second tab engaging section  56  and the projection  68  of the second resilient contact arm  64  is less than the thickness of the mating tab  92 , the second tab engaging section  56  and the projection  68  engage the mating tab  92  to mechanically and electrically connect the second tab engaging section  56  and the projection  68  to the mating tab  92 . This causes the second arcuate section  56  and the second resilient contact arm  64  to be moved to a stressed position, which in turn causes the second tab engaging section  54  and the projection  68  to exert a normal force on the mating tab  92 . The normal force allows the second tab engaging section  54  and the projection  68  to maintain engagement with the mating tab  92  over time and over many cycles. In addition, the normal force allows the second tab engaging section  54  and the projection  68  to wipe the mating tab  92  as insertion continues to eliminate any contaminants in the engagement area. 
     The terminal  10  allows the first contact leg  14  and the second contact leg  16  to act as a single terminal applying the same retention force to be applied to both mating tabs  92 . The use of the positioning walls  26 ,  36  ensures that the mating tabs  92  will be properly positioned relative to the first resilient contact portion  22  and the second resilient contact portion  32 , allowing the first tab engaging section  50  and the second tab engaging section  54  to extend over the center line of the mating tabs  92 . This ensures that a proper electrical connection will be made and retained between the terminal  10  and the mating tabs  92 . 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention as defined in the accompanying claims. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials and components and otherwise used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims, and not limited to the foregoing description or embodiments.