Patent Publication Number: US-9905952-B2

Title: Electrical power contact

Description:
The present application is a U.S. national stage filing under 35 U.S.C. § 371 based on International Application No. PCT/US2015/040511 entitled “ELECTRICAL POWER CONTACT”, filed Jul. 15, 2015, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 62/028,449, filed Jul. 24, 2014, which are hereby incorporated by reference in their entireties. 
    
    
     BACKGROUND 
     Electrical assemblies can include at least one electrical conductor, and an electrical insulator that surrounds the electrical conductor. The at least one electrical conductor typically defines a first end for electrical connection to an electrical contact, and a second end for electrical connection to a mounting member. The electrical contact and the mounting member can be placed in electrical communication with respective complementary electrical components. The at least one electrical conductor can be configured to carry electrical power or data signals between the complementary electrical devices. The size of electrical power contacts and the current-carrying capacity of electrical power contacts are often competing design characteristics. 
     SUMMARY 
     In accordance with one embodiment, an electrical contact, such as an electrical power contact for example, can include a mounting portion con figured to electrically connect to an electrical cable. The electrical contact can further include a mating portion spaced from the mounting portion in a forward direction. The mating portion can include first and second contact blades spaced from each other along a second direction that is substantially perpendicular to the forward direction. The electrical contact can further include a transition region that extends from the mounting portion to the mating portion. The transition region can be configured to transmit electrical current from the mounting portion to the mating portion. The transition region can define a first end and a second end spaced from the first end in the forward direction. The first and second ends can define first and second heights, respectively, measured along a third direction that is substantially perpendicular to both the forward direction and the second direction, and second height can be greater than the first height. 
     In another example embodiment, an electrical contact, for instance an electrical power contact, includes a mounting portion and a mating portion spaced from the mounting portion in a forward direction. The mounting portion is configured to electrically connect to an electrical cable. The mating portion can include first and second contact blades spaced from each other along a second direction that is substantially perpendicular to the forward direction. Each of the first and second contact blades can define a respective first surface and a respective second surface spaced from the respective first surface along a third direction that is substantially perpendicular to both the forward direction and the second direction. One of the first and second contact blades can define a seam elongate along the forward direction. The seam can be closer to one of the first and second surfaces as compared to the other of the first and second surfaces. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing summary, as well as the following detailed description of example embodiments of the application, will be better understood when read in conjunction with the appended drawings, in which there is shown in the drawings example embodiments for the purposes of illustration. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. In the drawings: 
         FIG. 1A  is a perspective view of a portion of an electrical assembly constructed in accordance with one embodiment, showing an electrical contact of an electrical cable assembly of the electrical assembly aligned to be mated with a complementary electrical contact of the electrical assembly; 
         FIG. 1B  is another perspective view of the electrical contact and the complementary electrical contact shown in  FIG. 1A ; 
         FIGS. 2A and 2B  are perspective views of the electrical contact shown in  FIGS. 1A and 1B ; 
         FIG. 2C  is a top plan view of the electrical contact illustrated in  FIGS. 2A and 2B ; and 
         FIG. 2D  is a front elevation view of the electrical contact illustrated in  FIGS. 2A and 2B . 
     
    
    
     DETAILED DESCRIPTION 
     For convenience, the same or equivalent elements in the various embodiments illustrated in the drawings have been identified with the same reference numerals. Certain terminology is used in the following description for convenience only and is not limiting. The words “left,” “right,” “front,” “rear,” “upper,” and “lower” designate directions in the drawings to which reference is made. The words “forward,” “forwardly,” “rearward,” “inner,” “inward,” “inwardly,” “outer,” “outward,” “outwardly,” “upward,” “upwardly,” “downward,” and “downwardly” refer to directions toward and away from, respectively, the geometric center of the object referred to and designated parts thereof. The terminology that is intended to be non-limiting includes the above-listed words, derivatives thereof and words of similar import. 
     Referring to  FIGS. 1A-2D  generally, an electrical assembly can include an electrical cable assembly that includes an electrical cable and an electrical contact  100 , which can be configured as an electrical power contact  100 . The electrical assembly can further include a complementary electrical component, such as an electrical connector that includes one or more electrical contacts, such as a complementary electrical contact  200 , supported by a connector housing. The electrical contact  100  can be configured to be attached to the electrical cable so as to place the electrical cable in electrical communication with the electrical contact  100 . The electrical connector assembly can further include a complementary electrical component. The electrical contact  100  is configured to mate with the complementary electrical component so as to place the complementary electrical component in electrical communication with the electrical contact  100 , and thus the electrical contact  100  can also be referred to as a mating member. In particular, the electrical contact can be configured to mate with the complementary electrical contact  200  along a mating direction M so as to establish an electrical connection between the electrical contact  100  and the complementary electrical contact  200 . The electrical cable assembly, including the electrical cable and the electrical contact  100 , can be configured to carry electrical power or data signals as desired. For instance, in accordance with one embodiment, the complementary electrical component can carry electrical power, such that the electrical assembly is configured as an electrical power assembly. It should be appreciated that the complementary electrical component can be configured as any suitable constructed alternative electrical component as desired. 
     Various structures are described herein as extending horizontally along a first or longitudinal direction “L” and a second or lateral direction “A” that is substantially perpendicular to the longitudinal direction L, and vertically along a third or transverse direction “T” that is substantially perpendicular to the longitudinal and lateral directions L and A, respectively. As illustrated, the longitudinal direction “L” extends along a forward/rearward direction of the electrical contact  100 , and defines a mating direction M along which one or both of the electrical contacts  100  and  200  are moved relative to the other so as to mate the electrical cable assembly with the complementary electrical component, and thus to mate the electrical contact  100  with the complementary electrical contact  200 . For instance, the mating direction M of the illustrated electrical contact  100  is in a forward direction, and the electrical contact  100  can be unmated from the complementary power contact  200  by moving the electrical contact  100  in an opposed longitudinally rearward direction relative to the complementary electrical contact  200 . As illustrated, the complementary electrical contact  200  can be moved relative to a substrate along the transverse direction T that defines a mounting direction of the complementary electrical component. As illustrated, the lateral direction A extends along a width of the electrical contact  100 , the longitudinal direction L extends along a length of the electrical contact  100 , and the transverse direction T extends along a height of the electrical contact  100 . 
     Thus, unless otherwise specified herein, the terms “lateral,” “longitudinal,” and “transverse” are used to describe the orthogonal directional components of various components. The terms “inboard” and “inner,” and “outboard” and “outer” and like terms when used with respect to a specified directional component are intended to refer to directions along the directional component toward and away from the center of the apparatus being described. It should be appreciated that while the longitudinal and lateral directions are illustrated as extending along a horizontal plane, and that while the transverse direction is illustrated as extending along a vertical plane, the planes that encompass the various directions may differ during use, depending, for instance, on the orientation of the various components. Accordingly, the directional terms “vertical” and “horizontal” are used to describe the electrical contact  100  as illustrated merely for the purposes of clarity and convenience, it being appreciated that these orientations may change during use. 
     With particular reference to  FIGS. 2A-D , the electrical contact  100  can include a mounting portion  114  configured to electrically connect to an electrical cable. The electrical contact  100  can further include a mating portion  102  spaced from the mounting portion  114  in the forward direction. The mating portion  102  can be configured to be electrically mated with a complementary electrical component, such as the complementary electrical contact  200 . The mating portion  102  can include a front end  102   a  and a rear end  102   h  opposite the front end in the rearward direction. In accordance with the illustrated embodiment, the mating portion  102  can include first and second contact blades  104  and  106 , respectively, spaced from each other along the lateral direction A that is substantially perpendicular to the forward direction. The first and second contact blades  104  and  106  can be monolithic with each other. The front end  102   a  can define a tapered end. As shown, each of the first and second contact blades  104  and  106  define the rear end  102   b  and the front end  102   a  spaced from the rear end  102   b  in the forward direction. One of the first and second contact blades  104  and  106 , respectively, can define a seam  108 . In accordance with the illustrated embodiment, one of the first and second contact blades  104  and  106  can define the seam  108  that is oriented along the forward direction. The seam  108  can be elongate along the forward direction. In an example embodiment, the seam  108  is oriented solely along the forward direction. The seam  108  can extend entirely through the contact blade along the lateral direction A. Although the first contact blade  104  defines the seam  108  in the illustrated embodiment, it will be understood that the second contact blade  106  can alternatively define the seam  108  as desired. 
     Each of the contact blades  104  and  106  can define first and second surfaces  110   a  and  110   b  spaced from each other along the transverse direction T. The seam  108  can be spaced closer to one of the first and second surfaces  110   a  and  110   b  along the transverse direction T as compared to the other of the first and second surfaces  110   a  and  110   b . The first and second contact blades  104  and  106  can be spaced apart from each other along the lateral direction A so as to define a receptacle  112  therebetween. The receptacle  112  can be sized so as to receive at least a portion of the complementary electrical contact  200 . The first and second contact blades  104  and  106  can each include inner surfaces  110   c  that face each other. The first and second contact blades  104  and  106  can each include a respective outer surface  110   d  opposite the respective inner surface  110   c . For instance, the outer surfaces  110   d  can be spaced from the respective inner surface  110   c  along the lateral direction A. The seam  108  can extend from the inner surface  110   c  to the outer surface  110   d  from the respective rear end  102   b  to the respective front end  102   a.    
     Still referring to  FIGS. 2A-D , in accordance with the illustrated embodiment, the electrical contact  100  can define a contact body  101  that defines an open end along the lateral direction A. The electrical contact  100  can further include the mounting portion  114  that is configured to electrically connect to an electrical cable. The mounting portion  114  can further be configured to physically attach to the electrical cable. The mounting portion  114  can include a pair of crimp arms  120  that extend from the contact body  101 . The crimp arms  120  can be disposed at a front end  114   a  of the mounting portion  114 . The mounting portion can further include a pair of strain relief arms  122  that are spaced rearward from the crimp arms  120  along the longitudinal direction L. 
     With continuing reference to  FIGS. 2A-D , in accordance with the illustrated embodiment, the electrical contact  100  can further include a transition region  116  that extends from the mounting portion  114 , in particular to the front end  114   a  of mounting portion  114 , to the mating portion  102 , in particular the rear end  102   b  of the mating portion  102 . The transition region  116  can be configured to transmit electrical current, for instance an increased amount of electrical current as compared to similar portions of other electrical contacts, between the mating portion  102  and the mounting portion  114 . For instance, the transition region  116  can transmit electrical current from the mounting portion  114  to the mating portion  102 . The transition region can define a first end  116   a  and a second end  116   b  spaced from the first end  116   a  in the forward direction. The first and second ends  116   a  and  116   b  can define first and second heights, respectively, measured along the transverse direction T that is substantially perpendicular to both the forward direction and the lateral direction A. As shown, the second height can be greater than the first height. For instance, the transition region  116  can flare outwardly from the first end  116   a  to the second end  116   b . It will be understood that the transition region  116  can define notches, can define steps, or can be otherwise shaped such that the second height is greater than the first height. For instance, the transition region  116  can extend from the mating portion  102  to the mounting portion  114 , and at least a portion of the transition region  116  can define an outermost dimension that increases in the forward direction. In accordance with the illustrated embodiment, the first end  116   a  can be interconnected with the mounting portion  114 . The second end  116   b  can be interconnected with the mating portion  102 . The mounting portion  114 , the mating portion  102 , and the transition region  116  can all be monolithic with each other. Further, the transition region  116  can be curved along at least a portion of its length between the first end  116   a  and the second end  116   b . For instance, the transition region  116  can be C-shaped. Further, the transition region  116  can have upper and lower ends spaced along the transverse direction T, such that the transition region  116  is open along the lateral direction A. 
     Still referring to  FIGS. 2A-D , each of the first and second contact blades  104  and  106  can define the rear end  102   b  that can be disposed at the transition region  116 , and the front end  102   a  opposite the rear end  102   b  in the forward direction. In an example embodiment, a select one of the first and second contact blades  104  and  106  defines a first portion  104   a  and a second portion  104   b  separated from the first portion  104   a  by the seam  108  that extends from the respective rear end  102   b  to the respective front end  102   a . In accordance with the illustrated embodiment, the first portion  104   a  includes the first surface  110   a  and a third surface  110   e  spaced from the first surface  110   a  along the transverse direction T, and the second portion  104   b  defines the second surface  110   b  and the fourth surface  110   f  spaced from the second surface  110   b  along the transverse direction T. As shown, the third and fourth surfaces  110   e  and  110   f  can face each other so as to define the seam  108 . The seam  108  can be spaced closer to one of the first and second surfaces  110   a  and  110   b  along the transverse direction T as compared to the other of the first and second surfaces  110   a  and  110   b . For instance, in accordance with the illustrated embodiment, the first surface  110   a  and the third surface  110   e  defines a first distance d 1  along the transverse direction T, the second surface  110   b  and the fourth surface  110   f  define a second distance d 2  along the transverse direction T, and the first distance d 1  is greater than the second distance d 2 . It will be understood that the seam  108  can be alternately disposed such that the second distance d 2  is greater than the first distance d 1 . 
     The mating portion  102  can further include at least one first bridge element, for instance a first bridge element  118   a , that connects the first portion  104   a  of a select one of the first and second contact blades  104  and  106  with the other of the first and second contact blades  104  and  106 . The mating portion  102  can further include at least one second bridge element, for instance a second bridge element  118   b , that connects the second portion  104   b  of a select one of the first and second contact blades  104  and  106  with the other of the first and second contact blades  104  and  106 . Thus, the first bridge element  118   a  can be disposed on the opposite side of the seam  108  with respect to the second bridge element  118   b  along the transverse direction T. The first bridge element  118   a  can be substantially C-shaped so as to be connected with the first surface  110   a  of the first contact blade  104  and the first surface  110   a  of the second contact blade  106 , and the second bridge element  118   b  can be substantially C-shaped so as to be connected with the second surface  110   b  of the first contact blade  104  and the second surface  110   b  of the second contact blade  106 . As shown, the first and second bridge elements  118   a  and  118   b  can disposed at the rear end  102   b  of the mating portion  102 , though it will be understood that the bridge elements can be alternatively located as desired. The transition region  116  can be connected to at least a portion of at least one of the first and second bridge elements  118   a  and  118   b . For instance, the transition region  116  can be connected to at least a portion of both of the first and second bridge elements  118   a  and  118   b . In an example embodiment, the first contact blade  104 , the second contact blade  106 , the first bridge element  118   a , and the second bridge element  118   b  are all monolithic with one other. 
     Referring also to  FIGS. 1A and 1B , an electrical connector assembly can include the electrical contact  100  and the complementary electrical contact  200  that is configured to physically contact the mating portion  102  such that a first contact portion  201   a  of the complementary electrical contact  200  contacts the first portion  104   a  of the select one of the first and second contact blades  104  and  106 , a second contact portion  201   b  of the complementary electrical contact  200  contacts the second portion  104   b  of the select one of the first and second contact blades  104  and  106 , and the complementary electrical contact  200  defines a gap  203  between the first and second contact portions that is aligned with the seam  108  when viewed along the lateral direction A. In particular, the complementary electrical contact  200  can include a pair of plate members  202  spaced apart from each other along the lateral direction A. A plurality of complementary contact blades  204  can extend from each of the plate members  202  along the longitudinal direction L. Further, a plurality of mounting tails  206  can extend downward along the transverse direction T from the plate members  202 . The mounting tails  206  can be configured to establish an electrical connection with a substrate when the electrical contact  200  is mounted to the substrate. The electrical connector assembly can include the electrical contacts  100  and  200  such that the inner surface  110   c  of the first contact blade  104  contacts a first plurality of complementary contact blades  204  when the electrical contact  100  is mated with the complementary electrical contact  200 . The inner surface  110   c  of the second contact blade  106  can contact, when the electrical contact  100  is mated with the complementary electrical contact  200 , a second plurality of complementary contact blades  204  that are spaced from the first plurality of complementary contact blades  204  along the lateral direction A. 
     In accordance with the illustrated embodiment, each of the first and second contact blades  104  and  106  contact three complementary contact blades  204  of the complementary electrical contact  200  when the electrical contact  100  is mated with the complementary electrical contact  200 , though it will be understood that the first and second contact blades can be configured to contact any number of complementary contact blades  204  as desired. As further illustrated, the first portion  104   a  of the select one of the first and second contact blades  104  and  106  contacts two complementary contact blades  204 , for instance a first complementary contact blade  204   a  and a second complementary contact blade  204   b , of the complementary electrical contact  200  when the electrical contact  100  is mated with the complementary electrical contact  200 . The second portion  104   b  of the select one of the first and second contact blades  104  and  106  contacts one complementary contact blade  204 , for instance a third complementary contact blade  204   c , of the complementary electrical contact  200  when the electrical contact  100  is mated with the complementary electrical contact  200 . In accordance with one embodiment, no complementary contact blade  204  is adjacent to the seam  108  along the lateral direction A when the electrical contact  100  is mated with the complementary electrical contact  200 , thereby maximizing current flow between the electrical contact  100  and the complementary electrical contact  200 . Thus, the seam  108  can be positioned such that a complementary contact blade  204  of the complementary electrical contact  200  does not lie on the seam  108  when the electrical contact  100  is mated with the complementary electrical contact  200 . Though each of the illustrated complementary contact blades  204  define a volume that is substantially equivalent to one another, it will be understood that the size, for instance the volume, of the complementary contact blades  204  can vary as desired. 
     The electrical contact  100 , including the first and second contact blades  104  and  106  and transition region  116 , can be made of any suitable electrically conductive material as desired, such as a copper alloy or the metal. The electrical contact  100  can be sized to carry electrical communications or data signals, or to support DC and/or AC power. 
     In another embodiment, an electrical cable assembly includes at least one electrical conductor that extends from a first end to a second end, and an electrical insulator surrounding the at least one electrical conductor, such that at least the first end extends out from the electrical insulator, and such that the first end is attached to the mounting portion  114  of the electrical contact  100  so as to establish an electrical connection between the at least one electrical conductor and the electrical contact  100 . 
     Example methods of constructing the electrical contact  100  are provided. An example method can include shaping a monolithic piece of electrically conductive material, for instance a copper alloy or other metal, so as to define the seam  108 . Alternatively, or additionally, the method can include shaping a monolithic piece of electrically conductive material so as to define the mounting portion  114 , the mating portion  102 , and the transition region  116 . A method of constructing an electrical assembly can include shaping a monolithic piece of electrically conductive material, for instance a copper alloy or other metal, so as to define the mating portion  102  and the mounting portion  114 . The method can further include applying a force to the pair of crimp arms  120  of the mounting portion  114  so as to attach a first end of at least one electrical conductor to the electrical contact  100 . The method can further include applying a force to a pair of strain relief arms  122  of the mounting portion  114  so that the strain relief arms  122  compress against the electrical insulator so as to attach the electrical insulator to the electrical contact  100 . 
     In operation, an example method of mating the electrical contact  100  with the complementary electrical contact  200  can include causing one or more complementary contact blades  204  of the complementary electrical contact  200  to be received along the mating direction M by the receptacle  112  defined by the first and second contact blades  104  and  106  spaced from each other along the lateral direction A so as to define the receptacle  112 . In an example embodiment, the method of mating further includes causing three complementary contact blades  204  of the complementary electrical contact  200  to contact the inner surface  110   c  of the first contact blade  104 , and causing three complementary contact blades  204  of the complementary electrical contact  200  to contact the inner surface  110   c  of the second contact blade  106 . It will be understood that any number of complementary contact blades  204  can be caused to contact the inner surface  110   c  of the first contact blade  104  and the inner surface  110   c  of the second contact blade  106  as desired. One of the first and second contact blades  104  and  106  can define the seam  108  that separates the first portion  104   a  of the one contact blade from the second portion  104   b  of the one contact blade along the transverse direction T. The method of mating can further include causing two complementary contact blades  204  to contact the first portion  104   a  of the one contact blade, and causing one complementary contact blade  204  to contact the second portion  104   b  of the one contact blade. The method of mating can further include causing a gap, for instance the gap  203 , defined by the complementary contact blades  204  to be aligned with the seam  108  when viewed along the lateral direction A. 
     A method of selling the electrical contact  100  can include teaching to a third party one or more up to all of the above-described method steps, and selling to the third party the electrical contact  100 . 
     The foregoing description is provided for the purpose of explanation and is not to be construed as limiting the invention. While various embodiments have been described with reference to preferred embodiments or preferred methods, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Furthermore, although the embodiments have been described herein with reference to particular structure, methods, and embodiments, the invention is not intended to be limited to the particulars disclosed herein. For instance, it should be appreciated that structure and methods described in association with one embodiment are equally applicable to all other embodiments described herein unless otherwise indicated. Those skilled in the relevant art, having the benefit of the teachings of this specification, may effect numerous modifications to the invention as described herein, and changes may be made without departing from the spirit and scope of the invention, for instance as set forth by the appended claims.