Patent Abstract:
A preferred embodiment of an electrical connection employs a stud having a patterned segment, a shoulder and a flange. In another aspect of the present invention, the shoulder has seven or more predominantly flat faces. In a further aspect of the present invention, the shoulder has an octagonal cross sectional shape.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This application is a continuation-in-part of U.S. Ser. No. 10/075,090, filed Feb. 12, 2002 now U.S. Pat. No. 6,746,285, which claims priority to U.S. Provisional Ser. No. 60/270,084, filed Feb. 20, 2001, both of which are incorporated by reference herein. 

   BACKGROUND OF THE INVENTION 
   This invention relates generally to an electrical connection and more specifically to an electrical connection for an automotive vehicle employing a grounding stud. 
   It is common to arc weld an elongated circular end of a threaded metal stud onto a sheet metal body panel of an automotive vehicle. Various parts are then inserted upon the single threaded stud and an internally threaded nut is rotationally inserted onto the stud. Conventional threaded weld studs have also been employed as electrical grounding points for a vehicle wire harness to an engine compartment frame or body panel. It is also known to employ a grounding weld stud that has a threaded portion, a circular flanged portion and a hexagonal shoulder portion for receiving an eyelet. This hexagonal shoulder configuration, however, provides undesirably large corner-to-corner and flat-to-flat dimensions across the shoulder in order to fit within standard stud welding machinery which can only handle a certain maximum outside diameter of stud; thus, the hexagonal shoulder leads to insufficient cross sectional area for electrical conductivity. 
   Screws have also been used to retain an electrical eyelet to a grounding panel. Conventional eyelets, having a circular inside aperture, often require upturned tabs to prevent rotation of the eyelets during installation of nuts for the stud construction or where screws are installed. This adds extra cost and complexity to the eyelet and installation process. Wire orientation is important for engine compartment use to prevent vehicle vibration from rotating the wire and loosening the nut, and to prevent wire pinching. One such example of a conventional orientation configuration is U.S. Pat. No. 5,292,264 entitled “Earthing Stud” which issued to Blank on Mar. 8, 1994, which discloses a threaded weld stud, interlocking plastic orientation part, and a cable terminal or eyelet; this patent is incorporated by reference herein. Another traditional construction is disclosed in EP 0 487 365 B1 to Rapid S.A. 
   SUMMARY OF THE INVENTION 
   In accordance with the present invention, a preferred embodiment of an electrical connection employs a stud having a patterned segment, a shoulder and a flange. In another aspect of the present invention, the shoulder has seven or more predominantly flat faces. In a further aspect of the present invention, the shoulder has an octagonal cross sectional shape. Still another aspect of the present invention provides a nut which is threadably engaged with the patterned segment of the stud and an eyelet secured between the nut and the flange of the stud. Yet another aspect of the present invention allows the stud to be welded onto an automotive body panel or the like for use as a grounding stud. 
   The stud and electrical connection of the present invention are advantageous over traditional devices in that the present invention maximizes the electrical contact area between the stud and the eyelet while also providing a set angular orientation to the eyelet and wire once the nut has been fastened onto the stud. The present invention also improves the electrical cross sectional area through the stud while also allowing for the manufacture of the stud in conventionally sized equipment. The preferred octagonal cross sectional shape of the shoulder advantageously increases automatic alignment of the eyelet, especially when the eyelet has a matching octagonal internal aperture shape, as compared to stud shoulders having six or less flat faces. The stud of the present invention advantageously accepts both an octagonally apertured eyelet for use as a grounding stud or a circularly apertured eyelet for use in other electrical stud connections such as to a junction box, battery or the like. Additional advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view showing an engine compartment of an automotive vehicle employing the preferred embodiment of a stud and electrical connection of the present invention; 
       FIG. 2  is an exploded view showing the preferred embodiment stud and electrical connection; 
       FIG. 3  is a side elevational view, taken partially in cross section, showing the preferred embodiment stud and electrical connection mounted to a vehicle body panel; 
       FIG. 4  is a side elevational view, taken partially in cross section, showing the preferred embodiment stud and electrical connection; 
       FIG. 5  is an end elevational view showing the preferred embodiment stud and nut; 
       FIG. 6  is a true elevational view showing the preferred embodiment of an eyelet employed with the stud and electrical connection of the present invention; 
       FIG. 7  is a cross sectional view showing the preferred embodiment stud and electrical connection; and 
       FIG. 8  is a true elevational view showing an alternate embodiment eyelet employed with the stud and electrical connection of the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1  shows a stud electrical connection  21  of the present invention employed in an engine compartment  23  of an automotive vehicle  25 . Stud electrical connection  21  is operable to conduct electricity from an electrical component, such as a battery  27 , direct current window wiper motor  29 , horn  31 , power distribution box  32  or the like, to a conductive metal panel or frame  33  of the vehicle. 
   Referring to  FIGS. 2–7 , the preferred embodiment of stud electrical connection  21  includes a grounding weld stud  51 , a nut  53 , and a female electrical connector  55 . Electrical connector  55  includes a wire  57 , branching from a wire harness  59  (see  FIG. 1 ), with a stamped metal eyelet  61  crimped onto an end thereof. Wire  57  is made of a flexible copper inner wire surrounded by an insulative casing. 
   Stud  51  includes a securing segment  62 , a flange  63 , a shoulder  64 , a patterned segment  65 , an inwardly tapered segment  67  and an anti-cross threading lead-in end segment  68 . Securing segment  62  has a hexagonal cross sectional shape with a centrally raised button. This portion forms the weld pool of material when stud  51  is drawn arc welded to panel  33 . Flange  63  has a circular peripheral shape and transversely extends beyond the rest of stud  51 . A unthreaded and reduced diameter neck  122  of stud  51  is located between the threaded segment and the shoulder, as shown in  FIG. 4 . The neck is somewhat different than the to a major diameter of the threaded segment and a cross-sectional area of the shoulder. 
   Shoulder  64  is defined by a set of generally flat faces  71  that are connected together and surround a longitudinal centerline  73  of stud  51 . It is important that shoulder  64  has more than six distinctly separate and angularly offset faces that are connected together in a polygonal manner when viewed in cross section. It is preferred that faces  71  of shoulder  64  define an octagonal shape in cross section. Rounded upper corners  73  are located between portions of each adjacent pair of faces  71 . The distance D between opposed faces  71  is preferably between 6.13 and 6.0 millimeters. Patterned segment  65  has a M 6.0×1.0 millimeter spiraling thread. The thread defines an external engagement pattern on the stud. Stud  51  is made as an integral single piece from 10B21, heat treated class 8.8 steel. Anti-cross threading segment  68  is of the type disclosed in one or more of the following U.S. Pat. No. 6,162,001 entitled “Anti-Cross Threading Fastener” which issued to Goodwin et al. on Dec. 19, 2000; U.S. Pat. No. 6,022,786 entitled “Anti-Cross Treading [sic] Fastener Lead-In Point” which issued to Garver et al. on May 16, 2000; and U.S. Pat. No. 5,730,566 entitled “Anti-Cross Threading Fastener” which issued to Goodwin et al. on Mar. 24, 1998; all of which are incorporated by reference herein. 
   The preferred embodiment eyelet  61  has an internal aperture  75  defined by an octagonally shaped edge. Aperture  75  of eyelet  61  closely matches the size of shoulder  64 ; close dimensional tolerances of aperture  75  and shoulder  64  are important. 
   Nut  53  has a circular-cylindrical, enlarged section  81  and a coaxial, reduced section  83 . A hexagonal cross sectional shape is externally provided on reduced section  83  while a spiral thread is internally disposed within reduced section  83  for engaging the threads of stud  51 . Enlarged section  81  has a flanged end  85  which abuts against and compresses eyelet  61  against flange  63  of stud  51 , when nut  53  is rotatably tightened by a torque wrench or the like upon stud  51 . In the fully fastened position, enlarged section  81  of nut  53  externally surrounds and covers at least part of shoulder  64 . Alternately, nut  53  is of a progressive torque, crown lock variety. 
   In the electrical grounding stud application, stud  51 , with nut  53  preassembled to prevent e-coat and paint incursion, is first welded to panel  33 . Subsequently, nut  53  is removed. Next, eyelet  61  is manually placed around threaded segment  65  of stud  51 . Nut  53  is thereafter rotatably driven onto stud. The rotation of nut  53  will cause the octagonal aperture  75  of eyelet  61  to become automatically aligned with the matching faces of the octagonal shoulder  64 , thereby allowing a fixed orientation of eyelet  61  and wire  57  relative to stud  51 . Nut  53  is then fully torqued onto stud. It is believed that the octagonal shape maximizes the face-to-face dimension D and also the corner-to-corner dimension of shoulder  64 . Notwithstanding, the cross sectional dimensions of shoulder  64  still allow for manufacturing of stud  51  in conventionally sized processing equipment. Additionally, the octagonal cross sectional shape of shoulder  64  allows for reduced circumferential rotation or angular displacement of the corresponding eyelet before alignment is achieved, especially compared to hexagonal or square cross sectional shapes. 
   An alternate embodiment eyelet  91  is shown in  FIG. 8 . This eyelet  91  has a circular internal aperture  93  which fits around octagonal shoulder  64 . This eyelet configuration is more suitable for non-grounding electrical connections, such as for junction boxes or batteries, where locked in wire orientation is not as important. 
   While the preferred embodiment grounding stud and electrical connection have been disclosed, it should be appreciated that other aspects can be employed within the scope of the present invention. For example, the securing segment of the stud can alternately have a screw thread, be suitable for spot welding or have an interference fit type push in configuration to the adjacent panel or member. Additionally, the internal nut threads can be replaced by inwardly projecting formations that are in a non-spiral configuration. Furthermore, nut  53  can be replaced by a crimped on collar. The stud electrical connection can also be used for non-automotive apparatuses such as household appliance, power tools or industrial machines. While various materials have been disclosed, other materials may be employed. It is intended by the following claims to cover these and any other departures from the disclosed embodiments which fall within the true spirit of this invention.

Technology Classification (CPC): 7