Patent Description:
The windshield and/or rear window of automotive vehicles often have an electrical device such as an antenna or defroster formed on or in the glass. To electrically connect the electrical device to associated equipment, for example, a radio transceiver or defroster control, an electrical terminal is first soldered to the glass in electrical communication with the electrical device. An electrical cable extending from the associated equipment is then secured to the electrical terminal for providing electrical communication therebetween. A problem with some current electrical terminals is that the terminals can be easily separated from the glass by peeling if accidental pulling forces are exerted on the electrical cable. In addition, some electrical terminal designs are prone to cause cracking of the glass during soldering because of heat related stress concentrations formed on the glass by the footprint of the terminal. There remains a need for an electrical terminal which is resistant to the peeling and cracking issues discussed above.

Publication <CIT> discloses a method for making a wire-receiving barrel terminal having a barrel with a desired inner diameter. The method comprises the steps of: selecting a metal stock having the desired properties; stamping a terminal blank having a forward portion adapted to be formed into at least one contact section, an intermediate portion extending rearwardly from said forward portion and a rearward portion adapted to be formed into first and second barrel sections. The second barrel section of said rearward portion is joined integrally with and extends rearwardly from said intermediate portion and the first barrel section is joined integrally with and extends from the second barrel section. The first and second barrel sections are generally rectangular and each has at least one lateral edge, and a lateral dimension equal to the circumference of a circle of desired wire receiving barrel inner diameter. In one embodiment first barrel section is laterally offset from second barrel section by bight section. A seamed barrel shaped member is formed from first barrel section. Seamed outer barrel member from second contact section is formed around barrel-shaped member after disposition thereof along a major surface of second barrel section by bending at bight section. The seams of barrel terminal member are essentially diametrically opposed and a continuous portion of the outer barrel member overlies the inner slam. Publication <CIT> discloses a bus bar configured to connect neighboring electrode terminals of a plurality of unit cells including the electrode terminals of positive electrodes and negative electrodes. The bus bar comprises a rectangular main body part that bridges the neighboring electrode terminals, and a wire connection part which extends from the main body part and is connected to a terminal of a detection wire. The main body part is configured by folding and overlapping a first plate part and a second plate part which are separated by folding parts. <CIT> discloses the preamble of independent claim <NUM>.

The subject matter discussed in the background section should not be assumed to be prior art merely because of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.

According to a first embodiment of the invention, an electrical terminal is provided. The electrical terminal includes a planar base portion having a base portion outer surface, a base portion inner surface, and two securing tabs extending from an edge of the planar base portion. The planar base portion has a first curved perimeter that is generally circular in shape and has a first diameter. The electrical terminal further includes a planar attachment portion having an attachment portion outer surface and an attachment portion inner surface. The planar attachment portion has a second curved perimeter that is generally circular in shape and has a second diameter, wherein the first diameter of the planar base portion is greater than the second diameter of the planar attachment portion. The base portion inner surface is arranged such that it is in contact with the attachment portion inner surface and the two securing tabs are bent over the attachment portion outer surface.

In an example embodiment having one or more features of the electrical terminal of the previous paragraph, the base portion is integrally formed with the planar attachment portion and the planar base portion is connected to the planar attachment portion by a U-shaped connecting member.

In an example embodiment having one or more features of the electrical terminal of the previous paragraph, the planar attachment member comprises an arm that is configured to secure the electrical terminal to a wire cable.

In an example embodiment having one or more features of the electrical terminal of the previous paragraph, the two securing tabs are arranged in opposition to one another.

In an example embodiment having one or more features of the electrical terminal of the previous paragraph, a width dimension of each of the two securing tabs is equal to <NUM>% or more of a circumferential dimension of the planar base portion.

According to a second embodiment of the invention, a method of forming an electrical terminal is provided. The method includes the step of providing a sheet metal terminal preform having a top surface and a bottom surface; forming a planar base portion with two securing tabs extending from an edge of the base portion and a planar attachment portion. The planar base portion has a first curved perimeter that is generally circular in shape and has a first diameter, wherein the planar attachment portion has a second curved perimeter that is generally circular in shape and has a second diameter, and wherein the first diameter of the planar base portion is greater than the second diameter of the planar attachment portion. The method also includes the step of bending the connecting member into a U-shape such that the bottom surface of the planar base portion is in contact with the bottom surface of the planar attachment portion. The method further includes the step of bending the two securing tabs such that they are bent over the attachment portion top surface.

In an example embodiment having one or more features of the method of the previous paragraph, the attachment member comprises an arm that extends from the planar attachment portion.

In an example embodiment having one or more features of the method of the previous paragraph, the method further comprises the step of deforming the arm to secure the electrical terminal to the wire cable.

In an example embodiment having one or more features of the method of the previous paragraph, the two securing tabs are arranged in opposition to one another and wherein a width dimension of each of the two securing tabs is equal to <NUM>% or more of a circumferential dimension of the base portion.

Reference numbers of similar elements in the various embodiments share the last two digits of the reference number.

Examples of electrical terminals that may be soldered to a conductive material applied to a glass surface of an automotive to provide electrical communication with an electrical device, such as an antenna or defroster formed on or in the glass, so that the electrical device may be electrically connected to associated equipment by an electrical cable are presented herein and illustrated in <FIG>. A method of forming such an electrical terminal is also presented herein and illustrated in <FIG> and <FIG>. The electrical terminal, hereinafter referred to as the terminal <NUM>, includes a planar base portion <NUM> having a base portion outer surface <NUM>, a base portion inner surface <NUM>, and two securing tabs <NUM> extending from an edge of the base portion <NUM>. The terminal <NUM> also includes a planar attachment portion <NUM> having an attachment portion outer surface <NUM>, an attachment portion inner surface <NUM>, and an attachment member <NUM> extending from the attachment portion outer surface <NUM>. The attachment member <NUM> is configured to secure a wire cable (not shown). The base portion inner surface <NUM> is arranged such that it is in contact with the attachment portion inner surface <NUM> and the two securing tabs <NUM> are bent over the attachment portion outer surface <NUM>. The securing tabs are arranged in opposition to one another. According to a first example of the terminal <NUM> shown in <FIG>, the securing tables are offset by about <NUM>° and a width dimension of each of the two securing tabs <NUM> is equal to <NUM>% or more of a circumferential dimension of the base portion <NUM>. According to a second example of the terminal <NUM> shown in <FIG>, the base portion <NUM> defines four securing tabs <NUM> that are offset from one another by about <NUM>° configured to secure the base portion <NUM> to the attachment portion <NUM>. Similarly to terminal <NUM>, the base portion <NUM> is connected to the attachment portion <NUM> by a U-shaped strap or connecting member <NUM> extending from the base portion <NUM> to the attachment portions and integrally formed with the base portion <NUM> and attachment portion <NUM>. The width dimension of each of the four securing tabs <NUM> is less than <NUM>% of the circumferential dimension of the base portion <NUM>. In alternative embodiments of the terminal, the base portion may be attached to the attachment portion by other means, e.g. welding or electrically conductive adhesive.

The terminal <NUM> is formed of sheet metal and has a generally curved outer perimeter or edge. The base portion <NUM> has a first curved perimeter <NUM> that is generally circular in shape. The attachment portion <NUM> has a second curved perimeter <NUM> that is also generally circular in shape. A first diameter of the base portion <NUM> is greater than a second diameter of the attachment portion <NUM>. The base portion outer surface <NUM> may be pre-coated with a layer of solder for facilitating the soldering process.

The attachment member <NUM> extends beyond the outer perimeter of the attachment portion <NUM> and is configured to crimp the terminal <NUM> to a wire electrical cable. The slots <NUM> extend from the outer perimeter of the attachment portion <NUM>, inwardly about halfway to the center line of the attachment portion <NUM>, thereby forming two wings thereof. The attachment member <NUM> has an intermediate portion <NUM> which is bent upwardly at an angle from the proximal end <NUM> at about the outer perimeter. The distal end <NUM> of the attachment member <NUM> includes a crimping portion <NUM> having two opposed crimping tabs <NUM> for crimping to an inner conductor wire of the cable (not shown). The attachment member <NUM> is bent between the intermediate portion <NUM> and the distal end <NUM> so that the distal end <NUM> is positioned parallel to and laterally offset from the attachment portion <NUM> as well as above the attachment portion outer surface <NUM>.

The base portion <NUM> is integrally formed with the attachment portion <NUM>. The base portion <NUM> is connected to the attachment portion <NUM> by a U-shaped strap or connecting member <NUM> extending from the base portion <NUM> to the attachment portions and integrally formed with the base portion <NUM> and attachment portion <NUM>.

In use, the terminal <NUM> is typically soldered to a glass substrate. The base portion <NUM> is generally circular in shape and does not tend to cause heat related stress concentrations in glass, and therefore, little or no cracking occurs during the soldering process. The proximal end <NUM> of the attachment member <NUM> extends from the attachment portion <NUM> and so does not interrupt the circular shape of base portion <NUM>. Once soldered, any accidental pulling forces on cable are transferred to the center of base portion <NUM> because the proximal end <NUM> of the attachment member <NUM> extends therefrom. Consequently, the terminal <NUM> is resistant to being separated from glass.

The base portion <NUM> and attachment portion <NUM> are sized, shaped, and arranged such that forces exerted on the attachment member <NUM> by the wire cable are laterally distributed across the base portion <NUM>. In addition, the upwardly angled intermediate portion <NUM> of the attachment member <NUM> is able to bend or deflect thereby absorbing forces exerted on the terminal <NUM> by cable. This may lessen the intensity of forces exerted on the base portion <NUM> by accidental pulling of the cable. For example, if a longitudinal pulling force is exerted on the cable, intermediate portion <NUM> would bend slightly to the left and absorb some of the force. In addition, if an upward pulling force is exerted on the cable, intermediate portion <NUM> would bend slightly upwardly and absorb some of the force. The angled intermediate portion <NUM> is also able to absorb forces that are forwardly and downwardly directed forces. Furthermore, the proximal end <NUM> of the attachment member <NUM> may also bend or deflect to absorb forces.

According to one example, the terminal <NUM> is formed of C260 brass, the base portion <NUM> is about <NUM> in diameter, and the terminal <NUM> is about <NUM> in length. Alternately, the terminal <NUM> may be formed of other conductive sheet materials. The intermediate portion <NUM> is bent at about a <NUM>° angle to provide equal force absorbing capabilities for longitudinal and vertical forces. The dimensions of terminal <NUM> may be varied to suit particular circumstances. Although intermediate portion <NUM> is preferably bent, alternatively, the intermediate portion <NUM> may be straight. In addition, the proximal end <NUM> may be bent instead of the intermediate portion <NUM>.

The terminal <NUM> is formed by a stamping and forming process <NUM> from a terminal preform <NUM>. The terminal preforms <NUM> may be attached to a carrier strip <NUM> by severable regions <NUM> extending from the crimping portion <NUM> of the attachment member <NUM> or the connecting member <NUM> to facilitate handling and processing of multiple terminals. The carrier strip <NUM> may be cut into to form a multiple terminal soldering assembly, so that multiple terminals may be soldered to glass at the same time. Cables may be crimped to terminals before soldering.

A method or process <NUM> of forming the terminals <NUM>, <NUM> is shown in flowchart form in <FIG> and is described below:.

STEP <NUM>, PROVIDE A SHEET METAL TERMINAL PREFORM HAVING A TOP SURFACE AND A BOTTOM SURFACE FORMING A BASE PORTION WITH TWO SECURING TABS EXTENDING FROM AN EDGE OF THE BASE PORTION, AN ATTACHMENT PORTION WITH AN ATTACHMENT MEMBER CONFIGURED TO SECURE A WIRE CABLE TO THE ELECTRICAL TERMINAL EXTENDING THEREFROM, AND A CONNECTING MEMBER INTERCONNECTING THE BASE PORTION WITH THE ATTACHMENT PORTION, includes providing a terminal preform <NUM>, as shown in <FIG>, having a top surface <NUM> and a bottom surface <NUM> forming a base portion <NUM> with two securing tabs <NUM> extending from an edge of the base portion <NUM>, an attachment portion <NUM> with an attachment member <NUM> configured to secure a wire cable to the electrical terminal extending therefrom, and a connecting member <NUM> interconnecting the base portion <NUM> with the attachment portion <NUM>. The terminal preform <NUM> is formed from sheet metal using conventional sheet metal cutting processes, such as stamping, blanking, or cutting;.

STEP <NUM>, BEND THE CONNECTING MEMBER INTO A U-SHAPE SUCH THAT THE BOTTOM SURFACE OF THE BASE PORTION IS IN CONTACT WITH THE BOTTOM SURFACE OF THE ATTACHMENT PORTION, includes bending the connecting member into a U-shape such that the base portion bottom surface <NUM> is in contact with the attachment portion bottom surface <NUM>; and.

STEP <NUM>, BEND THE TWO SECURING TABS SUCH THAT THEY ARE BENT OVER THE ATTACHMENT PORTION TOP SURFACE, includes bending the two securing tabs <NUM> such that they are bent over the attachment portion top surface <NUM>, thereby securing the base portion <NUM> to the attachment portion <NUM>.

Claim 1:
An electrical terminal (<NUM>) configured to be soldered to a conductive material applied to a glass surface, comprising:
a planar base portion (<NUM>) having a base portion outer surface (<NUM>), a base portion inner surface (<NUM>), and two securing tabs (<NUM>) extending from an edge of the planar base portion (<NUM>), wherein the planar base portion (<NUM>) has a first curved perimeter (<NUM>) that is generally circular in shape and has a first diameter; characterised in that it further comprises
a planar attachment portion (<NUM>) having an attachment portion outer surface (<NUM>) and an attachment portion inner surface (<NUM>), wherein the planar attachment portion (<NUM>) has a second curved perimeter (<NUM>) that is generally circular in shape and has a second diameter, and wherein the first diameter of the planar base portion (<NUM>) is greater than the second diameter of the planar attachment portion (<NUM>), wherein the base portion inner surface (<NUM>) is in contact with the attachment portion inner surface (<NUM>) and wherein the two securing tabs (<NUM>) are bent and overlay the attachment portion outer surface (<NUM>).