Electrical connectors – Metallic connector or contact having movable or resilient... – Spring actuated or resilient securing part
Reexamination Certificate
2000-08-31
2001-09-11
Bradley, Paula (Department: 2833)
Electrical connectors
Metallic connector or contact having movable or resilient...
Spring actuated or resilient securing part
C439S790000
Reexamination Certificate
active
06287156
ABSTRACT:
TECHNICAL FIELD
The present invention relates to electrical terminal connectors.
BACKGROUND ART
Electrical terminal connectors generally include a male terminal and a female receptacle. A universal terminal connection was the subject of U.S. Pat. No. 5,911,605 to Wooldridge. This design offered many advantages flowing from the fact that two generally identical parts can be used as a terminal connection. This design also offers a large number of contact points and an extensive contact area.
The present invention focuses on improving the design of the prior art Wooldridge patent that improves the manufacturability and robustness of the terminal design. The prior design also did not facilitate automatic assembly.
One problem encountered by the prior terminal blade was that the terminal connectors were subject to thermal expansion that could cause expansion of the gap defined by the terminal blade. A gap or looseness in the fit of one terminal to another could result in a reduction of contact pressure. In addition, the terminal blade in the prior terminal blade required careful alignment so that the two squared off terminal blades could be assembled together. Furthermore, the wire crimp connector of the prior terminal blade included a wire crimp connector having a smooth surface that was not well adapted to clamping small gauge wires to a flexible cable.
The prior design included a spring contact strip that was not easily assembled by means of automated assembly tools. Difficulty in locating the spring contact strip within the terminal blades was caused by a lack of effective locating devices for holding the contact strip in place in the blade, a lack of insertion alignment guides and a lack of positive stops for preventing over-insertion of the spring contact strip in the terminal blade.
These and other disadvantages and problems related to the prior art are addressed by Applicant's invention as summarized below.
DISCLOSURE OF INVENTION
According to the present invention, an electrical terminal connector is provided that comprises a blade having two spaced legs connected on a first edge by a bight. The connector includes a wire crimp connector. The wire crimp connector has a knurled surface on one side thereof that contacts small gauge wires of a high-flex cable that are gripped by the knurled surface of the crimp connector. An L-shaped tab extends from one of the legs to the other leg to lock the two spaced legs together in a spaced relationship thereby preventing expansion of the space between the legs. A spring contact strip having two spaced flanges connected by a reversely turned bend is received by the blade between the two spaced legs adjacent the bight with the reversely turned bend adjacent the bight.
According to another aspect of the present invention, an electrical terminal connector is provided that comprises a blade having two spaced legs connected on a first edge by a bight. The blade also has a wire crimp connector and at least one opening formed in each of the legs. A spring contact strip having two spaced flanges connected by a reversely turned bend is received by the blade between the two spaced legs adjacent the bight with the reversely turned bend adjacent the bight. The spring contact strip has locking tabs corresponding in number and location to openings formed in the legs. When the spring contact strip is assembled to the blade, the locking tabs of the spring contact strip are received in the openings in the blade. While any number of openings may be provided, two openings are preferably provided on each of the legs that receive two locking tabs of the spring contact strip. Openings in the legs are provided between the bight and the distal end of the legs. Locking tabs are provided on the distal end of the spaced flanges of the spring contact strip.
The present invention also relates to providing an electrical terminal connector comprising a blade having two spaced legs connected on a first edge by a bight and also including a wire crimp connector. A spring contact strip having two spaced flanges is connected by a reversely turned bend. The spring contact strip is received by the blade between the two spaced legs adjacent the bight with a reversely turned bend adjacent the bight. The spring contact strip includes stops on an exterior edge of the two spaced flanges that extend substantially perpendicular from the reversely turned edge. Upon assembly of the spring contact strip to the blade, the stops engage an edge of the spaced legs that extends substantially perpendicularly from the bight to prevent the contact strip from being inserted too deeply into the blade. The leading edges of the blade extend substantially perpendicularly from the bight and each preferably includes a notch for receiving one of the stops.
In accordance with another aspect of the present invention, a blade having two spaced legs connected on a first edge by a bight and having a wire crimp connector is provided. A spring contact strip having two spaced flanges connected by a reversely turned bend is received by the blade between the two spaced legs adjacent the bight with the reversely turned bend adjacent the bight. The spring contact strip includes lead in flanges on an interior edge of the two spaced flanges thereof that extend substantially perpendicular from the reversely turned edge. During assembly of the spring contact strip to the blade, each of the lead in flanges contact an edge of the spaced legs that extend substantially perpendicularly from the bight to facilitate assembly of the spring contact strip to the blade.
According to the invention, an electrical terminal connector is provided that includes a blade as previously described and a spring contact strip having two spaced flanges connected by a reversely turned bend. The spring contact strip is received as described above between the two spaced legs of the blade. The spring contact strip preferably includes louvers formed in each of the two spaced flanges and dimples formed on the two spaced flanges adjacent the louvers to resist over-compression of the louvers. A dimple is preferably provided adjacent both ends of each elongated louver.
The present invention also comprehends an electrical connection comprising first and second electrical terminal connectors of substantially identical configuration. The first and second electrical terminal connectors each have a blade formed to have two spaced legs connected on a first edge by a bight and a crimp connector. An L-shaped tab is provided that has a first segment extending from one of the legs to the other leg and a second segment extending from the outside of the other leg to lock the two spaced legs together in a spaced relationship thereby preventing expansion of the space between the legs. A spring contact strip having two spaced flanges connected by a reversely turned bend is received by the blade between the two spaced legs adjacent the bight. The first and second terminal connectors are assembled to each other and inverted relative to each other.
The spaced legs of the first and second electrical terminal connectors preferably each include a distal edge opposite their respective bights. The distal edges are tapered on a corner opposite the wire crimp connector to facilitate connecting first and second electrical terminal connectors together.
These and other objects and advantages of the present invention will be better understood in view of the attached drawings and detailed description of the invention.
REFERENCES:
patent: 2523465 (1950-09-01), Graham
patent: 2615736 (1952-10-01), Bergan et al.
patent: 2636071 (1953-04-01), Matthysse
patent: 2744244 (1956-05-01), Schumacher et al.
patent: 2785387 (1957-03-01), Batcheller
patent: 3079579 (1963-02-01), Crimmins et al.
patent: 3169814 (1965-02-01), Collins
patent: 3471823 (1969-10-01), Renshaw, Jr.
patent: 3514740 (1970-05-01), Filson
patent: 3516043 (1970-06-01), Spofford
patent: 3838387 (1974-09-01), Grillet
patent: 4199208 (1980-04-01), Hawkins
patent: 4291934 (1981-09-01), Kund
patent: 5035655 (1991-07-0
Berels David J.
Ng Jerome
Swan James L.
Wisner Stephen J.
Bradley Paula
Brooks & Kushman P.C.
Lear Corporation
Tsukerman Larisa
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