Electrical connectors – Metallic connector or contact having movable or resilient... – Spring actuated or resilient securing part
Reexamination Certificate
2002-02-21
2004-01-06
Ta, Tho D. (Department: 2833)
Electrical connectors
Metallic connector or contact having movable or resilient...
Spring actuated or resilient securing part
C439S587000, C439S271000
Reexamination Certificate
active
06672911
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to sealed power connectors for 90° terminal assemblies and power feed attachments, such including resilient engagement capability. More particularly, the present invention is directed to an electrical terminal socket assembly and method for constructing which incorporates a substantially rectangular and compressible contact spring cage and an encircling compressible terminal sleeve for holding the spring cage in place. The contact spring cage and sealed connector assembly provides a low cost solution for a quick connect assembly and which provides both increased contact surface area between the spring cage and associated male terminal, as well as a much greater degree of torque control in assembly as opposed to prior art bolt and nut type cable connections. The present invention further discloses a 90° sealed connection housing, which includes angled variations of the terminal socket assembly enclosed within interengaging male and female outer connecting portions, and for better insulating and sealing the electrical connections established by the socket assembly. The configuration of the rectangular spring cage has further been found to provide sufficient contact surfaces necessary for maintaining the voltage and current carrying applications associated with larger capacity battery/power sources.
BACKGROUND OF THE INVENTION
Electrical connectors of the terminal socket variety are well known in the art, one primary application of which being in the automotive field for establishing connections between heavier sized output cable and components such as generators or alternators. The frictional grip imparted by the connector must be of sufficient strength to maintain firm mechanical and adequate electrical connection, yet must permit relatively easy manual withdrawal or insertion of a prong into the connector socket.
One type of known prior art electrical cable connection is the bolt-nut type electrical cable connection. A significant problem associated with such bolt and nut arrangements arises from the amount of torque which is necessary to assemble the connector and the difficult quality control issues which arise from its large scale use such as over torque, under torque and cross thread.
Most power connection systems in the relevant art include circular type terminals. For certain applications, these require a number of components and processes in their assembly. For example, in power electrical distribution systems such as in vehicle fuse boxes, part of a copper sheet is stamped and formed into a round hollow pin. Occasionally, an additional solid pin is staked onto the copper sheet. However, and if a blade terminal is utilized, the male blade is stamped (not formed like a pin) as part of the copper sheet. This assembly does not require more process stages or par like a round pin.
It has been found that power blade terminals provide a better solution for space limitation in one direction, in some applications than in utilizing round power pin terminals. Conventional power blade terminals typically include a loose spring cage within a sleeve and in which a contact length established between the spring beam and male blade is small, thus resulting in the current carry capability being relatively low. Mechanically, a good terminal system ensures a low engaging force, while establishing a high normal (perpendicular) force. This results in the higher ratio of terminal insertion force over normal force between the male and female terminals providing an overall better terminal system. The ratio of insertion force over normal force has also been found to be very low for most conventional blade terminals.
It has also been found that aftermarket sealed female connectors (plastic housings) are typically only provided for straight terminal assemblies. In order to accommodate 90° connections, male pin or blade terminals usually are bent to right angles then mated with a straight female terminal assembly sealed inside a female connector. However, some applications do not allow or are not cost effective to bend the male terminal to 90° angular relationship. Thus, there has not been found to be any acceptable remedy to this kind of situation, especially for any power connection systems.
In sun, the present invention lacks a power blade terminal system which provides cost effective design and optimal package space in certain applications. It has also been determined that it is important to maintain sufficient contact surface and high normal force (between the male pin and socket cage) in order to guarantee that an adequate amount of electrical current is carried through the terminal assembly, while at the same time reducing the insertion force as low as possible. A sealed 90° female connection has also been determined to be required for certain power applications.
SUMMARY OF THE INVENTION
The present invention discloses an electrical terminal socket assembly and method for constructing which incorporates, as a subassembly of the overall socket assembly, a substantially rectangular and compressible spring cage and a supporting rectangular shaped and compressible terminal/contact sleeve for holding the spring cage in place. As previously explained, the present assembly and method for constructing provides a low cost solution for a quick connect assembly and which requires a much greater degree of torque control in assembly, as opposed to prior art bolt and nut type cable connections. The present invention is also an improvement over prior art assembly techniques which require the spring cage element to be formed in place after it is has been inserted into the corresponding sleeve component, particularly in that the present invention provides only two components and a simplified assembly process. It is further contemplated that the assembly part can be manufactured in conjunction with a fast speed progression die.
A spring cage blank has first and second extending edges and a plurality of spaced apart and angled beams extending between the edges. As disclosed in copending application Ser. No. 09/951,012, filed Sep. 14, 2001, and in a preferred variant, it is contemplated that a plurality of the spring cage blanks may be provided in spaced fashion between first and second carrier strips and which permit the blanks to be transferred in succession into an appropriate die stamping, tool punching or other suitable forming operation. As is again previously described in U.S. Ser. No. 09/951,012, it is further contemplated that such stamping or other forming operation may further include the provision of first and second spaced apart and opposing mandrels, each exhibiting a suitable exterior configuration for shouldering and forming the three dimensional rectangular configuration of the compressible spring cage.
Aspects of the rectangularly formed spring cage include the combined bending of the individual beams along their axially extending directions, combined with torsioning (or twisting) each of the beams in a direction perpendicular to their axial extending length. The suitable tool punching or die forming operations performed on the spring cage, during its transition from a blank form to a substantially rectangular and three dimensional shape, further imparts an outwardly flared and arcuate configuration to each of the spaced apart faces of the spring cage.
The contact sleeve is likewise provided in initial blank form and, upon completion of the suitable forming operations, exhibits a likewise substantially rectangular shaped three dimensional body with open interior communicated by first and second open ends. The longer sides of the rectangular shaped cage are slightly imparted to be outwardly flared and adopt an arcuate configuration relative to the sleeve. Contact tab portions extend from the rectangular encasing portion of the sleeve and, as will be subsequently described, are crimped/bent to engage extending and exposed wire end portions of an associated electrical cable.
The contact sleeve is otherwise shaped with an open interio
Gutman Robert F.
Zhao Weiping
Alcoa Fujikura Limited
Beiriger Tracey D.
Tsukerman Larisa
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