Two piece male pin terminal connector

Details Two piece male pin terminal connector Two piece male pin terminal connector

1999-12-01

2001-09-18

Luebke, Renee (Department: 2833)

Electrical connectors

Metallic connector or contact also having securing part...

Multipart assembly

C439S891000

Reexamination Certificate

active

06290556

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates generally to the field of joining electrical conductors to electrical terminals, and more specifically, to male pin terminal connectors. In even greater particularity, the present invention is directed to an improved two-piece solid male pin to crimp saddle terminal connector and method of manufacture.
BACKGROUND OF THE INVENTION
A multitude of approaches have been taken to join electrical conductors to terminal connectors. In order to construct a typical male pin terminal connector, the insulation must be removed from a portion of the conductor to permit contact between the metallic wire barrel of the connector and the uninsulated portion of the conductor. Joinder of the connector and conductor is accomplished by externally applied mechanically deforming forces to make a mechanical and electrical coupling between the conductor and connector. Another method of constructing a male pin terminal connector is described in U.S. Pat. No. 5,399,110. However, although the above techniques may be satisfactory for some purposes, the strength of such connectors has been noted to be unreliable in some applications. Accordingly, there is a need for a male pin terminal connector having reliable and improved strength, yet is inexpensive and easy to manufacture.
SUMMARY OF THE INVENTION
In accordance with the purposes of the invention as embodied and broadly described herein, the present invention addresses the above need by providing one embodiment which is directed to an electrically conductive contact member for use in a two-piece male pin terminal connector whereby electrical conductors in an insulated electrical cable are mechanically and electrically connected to a terminal cavity. The contact member includes an elongated cylindrically shaped solid pin formed along a forward portion of the contact member. The pin may further include a rounded point at its forward most end to facilitate insertion of the contact member into the terminal cavity. A flattened portion is formed at a rearward portion of the contact member which has a slightly arcuate shape for establishing electrical contact between the contact member and the electrical conductors in the insulated electrical cable. The flattened portion further includes a plurality of transversely extending grooves on an upper surface thereof and a plurality of transversely extending ribs on a lower surface thereof The pin further includes at least one clamping portion adjacent the flattened portion which includes at least one annular groove. The clamping portion on the pin may include two annular grooves. The pin may include two clamping portions adjacent the flattened portion. The lower surface of the flattened portion may further include an extruded post.
Another embodiment of the present invention is directed to an electrically conductive crimp saddle attachment member for use in a two-piece male pin terminal connector having a male contact member whereby an insulated electrical cable having a conductor core is mechanically and electrically connected to a terminal cavity. The attachment member includes a generally rectangular first attachment portion formed at a forward most end of the attachment member. The first attachment portion includes at least one transversely extending rib for engaging the male contact member, wherein the first attachment portion is tightly rolled and formed into a generally cylindrical shape around the male contact member so as to secure said male contact member to the attachment member. The attachment member further includes a winged connect portion adjacent the first attachment portion. The winged connect portion is manipulated about the male contact member to form a generally triangular shaped configuration having first and second wings which taper away from the longitudinal axis of the male contact member wherein the wings operate to secure the two-piece male pin terminal connector to the terminal cavity. The attachment member further includes a second generally rectangular attachment portion adjacent the winged connect portion wherein the first attachment portion is tightly rolled and formed into a generally cylindrical shape around the male contact member so as to further secure the male contact member to the attachment member. The attachment member further includes a generally rectangular core crimp portion adjacent the second generally rectangular attachment portion. The core crimp portion is fashioned to form an open generally U-shaped channel for receiving the male contact member and the conductor core of the electrical cable. The core crimp portion further includes a plurality of transversely extending grooves for engaging the male contact member. The attachment member further includes a generally rectangular insulation crimp portion adjacent the core crimp portion wherein the insulation crimp portion is fashioned to form an open generally U-shaped channel for receiving the insulated electrical cable. In this particular embodiment, the attachment member may be formed from a sheet metal blank.
In another embodiment of the present invention, a two-piece male pin terminal connector for mechanically and electrically connecting an insulated electrical cable having a conductor core to a terminal cavity is provided. The connector includes an electrically conductive contact member having an elongated cylindrically shaped pin formed along a forward portion of the contact member and a flattened portion formed at a rearward portion of the contact member. The flattened portion has a slightly arcuate shape for establishing electrical contact between the contact member and the conductor core in the insulated electrical cable. The flattened portion further includes a plurality of transversely extending grooves on an upper surface thereof and a plurality of transversely extending ribs on a lower surface thereof. The pin further includes a first clamping portion adjacent the flattened portion wherein the first clamping portion includes at least one annular groove. The connector further includes an electrically conductive crimp saddle attachment member formed from a sheet metal blank. The attachment member includes a generally rectangular first attachment portion formed at its forward most end for receiving and engaging the first clamping portion of the pin. The first attachment portion includes at least one transversely extending rib for engaging the at least one annular groove in the first clamping portion wherein the first attachment portion is tightly rolled and formed into a generally cylindrical shape around the first clamping portion so as to secure the contact member to the attachment member. The attachment member further includes a generally rectangular core crimp portion which is fashioned to form an open generally U-shaped channel for receiving the flattened portion of the contact member and the conductor core of the insulated electrical cable. The core crimp portion further includes a plurality of transversely extending grooves for engaging said plurality of transversely extending ribs on the lower surface of the flattened portion wherein the core crimp portion is crimped onto the conductor core and the flattened portion so as to press the conductor core into the plurality of transversely extending grooves on the upper surface of the flattened portion thereby making electrical connection between the conductor core and the contact member. The lower surface of the flattened portion may further include an extruded post. The core crimp portion may further include a hole formed in the bottom of the U-shaped channel for receiving the extruded post on the lower surface of the flattened portion. The extruded post may be coined down so as to form a flange which engages the core crimp portion at locations surrounding the hole thereby further enhancing the securing of the contact member to the attachment member. The pin may further include a second clamping portion adjacent the flattened portion. The attachment member may further include a second generally rectangula

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