EP0349154A2

EP0349154A2 - Electrical terminal and connector for bladed fuse

Info

Publication number: EP0349154A2
Application number: EP89306022A
Authority: EP
Inventors: Stephen A. Colleran; Robert J. Gugellmeyer; Bill B. Wilson
Original assignee: Molex LLC
Current assignee: Molex LLC
Priority date: 1988-06-29
Filing date: 1989-06-14
Publication date: 1990-01-03
Also published as: EP0349154A3; JPH0246619A

Abstract

A terminal (10) comprises first and second U-shaped contact structures (12, 14) disposed in spaced relationship to define a blade receiving slot (38) for a contact blade (74, 76) (Fig. 5) of an automotive fuse (72) therebetween. The contact structures (12, 14) have first and second contact arms (16, 18, 22, 24) and a connecting portion (20, 26) and each contact arm has a generally convex arcuate contact edge (42, 43, 44, 45) extending into the blade receiving slot (38) to make contact with the blade (74, 76). The terminal further comprise mounting bases (28, 30). A pair or pairs of the terminals (10, 10A) are mounted in a dielectric housing (62) (Fig. 5) with their blade receiving slots (38) in line to receive the respective contact blades (74, 76) of the fuse (72). Solder tails (36) on the terminal bases (28) makc electrical contact with conductors of a printed circuit board (70).

Description

Many electrical fuses, including the fuses employed in automotive vehicles, comprise a pair of generally planar blade terminals which are electrically connected to one another. The electrical connection between the blade terminals of the fuse is selected in accordance with the specified current to be carried by the circuit into which the fuse is incorporated. An electrical current level which exceeds the specified level will damage the electrical connection between the blade terminals of the fuse, thereby breaking the circuit and preventing more serious damage to other electrical components. The fuse is removably mounted in the electrical circuit such that the fuse can be removed and replaced if the electrical fuse connection between the blade terminals is broken.
Typically the planar blade terminals of the fuse are disposed in spaced generally coplanar relationship. The blade terminals generally are elongated substantially rectangular structures aligned with their respective long axes generally parallel. One longitudinal end of each blade and the electrical connection therebetween typically is mounted in a non-conductive fuse housing. The opposed longitudinal end of each blade terminal extends from the non-conductive fuse housing for insertion into two separate blade receiving terminals which are mounted in a fuse block to form an electrical connector. Thus, the fuse completes an electrical circuit between the two blade receiving terminals in the fuse block. However, upon damage to the electrical connection in the fuse between the fuse terminal blades, the circuit between the two blade receiving terminals in the fuse block is broken.
The above described bladed fuses are widely used in the automotive industry to protect virtually all of the electrically powered equipment of an automobile, including the headlights, sound systems, dashboard indications, air conditioners and such. The entire electrical system, including the fuses, is necessarily subjected to very substantial vibrations and extreme ranges in temperature within the automotive environment. Thus, the blade receiving terminals into which the above described bladed fuses are inserted must achieve the seemingly conflicting objectives of providing for removability in the event of damage to the fuse and providing for a high quality electrical connection through all extreme ranges of vibration and temperature.
The prior art terminals for receiving the blade terminals of a fuse typically have been stamped and formed from strips of metal to define opposed terminal contact arms for mechanically and electrically engaging opposed sides of the blade terminals of the fuse. More particularly, the strips of metal have been formed in the prior art terminals such that the major planar surface of the formed metal strip is in face to face contact with one of the planar surfaces of the bladed fuse terminal. This prior art construction is intended to maximize the area of contact between the blade terminal of the fuse and the blade receiving terminal. To improve the contact pressure, the prior art blade receiving terminals have been formed such that the opposed contact arms must be biased away from one another by the insertion of the bladed fuse terminals therebetween.
An example of a typical prior art bladed fuse receiving terminal is shown in U.S. Patent No. 4,460,239 which issued to Inoue on July 17, 1984. It will be noted that the terminals shown in U.S. Patent No. 4,460,239 each are formed from a single strip of metal having major length and width dimensions defining opposed major surfaces and having a minor thickness dimension which extends between the major surfaces. A blade receiving slot is defined between two opposed major surfaces of the formed metal strip. One strip of metal defining the blade receiving slot must be resiliently deflected about an axis disposed in or parallel to the plane of the metal to receive the fuse blade in the slot. The resiliency of the metal is then intended to exert a force against the fuse blade terminal mounted in the slot. The formed fuse blade receiving terminal of U.S. Patent No. 4,460,239 further includes a pair of slots for mounting the terminal to a bussing strip.
A similar prior art fuse blade receiving terminal is shown in U.S. Patent No. 4,451,109 which also issued to Inoue. The terminal of U.S. Patent No. 4,451,109 is formed from a single strip of metal and is provided with a pair of slots for mounting the terminal to a bussing strip. A terminal contact arm is bent around an axis disposed in or parallel to the plane of the metal, and is angularly directed toward the bussing strip engaged in the pair of slots. Thus, the terminal shown in U.S. Patent No. 4,451,109 is operative to urge a blade terminal of a fuse mounted therein against the bussing strip.
Other prior art using fuse blade receiving terminals defined by strips of metal bent around an axis disposed in or parallel to the plane of the metal material are shown in U.S. Patent No. 4,391,485 which issued to Urani on July 5, 1983; U.S. Patent No. 4,466,683 which issued to Ballarini on August 21, 1984; U.S. Patent No. 4,456,274 which issued to Olivera on December 3, 1985 and U.S. Patent No. 4,560,227 which issued to Bukala on December 24, 1985.
A particularly effective electrical terminal for applications other than fuses is shown in U.S. Patent No. 4,693,536 which issued to Colleran et al on September 15, 1987 and which is assigned to the assignee of the subject invention. The terminal shown in U.S. Patent No. 4,693,536 includes insulation displacement terminal structure at one end and a pin or spade receiving terminal structure at the opposed end. The pin or spade receiving end of the terminal shown in U.S. patent No. 4,693,536 is formed from a metallic strip bent about an axis extending parallel to the plane of the metal to define a generally U-shape having a pair of parallel arms and a connecting portion. A pin or spade receiving slot of uniform width along its length extends through the connecting portion of the U-shape and longitudinally through each arm. Thus, the slot shown in U.S. Patent No. 4,693,536 effectively defines a pair of opposed U-shaped terminal portions which are spaced equal distances from one another along the entire length of the uniform width slot. A plurality of such terminals are mounted in a housing constructed to receive spade or pin terminals at one end and insulated conductors at the opposed end. The terminals are aligned in the housing such that the respective arms of the U-shaped structures lie in two opposed generally parallel planes. The slots in the array of terminals define spaced apart parallel planes, with the number of such planes being equal to the number of terminals. Thus, for example, in an array of two such terminals, the first arms of a first terminal would lie in the same plane as the first arms of a second terminal. Similarly, the second arms of the first terminal would lie in the same plane as the second arms of the second terminal. The slots formed in the two terminals would define two spaced apart generally parallel planes. Although the pin or spade receiving portions of the terminal shown in U.S. Patent No. 4,693,536 provides desirable electrical connection for many purposes, this terminal is not designed for receiving a blade fuse in the high vibration environments encountered in automotive electronics and does not provide any specific teaching directed to the above described automotive fuses.

SUMMARY OF THE INVENTION

The subject invention is directed in one aspect to an electrical connector for connecting an automotive fuse to another circuit member, said automotive fuse being of the type including an elongate dielectric fuse housing having a body portion with an edge and a pair of coplanarly aligned, spaced apart, flat metallic contact blades extending from said edge, said electrical connector comprising a dielectric connector housing including a front end with at least one elongate opening and an opposed rear end with at least one pair of spaced and aligned openings, a fuse-receiving slot extending rearwardly from said elongate opening in the front end to a rear slot surface disposed intermediate the front end and the rear end of the housing, and at least one pair of spaced-apart terminal receiving cavities extending forwardly from said pair of rear end openings to said rear slot surface and communicating with said fuse receiving slot; and at least one pair of unitary metallic strip terminals, each terminal including first and second spaced apart bases and a pair of adjacent spaced apart U-shaped contact structures extending between and interconnecting the first and second bases and defining a blade-receiving contact slot therebetween, each said U-shaped contact structure including a first contact arm extending from said first base and a second contact arm extending therebetween, said first contact arms and said second contact arms each having a generally convex arcuate contact edge portion extending into said blade-receiving contact slot such that the distance between opposing arcuate edge portions of said U-shaped contact structures is less than the thickness of a said flat contact blade of an automotive fuse, each terminal being mounted in one of said terminal-receiving cavities so that the blade-receiving contact slot is aligned with the fuse-receiving slot and the bases are disposed adjacent the rear end of the housing, each terminal further including a second contact portion extending from one of said bases for electrically engaging said another circuit member, whereby, insertion of an automotive fuse into said fuse-receiving slot so that the edge of the fuse housing generally abuts said rear slot surface and the flat blade contact portions are received in the blade receiving contact slots of the terminals causes the U-shaped contact structures of each terminal to be deflected away from one another generating four vibration-resistant points of electrical contact between each terminal and each fuse blade to securely, elec trically and mechanically engage the automotive fuse in said connector.
The subject invention also comprehends the unitarily stamped and formed metallic terminal for achieving excellent mechanical and electrical connection to a blade terminal, such as the blade terminal of an automotive fuse used in a high vibration environment.
Thus, the subject terminal comprises a pair of spaced apart U-shaped contact structures defining a blade-receiving slot between the U-shaped contact structures. More particularly, each U-shaped contact structure comprises first and second spaced apart generally parallel contact arms and a connecting strip extending unitarily between the first and second contact arms. Each contact arm comprises a pair of opposed generally parallel major surfaces and a pair of opposed minor side edges. Each U-shaped contact structure is formed such that major surfaces of the first and second contact arms thereof are disposed in opposed facing relationship. This configuraion is achieved by forming the metallic material of the U-shaped contact structure about an axis that is parallel to or within the initial plane of the metal.
The terminal further comprises first and second bases for locking engagement with a housing, such as a plastics fuse block housing. The bases are unitary with the U-shaped contact structures and are disposed at locations thereon remote from the connecting strips of each U-shaped contact structure. More particularly, the first base is unitary with the two first contact arms, while the second base is unitary with the two second contact arms. The bases may be generally planar and disposed in generally parallel spaced apart relationship. At least one of the first and second bases may be provided with means for lockingly engaging the terminal in a non-conductive housing, such as a fuse block housing. For example, the first and second bases may be provided with cantilevered locking tangs extending angularly from each base. One base may be provided with a solder tail to permit mounting of the fuse receiving terminal directly to a printed circuit board. However, other termination means, such as crimp-on structures may be provided instead of a solder tail.
The two U-shaped contact structures are disposed such that a fuse blade inserted therebetween will contact the minor side edges of the two U-shaped contact structures. More particularly, the first contact arms may be disposed in generally coplanar relationship to contact substantially opposite locations on a fuse blade. Similarly, the second contact arms may also be disposed generally in coplanar relationship to contact opposite locations on the same fuse blade.
As noted above, a fuse blade receiving slot is defined between the two U-shaped contact structures. The width of the blade receiving slot is selected to ensure that the insertion of the fuse blade therein biases the two U-shaped contact structures away from one another. However, this is substantially unlike the prior art fuse terminals which place the fuse blade between the arms of a single U-shaped structure to deflect the arms about an axis within or parallel to the plane of the metal. Rather, the subject terminal requires each U-shaped structure to be biased about an axis extending orthogonal to the plane of the metal from which the terminal is formed. This substantial difference results in significantly greater contact pressure against the fuse blade.
In one embodiment, as explained further below, the side edges of the U-shaped contact structures that face one another are configured to define generally arcuate ramped camming contact edges. More particularly, each contact arm may be provided with a generally convex arcuate ramped contact edge extending into the blade receiving slot. With this configuration a high quality wiping electrical connection is achieved with contact forces gradually increasing as the fuse blade terminal is inserted into the slot. Consequently, each fuse blade will be securely mechanically and electrically engaged between two pairs of opposed convex arcuate contact edges.
The subject invention may further comprise a pair of terminals as described herein. The terminals in each pair may be appropriately disposed such that the blade receiving slots are substantially in a common plane. Thus, the blade receiving slots of the two terminals can receive a pair of spaced apart but generally coplanar blade terminals of a standard automotive fuse. With this construction, the U-shaped contact structures in each terminal will be biased away from one another as the double bladed fuse is urged into the aligned slots. In this embodiment, each blade of the automotive fuse will be securely electrically and mechanically engaged by four contact edges, with two spaced apart contact edges on each side of each blade. Furthermore, the contact edges on one side of each blade will be generally aligned with but opposite to the contact locations on the other side of the blade to ensure an extremely tight gripping engagement of the blade and enhanced electrical connection in the high vibration automotive environment.
One way of carrying out the present invention in each of its various aspects will now be described in detail by way of example with reference to drawings which illustrate a specific embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a terminal of the subject invention;
FIG. 2 is a side elevational view of the terminal shown in Fig. 1;
FIG. 3 is a front elevational view of the terminal;
FIG. 4 is a cross-sectional view of an electrical connector of the subject invention showing one of a pair of the terminals of Figs. 1, 2 and 3 mounted in a housing and to a printed circuit board and further showing a fuse engaged in the terminals;
FIG. 5 is a cross-sectional view of the connector showing the pair of terminals having the fuse mounted therein.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

The bladed fuse receiving terminal of the subject invention is identified generally by the numeral 10 in Fig. 1. The terminal 10 is formed from a phosphor bronze alloy having a thickness "a" of approximately 0.38 mm ± 0.013 mm. The terminal 10 is stamped and formed into the configuration shown in Fig. 1 to define a pair of substantially identical parallel spaced apart U-shaped contact structures 12 and 14. More particularly, the U-shaped contact structure 12 comprises first and second generally parallel spaced apart contact arms 16 and 18 and a connecting strip 20 extending unitarily between the contact arms 16 and 18. Similarly, the U-shaped contact structure 14 comprises first and second spaced apart generally parallel contact arms 22 and 24 and a connecting strip 26 extending unitarily therebetween. The U-shaped configuration of the contact structures 12 and 14 is obtained by forming the metallic material of the terminal 10 about an axis "b" extending parallel to the major surfaces of the metallic material of terminal 10.
The terminal 10 further comprises first and second bases 28 and 30 for mounting the terminal 10 in a non-conductive housing of an electrical connector of the subject invention as explained further below. The first and second bases 28 and 30 are disposed in spaced apart generally parallel relationship to one another. Additionally, the first contact arms 16 and 22 extend unitarily from the first base 28, while the second contact arms 18 and 24 extend unitarily from the second base 30. The actual configuration of each base 28 and 30 is dependent upon the particular construction of the non-conductive housing into which the terminal 10 is to be mounted. However, in most instances, the bases 28 and 30 will be generally planar as depicted in the figures hereto. The bases 28 and 30 further comprise cantilevered deflectable locking tangs 32 and 34 extending therefrom. The tangs 32 and 34 are disposed to lockingly engage corresponding structures on the non-conductive housing into which the terminal 10 is inserted.
The terminal 10 further comprises a solder tail 36 extending unitarily from the first base 28 thereof. The terminal 10 will be mounted in a non-conductive housing such that the solder tail 36 thereof extends from one side of the housing. As a result, the solder tail 36 can be extended through an aperture in a printed circuit board to be electrically connected to an electrically conductive lead that is printed or otherwise disposed on the circuit board. Alternatively, however, the terminal 10 may be provided with a crimp-on contact portion instead of the solder tail 36. The solder tail 36 is depicted as having its longitudinal axis extending generally within the plane of the first base 28 and generally parallel to the first contact arms 16 and 22. However, it is to be understood that the solder tail 36, or other such connecting structure, could be disposed at an angle to the alignment depicted in Fig. 1. For example, a right angle solder tail or crimp-on connecting structure could be provided in lieu of the solder tail 36 depicted in the figures hereto.
As shown most clearly in Figs. 1 and 3, the U-shaped contact structures 12 and 14 are disposed in spaced apart generally parallel relationship to define a blade receiving slot 38 therebetween. The minimum width of the blade receiving slot 38, as indicated by dimension "c" in Fig. 3 is defined by contacts 40 and 41 on the respective first contact arms 16 and 22 and by the contacts 42 and 43 on the second respective contact arms 18 and 24. The contacts 40-43 lie generally in the same plane as adjacent portions of the corresponding contact arms 16, 22, 18 and 24. However, the contacts 40-43 are defined by convex arcuate contact edges 44-47 respectively which are in opposed facing relationship. The distance "c" separating the convex arcuate contact edges 44 and 45 on the first contact arms 16 and 22 and separating the convex arcuate contact edges 46 and 47 on the second contact arms 18 and 24 is selected to be less than the thickness of the fuse blade terminal to be inserted into the blade receiving slot 38. However, the distance "d" separating the first contact arms 16 and 22 or the second contact arms 18 and 24 at locations spaced from the convex arcuate contacts 40-43 preferably exceeds the thickness of the fuse blade terminal to be inserted in the blade receiving slot 38.
As shown in Figs. 4 and 5, a pair of the terminals 10, 10A are mounted in a terminal receiving cavity 60 of a dielectric connector housing 62. In particular, each terminal 10 is mounted in the housing 62 such that the solder tail 36 thereof extends away from one peripheral portion of the housing 62. Thus, each terminal 10 and the housing 62 can be mounted to a printed circuit board 64 having a through hole 68 extending entirely therethrough for receiving the solder tail 36. The solder tail 36 may then be electrically and mechanically connected to a conductive lead 70 printed on the circuit board 64.
With reference to Fig. 5, the terminals 10, 10A are disposed in the housing 62 such that the blade receiving slots thereof define a substantially common plane. Thus, returning to Fig. 4, the terminal 10A and its associated blade receiving slot is directly behind and substantially in register with the terminal 10 and blade receiving slot 38 depicted in Fig. 4.
The fuse 72 shown in Figs. 4 and 5 is of the type typically used in automotive applications and comprises a pair of spaced apart blade terminals 74 and 76 extending from a dielectric fuse housing 78 having a body portion with an edge 78A. The blade terminals 74 and 76 each are substantially planar and lie substantially in the same plane. Additionally, the blade terminals 74 and 76 are disposed with respect to the housing 78 such that portions of each blade terminal 74 and 76 extend from the housing edge 78A, while the remaining portions are disposed within the housing 78. The fuse 72 further comprises a fuse wire 80 extending between and connecting portions of the terminal blades 74 and 76 that are disposed within the non-conductive housing 78. The fuse wire 80 provides an electrical connection between the terminals 74 and 76. However, the fuse 72 is operative for a selected current level. If the specified current level is exceeded, the fuse wire 80 will break, thereby preventing a transmission of electrical current between the terminal blades 74 and 76.
The terminal housing 62 has its rear end mounted to the printed circuit board 64 such that the solder tail 36 extends through the through hole 68 therein and such that the solder tail 36A of terminal 10A extends through a second through hole 82 in the printed circuit board 64. As noted above, the solder tail 36 is electrically and mechanically connected to a conductive lead 70 on the printed circuit board, while the solder tail 36A is connected to a second conductive lead 84 on printed circuit board 64. As a result, the fuse 72 provides for electrical connection between the conductive leads 70 and 84 of the printed circuit board 64.
As noted above, the electrical circuitry of automobiles frequently is subjected to extreme vibrations and extreme ranges in temperature. Such vibrations and temperature variations can adversely affect the quality of the electrical connection of terminals to a bladed fuse. However, the terminals 10 and 10A shown and described herein ensure superior electrical and mechanical connection to the fuse 72 through virtually all ranges of vibration and temperature that are likely to be encountered. In particular, as shown more clearly in Fig. 4, the insertion of the fuse 72 into the fuse housing 62 urges the fuse blade 74 into the blade receiving slot 38 between the U-shaped contact structures 12 and 14. The fuse blade 74 is simultaneously urged into a camming wiping engagement with the convex arcuate contact edges 44-47. Thus, the arcuate convex contact edges 44-47 function as ramps or cams which cause the respective U-shaped contact structures 12 and 14 to be biased away from one another. Simultaneously, a corresponding biasing of the U-shaped structures of terminal 10A will occur in response to camming engagement with fuse blade 76. By virtue of the above described unique construction of the terminals 10 and 10A, the U-shaped contact arm structures 12 and 14 will be urged away from one another, with pivoting actions occurring substantially along the axes "d" and "e" and in the direction of arrows "f" and "g" shown in Fig. 1.
It will be appreciated that the rotation of the U-shaped terminal structures caused by the insertion of the fuse 72 and indicated generally by the arrows "f" and "g" will cause the U-shaped contact structures 12 and 14 to deflect with respect to a major thickness dimension thereof. In particular, as shown most clearly in Fig. 4, the width "h" and "i" of each contact arm 16, 18 and 22, 24 respectively is several times greater than the thickness "a" of the metal material from which the terminal 10 is formed. As a result, substantial residual biasing forces will be exerted against the blade terminals 74 and 76 by the U-shaped contact structures of the respective terminals 10 and 10A.
The camming interaction between the blade terminals 74, 76 and the respective convex arcuate contact edges 44-47 enables a fairly easy insertion of the fuse 72 into the terminals 10 and 10A, yet also achieves the desirable wiping contact and the gradual development of substantial inwardly directed forces against the terminal blades 74 and 76. Upon complete insertion of the fuse 72 into the terminals 10 and 10A, as shown in Figs. 4 and 5, the residual forces exerted by the terminals 10 and 10A against the blade terminals 74 and 76 result in superior mechanical and electrical connection. It should also be noted that a terminal having substantially parallel and/or planar contact edges defining the blade receiving slot could not both achieve the relatively easy insertion of the fuse into the blade receiving slot and simultaneously develop the substantial contact forces enabled with the terminals 10 and 10A as described and shown herein. It should further be noted that the contact forces against the blade terminals 74 and 76 by the blade receiving terminals 10 and 10A is much greater than the forces enabled by the standard fuse receiving terminal which develops contact forces by deflecting contact arms about axes lying within the plane of the metal in the terminals, rather than about axes extending orthogonal thereto. Although the terminals 10 and 10A described herein achieve a smaller contact surface, the much greater contact forces against the blade terminals of the fuse result in a much more effective mechanical and electrical connection for the high vibration, temperature-variable environment in which an automotive fuse is employed.
In summary, a blade receiving terminal 10, 10A has been described for receiving the blade terminal 74, 76 of an automotive fuse. The terminal 10 comprises first and second U-shaped contact structures 12, 14 with a blade receiving slot 38 therebetween for achieving mechanical and electrical contact with the opposed first and second sides respectively of the blade terminal 74, 76. The first and second U-shaped contact structures are formed by bending the metal material of the terminal 10, 10A about an axis "b" extending parallel to the plane of the metal. Each U-shaped contact structure comprises first and second contact arms 16, 18, 22, 24, with the first contact arms being unitary with a first base 28 and the second contact arms being unitary with a second base 30. The bases of the terminal are securely mountable in a dielectric connector housing 62. A solder tail 36 or other such connector means may extend from one of the bases 28. Each contact arm 16, 18, 22, 24 com prises a generally convex arcuate contact edge 44, 45, 46, 47 extending into the blade receiving slot 38 between the contact structures and toward the opposed U-shaped contact structure. The spacing between opposed convex arcuate contact edges is less than the thickness of the blade 74, 76 to be inserted into the terminal 10, 10A. Thus, the movement of the blade 74, 76 into the blade receiving slot 38 of the terminal causes a camming interaction between the blade terminal 74, 76 and the convex arcuate contact edges 44, 45, 46, 47. As a result, the respective U-shaped contact structures 12, 14 will be urged away from one another about an axis extending generally orthogonal to the plane of the metal from which the terminal is formed. Substantial residual contact forces are developed which achieve superior electrical and mechanical connection to the blade terminal 74, 76 of the fuse. Terminals 10, 10A of the subject invention may be employed in pairs such that the terminal receiving slots 38 thereof lie generally in a common plane. In particular, the electrical connector of the subject invention, which has been described and illustrated in the drawings, and which is intended for connecting one or more automotive fuses, e.g. 72, to another circuit member, e.g. printed circuit board 64, comprises at least one pair of the terminals 10, 10A housed in the dielectric connector housing 62 which includes a front end with at least one elongate opening 100 and an opposed rear end with at least one pair of spaced and aligned openings 101, a fuse receiving slot 102 extending rearwardly from said front elongate opening 100 in the front end of the housing 62 to a rear slot surface 103 disposed intermediate the front end and the rear end of the housing 62, the at least one pair of terminals 10, 10A being housed in at least one pair of spaced-apart terminal receiving cavities 60 extending forwardly from said pair of rear end openings 101 to said rear slot surface 103 and communicating with said fuse receiving slot 102. The insertion of the fuse 72 into the fuse receiving slot 102 so that the edge 78A of the fuse housing 78 generally abuts said rear slot surface 103 and so that the flat blade contact portions 74, 76 are received in the blade receiving contact slots 38 of the terminals 10, 10A causes the U-shaped contact structures of the terminals to be deflected away from one another generating four vibration-resistant points of electrical contact between each terminal 10, 10A and each fuse blade 74, 76 to securely, electrically and mechanically engage the automotive fuse 72 in the connector.
There has also been described an electrical terminal for achieving superior electrical and mechanical connection to a bladed fuse terminal in a high vibration automotive environment.
The terminal is adapted for mounting to a printed circuit board and for securely but removably receiving a blade terminal of a fuse.

Claims

1. An electrical connector for connecting an automotive fuse to another circuit member, said automotive fuse being of the type including an elongate dielectric fuse housing having a body portion with an edge and a pair of coplanarly aligned, spaced-apart, flat metallic contact blades extending from said edge, said electrical connector characterized by
a dielectric connector housing including a front end with at least one elongate opening and an opposed rear end with at least one pair of spaced and aligned openings, a fuse-receiving slot extending rearwardly from said elongate opening in the front end to a rear slot surface disposed intermediate the front end and the rear end of the housing, and at least one pair of spaced-apart terminal receiving cavities extending forwardly from said pair of rear end openings to said rear slot surface and communicating with said fuse-receiving slot; and
at least one pair of unitary metallic strip terminals, each terminal including first and second spaced apart bases and a pair of adjacent spaced apart U-shaped contact structures extending between and interconnecting the first and second bases and defining a blade-receiving contact slot therebetween, each said U-shaped contact structure including a first contact arm extending from said first base and a second contact arm extending therebetween, said first contact arms and said second contact arms each having a generally convex arcuate contact edge portion extending into said blade-receiving contact slot such that the distance between opposing arcuate edge portions of said U-shaped contact structures is less than the thickness of a said flat contact blade of an automotive fuse, each terminal being mounted in one of said terminal-receiving cavities so that the blade-receiving contact slot is aligned with the fuse-receiving slot and the bases are disposed adjacent the rear end of the housing, each terminal further including a second contact portion extending from one of said bases for electrically engaging said another circuit member,
whereby, insertion of an automotive fuse into said fuse-receiving slot so that the edge of the fuse housing generally abuts said rear slot surface and the flat blade contact portions are received in the blade receiving contact slots of the terminals causes the U-shaped contact structures of each terminal to be deflected away from one another generating four vibration-resistant points of electrical contact between each terminal and each fuse blade to securely, electrically and mechanically engage the automotive fuse in said connector.

2. An electrical connector as in claim 1, wherein said second contact portion of each terminal electrically engages a conductive lead.

3. An electrical connector as in claim 1, wherein said another circuit member includes a printed circuit board having conductive regions defined thereon and the second contact portion on each terminal electrically engages a conductive region on said printed circuit board.

4. An electrical connector as in claim 3, wherein said second contact portion comprises a solder tail.

5. An electrical connector as in claim 1, further including means for lockably mounting the terminals in the terminal-receiving cavities.

6. A blade receiving terminal for receiving a generally planar blade of a bladed fuse, said terminal being formed from a metallic material having opposed generally parallel surfaces and a plurality of side edges extending between and connecting said surfaces, said terminal comprising first and second generally U-shaped contact structures defining a blade receiving slot between said U-shaped contact structures, said U-shaped contact structures being defined by forming the metallic material of said terminal about an axis extending parallel to said surfaces of said metallic material, each said U-shaped contact structure comprising first and second contact arms and a connecting strip extending unitarily between said contact arms, the first contact arms extending unitarily from a first base and said second contact arms extending unitarily from a second base, said first and second bases being disposed at locations on said contact arms remote from the connecting strips of said U-shaped contact structures, said contact arms comprising generally convex arcuate contact edges extending into the blade receiving slot, such that the contact edges of one U-shaped contact structure are disposed in generally opposed aligned relationship to the contact edges of the other U-shaped contact structure, the U-shaped contact structures being disposed with respect to one another such that the contact edges thereof exert contact forces on opposed sides of the blade terminal inserted in the blade receiving slot.

7. A terminal as in claim 6 wherein the convex arcuate contact edges of one U-shaped contact structure are generally in opposed aligned relationship to the convex arcuate contact edges of the other U-shaped contact structure.