EP3467949B1 - Elektrischer hochstromverbinder - Google Patents

Elektrischer hochstromverbinder Download PDF

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Publication number
EP3467949B1
EP3467949B1 EP18198056.6A EP18198056A EP3467949B1 EP 3467949 B1 EP3467949 B1 EP 3467949B1 EP 18198056 A EP18198056 A EP 18198056A EP 3467949 B1 EP3467949 B1 EP 3467949B1
Authority
EP
European Patent Office
Prior art keywords
sidewall
contact
electrical
terminal
male
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP18198056.6A
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English (en)
French (fr)
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EP3467949A1 (de
Inventor
Hoi Lui
James M. Rainey
Patrick J REEDY
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aptiv Technologies Ltd
Original Assignee
Aptiv Technologies Ltd
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Publication date
Priority claimed from US15/724,682 external-priority patent/US10230191B2/en
Application filed by Aptiv Technologies Ltd filed Critical Aptiv Technologies Ltd
Publication of EP3467949A1 publication Critical patent/EP3467949A1/de
Application granted granted Critical
Publication of EP3467949B1 publication Critical patent/EP3467949B1/de
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/15—Pins, blades or sockets having separate spring member for producing or increasing contact pressure
    • H01R13/187—Pins, blades or sockets having separate spring member for producing or increasing contact pressure with spring member in the socket
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/04—Pins or blades for co-operation with sockets
    • H01R13/05—Resilient pins or blades
    • H01R13/052—Resilient pins or blades co-operating with sockets having a circular transverse section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/10—Sockets for co-operation with pins or blades
    • H01R13/11—Resilient sockets
    • H01R13/113—Resilient sockets co-operating with pins or blades having a rectangular transverse section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
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    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/193—Means for increasing contact pressure at the end of engagement of coupling part, e.g. zero insertion force or no friction
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/26—Pin or blade contacts for sliding co-operation on one side only
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/28—Contacts for sliding cooperation with identically-shaped contact, e.g. for hermaphroditic coupling devices
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    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/44—Means for preventing access to live contacts
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    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/502—Bases; Cases composed of different pieces
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    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5202—Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings
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    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5205—Sealing means between cable and housing, e.g. grommet
    • H01R13/5208—Sealing means between cable and housing, e.g. grommet having at least two cable receiving openings
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5219—Sealing means between coupling parts, e.g. interfacial seal
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    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/53—Bases or cases for heavy duty; Bases or cases for high voltage with means for preventing corona or arcing
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    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/58—Means for relieving strain on wire connection, e.g. cord grip, for avoiding loosening of connections between wires and terminals within a coupling device terminating a cable
    • H01R13/5804—Means for relieving strain on wire connection, e.g. cord grip, for avoiding loosening of connections between wires and terminals within a coupling device terminating a cable comprising a separate cable clamping part
    • H01R13/5812—Means for relieving strain on wire connection, e.g. cord grip, for avoiding loosening of connections between wires and terminals within a coupling device terminating a cable comprising a separate cable clamping part the cable clamping being achieved by mounting the separate part on the housing of the coupling device
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
    • H01R13/621—Bolt, set screw or screw clamp
    • H01R13/6215—Bolt, set screw or screw clamp using one or more bolts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/66—Structural association with built-in electrical component
    • H01R13/665—Structural association with built-in electrical component with built-in electronic circuit
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/66—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure with pins, blades or analogous contacts and secured to apparatus or structure, e.g. to a wall
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/20—Pins, blades, or sockets shaped, or provided with separate member, to retain co-operating parts together
    • H01R13/207—Pins, blades, or sockets shaped, or provided with separate member, to retain co-operating parts together by screw-in connection
    • H—ELECTRICITY
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    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
    • H01R13/629—Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure electrical locking indicators, manufacturing tolerances
    • H01R13/633—Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure electrical locking indicators, manufacturing tolerances for disengagement only
    • H01R13/6335—Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure electrical locking indicators, manufacturing tolerances for disengagement only comprising a handle
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/66—Structural association with built-in electrical component
    • H01R13/665—Structural association with built-in electrical component with built-in electronic circuit
    • H01R13/6683—Structural association with built-in electrical component with built-in electronic circuit with built-in sensor
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    • H01R2103/00—Two poles
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    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/28—Clamped connections, spring connections
    • H01R4/50—Clamped connections, spring connections utilising a cam, wedge, cone or ball also combined with a screw
    • H01R4/5083—Clamped connections, spring connections utilising a cam, wedge, cone or ball also combined with a screw using a wedge
    • H01R4/5091—Clamped connections, spring connections utilising a cam, wedge, cone or ball also combined with a screw using a wedge combined with a screw

Definitions

  • This disclosure generally relates to an electrical connector, and more particularly relates to an electrical connector that is capable of transferring electrical current in excess of 200 Amperes.
  • electrical connectors capable of transferring electrical current in excess of 100 Amperes (100 A) in electric vehicles (EVs) and hybrid-electric vehicles (HEVs).
  • EVs electric vehicles
  • HEVs hybrid-electric vehicles
  • electrical connectors require increasingly robust, reliable, and safe designs.
  • High current connectors have used torsional contact beams to increase the contact force between male and female electrical terminals. These contact beams have typically only had two contact points on each beam. Increasing electrical current carrying capacity of these connector designs is typically accomplished by increasing the number of beams to increase the number of contact points which will cause an undesirable increase in the size of the terminal components, making the resulting connector systems more difficult to package within a vehicle. Therefore, the present invention aims at providing a high current electrical connector that has increased current capacity without increased size.
  • Publication US 2012/156947 A1 discloses a receptacle terminal including a terminal body with a cable end configured to be terminated to a cable and a mating end configured to be mated with a blade terminal.
  • the terminal body includes a receptacle at the mating end.
  • the receptacle has a first wall and a second wall generally parallel to, and spaced apart from, the first wall.
  • the receptacle has a receiving space between the first and second walls configured to receive the blade terminal.
  • a contact spring is separately provided from, and coupled to, the terminal body and has a spring wall received in the receiving space that is positioned between the first wall and the blade terminal.
  • the spring wall has an inner surface and an outer surface. The inner surface is spring biased against the first wall. The outer surface is configured to be spring biased against the blade terminal.
  • Publication US 2003/0194919 A discloses another high current terminal blade connection system with a male connector, a female connector, and a contact insert including dimples
  • the high-current electrical connector includes a female electrical-terminal, a male electrical terminal, and a contact-spring.
  • the female electrical-terminal is configured to receive a male electrical-terminal and is formed of a single piece of electrically conductive material.
  • the female electrical-terminal has a first-sidewall and a second-sidewall.
  • the second-sidewall defines a first-end, a second-end, and a medial-zone disposed therebetween.
  • the first-sidewall is opposite and parallel at the first-end to the second-sidewall.
  • the contact-spring is formed of a single piece of electrically conductive material disposed intermediate to the first-sidewall and the second-sidewall.
  • the contact-spring defines a plurality of opposed-pair contact-beams.
  • Each of the plurality of opposed-pair contact-beams have a plurality of outer-contact-points in electrical and physical contact with the female electrical-terminal, and have a plurality of inner-contact-points.
  • the plurality of inner-contact-points are in electrical and physical contact with opposed sides of the male electrical-terminal. Electrical and physical contact is formed between the contact beam, the female electrical-terminal, and the male electrical-terminal in at least four separate locations.
  • the male electrical-terminal includes a planar blade-shaped portion formed of an electrically conductive material and has two exposed-edges of the planar blade-shaped portion formed of a dielectric material.
  • the dielectric material is integrally formed with a header-wall and a base of a male-connector.
  • the plurality of opposed-pair contact-beams are characterized as having a sinusoidally shaped cross-section.
  • the plurality of inner-contact-points and the plurality of outer-contact-points are characterized as having a rounded shape.
  • the contact-spring includes a pair of opposing guide-ribs formed in leading-edges of the contact-spring.
  • the guide-ribs are configured to engage and align the male electrical-terminal upon insertion into the female electrical-terminal.
  • the guide-ribs reduce a transverse-movement of the male electrical-terminal when the male electrical-terminal is in a seated-position.
  • the contact-spring is characterized as having a U-shape.
  • the female electrical-terminal further includes a third-sidewall that extends from a medial-edge of the first-sidewall to the medial-zone of the second-sidewall.
  • the third-sidewall is in electrical and physical communication with the medial-zone of the first-sidewall.
  • the third-sidewall is joined to the medial-zone by a single clinch-rivet.
  • a female terminal assembly in another embodiment, includes a female electrical-terminal and a contact-spring.
  • the female electrical-terminal is formed of a single piece of electrically conductive material.
  • the female electrical-terminal has a first-sidewall and a second-sidewall.
  • the second-sidewall defines a distal-end, a proximal-end, and a medial-zone disposed therebetween.
  • the first-sidewall is opposite and parallel to the distal-end of the second-sidewall.
  • the contact-spring is formed of a single piece of electrically conductive material disposed intermediate to the first-sidewall and the second-sidewall.
  • the contact-spring defines a plurality of opposed-pair contact-beams.
  • Each of the plurality of opposed-pair contact-beams have a plurality of outer-contact-points in electrical and physical contact with the female electrical-terminal, and have a plurality of inner-contact-points.
  • the plurality of inner-contact-points are in electrical and physical contact with opposed sides of the male electrical-terminal. Electrical and physical contact is formed between the contact beam, the female electrical-terminal, and the male electrical-terminal in at least four separate locations.
  • the plurality of opposed-pair contact-beams are characterized as having a sinusoidally shaped cross-section.
  • the plurality of inner-contact-points and the plurality of outer-contact-points are characterized as having a rounded shape.
  • the contact-spring includes a pair of opposing guide-ribs formed in leading-edges of the contact-spring.
  • the guide-ribs are configured to engage and align the male electrical-terminal upon insertion into the female electrical-terminal.
  • the guide-ribs reduce a transverse-movement of the male electrical-terminal when the male electrical-terminal is in a seated-position.
  • the contact-spring is characterized as having a U-shape.
  • the female electrical-terminal further includes a third-sidewall that extends from a medial-edge of the first-sidewall to the medial-zone of the second-sidewall.
  • the third-sidewall is in electrical and physical communication with the medial-zone of the first-sidewall.
  • the third-sidewall is joined to the medial-zone by a single clinch-rivet.
  • a contact-spring is provided.
  • the contact-spring is formed of a single piece of electrically conductive material configured to be disposed within a female electrical-terminal.
  • the contact-spring defines a plurality of opposed-pair contact-beams.
  • Each of the plurality of opposed-pair contact-beams have a plurality of outer-contact-points and a plurality of inner-contact-points.
  • the plurality of outer-contact points are configured to be in electrical and physical contact with the female electrical-terminal.
  • the plurality of inner-contact-points are configured to be in electrical and physical contact with opposed sides of a male electrical-terminal. Electrical and physical contact is formed between the contact beam, the female electrical-terminal, and the male electrical-terminal in at least four separate locations.
  • the plurality of opposed-pair contact-beams are characterized as having a sinusoidally shaped cross-section.
  • the plurality of inner-contact-points and the plurality of outer-contact-points are characterized as having a rounded shape.
  • the contact-spring includes a pair of opposing guide-ribs formed in leading-edges of the contact-spring.
  • the guide-ribs are configured to engage and align the male electrical-terminal upon insertion into the female electrical-terminal.
  • the guide-ribs reduce a transverse-movement of the male electrical-terminal when the male electrical-terminal is in a seated-position.
  • the contact-spring is characterized as having a U-shape.
  • a female terminal assembly in yet another embodiment, includes a female electrical-terminal and a contact-spring.
  • the female electrical-terminal is formed of a single piece of electrically conductive material.
  • the female electrical-terminal has a first-sidewall, a second-sidewall, and a third-sidewall.
  • the second-sidewall defines a distal-end, a proximal-end, and a medial-zone disposed between the distal-end and the proximal-end.
  • the first-sidewall is opposite and parallel at the distal-end to the second-sidewall.
  • the third-sidewall extends from a medial-edge of the first-sidewall and contacts the second-sidewall from the medial-zone to the proximal-end.
  • the third-sidewall is in electrical and physical communication with the first-sidewall.
  • the contact-spring is formed of a single piece of electrically conductive material disposed intermediate to the first-sidewall and the second-sidewall.
  • the contact-spring defines a plurality of opposed-pair contact-beams.
  • Each of the plurality of opposed-pair contact-beams have a plurality of outer-contact-points and have a plurality of inner-contact-points.
  • the plurality of outer-contact-points are in electrical and physical contact with the female electrical-terminal.
  • the plurality of inner-contact-points are in electrical and physical contact with opposed sides of the male electrical-terminal. Electrical and physical contact is formed between the contact beam, the female electrical-terminal, and the male electrical-terminal in at least four separate locations.
  • the third-sidewall defines a plurality of weld-slots longitudinally extending from the medial-zone to the proximal-end.
  • the weld-slots are configured to interface with an electrical-cable sonically welded to the female terminal.
  • the plurality of opposed-pair contact-beams are characterized as having a sinusoidally shaped cross-section.
  • the plurality of inner-contact-points and the plurality of outer-contact-points are characterized as having a rounded shape.
  • the contact-spring includes a pair of opposing guide-ribs formed in leading-edges of the contact-spring.
  • the guide-ribs are configured to engage and align the male electrical-terminal upon insertion into the female electrical-terminal.
  • the guide-ribs reduce a transverse-movement of the male electrical-terminal when the male electrical-terminal is in a seated-position.
  • the contact-spring is characterized as having a U-shape.
  • This invention uses a contact insert with quadruple contact points on each contact beam for increasing the electrical current carrying capability of the connector.
  • This electrical connector may also include a clinching joint to increasing the rigidity of the terminal box without affecting the cable welding area.
  • Fig. 1 illustrates a non-limiting example of a high-current electrical connector 10, hereafter referred to as the connector 10.
  • the connector 10 is shown in the un-mated condition to illustrate the internal components, as will be described in more detail below.
  • the connector 10 includes female-connector 12 having a female electrical-terminal 14 configured to receive a male electrical-terminal 16 disposed within a male-connector 18.
  • the male electrical-terminal 16 may be a planar-type terminal with two exposed sides, and is formed of an electrically conductive material, such as a copper-based alloy that may also include a coating of another conductive material (e.g. tin-based, silver-based coating).
  • the male electrical-terminal 16 may include a non-conductive material covering edges of the electrically conductive material.
  • Fig. 2 illustrates one female electrical-terminal 14 isolated from the female-connector 12 that is shown positioned above the mating male-connector 18.
  • the female electrical-terminal 14 may include a housing (not shown) composed of a dielectric material 58 that is configured to engage retention devices (not shown) within the female-connector 12.
  • the female electrical-terminal 14 is shown attached to an electrical-cable that may connect to electrical-circuits elsewhere in an electrical-system of a vehicle.
  • the electrical-cable is attached to the female electrical-terminal 14 by a sonic welding process. Alternate embodiments may be envisioned in which other known welding processes are used to attach the electrical-cable to the female electrical-terminal 14.
  • Fig. 3 illustrates the female electrical-terminal 14 of Fig. 2 in a sideview to expose internal components.
  • the female electrical-terminal 14 is formed of a single piece of electrically conductive material, such as a copper-based alloy and may include a coating of another conductive material (e.g. tin-based, silver-based coating).
  • the female electrical-terminal 14 has a first-sidewall 20 and a second-sidewall 22 that are connected by a web 24 of material created during a forming operation.
  • the second-sidewall 22 defines a distal-end 26, a proximal-end 28, and a medial-zone 30 disposed between the distal-end 26 and the proximal-end 28.
  • the first-sidewall 20 is opposite and parallel at the distal-end 26 to the second-sidewall 22 creating a channel configured to receive the two exposed sides of the male electrical-terminal 16 (not shown).
  • the female electrical-terminal 14 also includes a contact-spring 32 formed of a single piece of electrically conductive material disposed intermediate to the first-sidewall 20 and the second-sidewall 22.
  • the contact-spring 32 is formed of a copper-based alloy and is characterized as having a U-shape 34.
  • the contact-spring 32 may include a conductive coating, such as a tin-based alloy and/or a silver-based alloy.
  • the contact-spring 32 may include retention features (not specifically shown) that engage the female electrical-terminal 14 and inhibit a removal of the contact-spring 32.
  • Alternative embodiments may be envisioned using a different conductive material, such as a steel or aluminum alloy to form the contact-spring 32 which may or not be coated with a conductive coating.
  • Figs. 4A-4C illustrate the contact-spring 32 separated from the female electrical-terminal 14.
  • the contact-spring 32 defines a plurality of opposed-pair contact-beams 36, wherein each of the opposed-pair contact-beams 36 have a plurality of outer-contact-points 38 in electrical and physical contact with the female electrical-terminal 14. That is, the outer-contact-points 38 of the contact-spring 32 are in electrical and physical contact with the inner face of the first-sidewall 20 and the inner face of the second-sidewall 22, and each individual contact-beam 36 has at least two contact-points 40 in connection with their respective sidewall (see Fig. 6B ).
  • each of the opposed-pair contact-beams 36 have a plurality of inner-contact-points 42 that are in electrical and physical contact with opposed sides of the male electrical-terminal 16, and each individual contact-beam 36 has at least two contact-points 40 in connection with each face of the male electrical-terminal 16.
  • electrical and physical contact is formed between each contact beam 36, the female electrical-terminal 14, and the male electrical-terminal 16 in at least four separate locations, as illustrated in Figs. 6A-6B .
  • the plurality of opposed-pair contact-beams 36 may be characterized as having a sinusoidally shaped cross-section 44, and the plurality of inner-contact-points 42 and the plurality of outer-contact-points 38 may be characterized as having a rounded shape 46.
  • the contact-beams 36 are formed such that a normal contact-force of between about 2.5 Newtons (2.5 N) to about 8 N is imparted on the male electrical-terminal 16 at each of the contact-points 40 of each individual contact-beam 36.
  • This range of contact-force provides sufficient normal-force to minimize a contact resistance between the male electrical-terminal 16 and the female electrical-terminal 14, while meeting the ergonomic requirements for assemblers.
  • Fig. 5 illustrates the contact-spring 32 spread open to more clearly reveal the geometry of the contact-beams 36, and denotes a bottom-half and top-half for illustration purposes only.
  • the opposed-pair contact-beams 36 are formed such that the inner-contact-points 42 of the contact-beam 36 in the bottom-half lay in a same-plane as the inner-contact-points 42 of the corresponding paired contact-beam 36 in the top-half.
  • This same-plane is illustrated by a dashed-line shown passing through the inner-contact-points 42.
  • the outer-contact-points 38 also lay in a same-plane.
  • the contact-spring 32 may further include a pair of opposing guide-ribs 48 formed in leading-edges of the contact-spring 32.
  • the guide-ribs 48 are configured to engage and align the male electrical-terminal 16 upon insertion into the female electrical-terminal 14 and thereby reduce a transverse-movement of the male electrical-terminal 16 when the male electrical-terminal 16 is in a seated-position 52 (see Fig. 6A).
  • Figs. 6A-6B illustrate the male electrical-terminal 16 as having a planar blade-shaped portion 54 disposed within the female electrical-terminal 14.
  • the guide-ribs 48 are preferably rounded to reduce the potential for gouging any conductive coating on the male electrical-terminal 16.
  • the guide-ribs 48 are preferably a continuous feature to maximize a contact-area between the contact-spring 32 and the male electrical-terminal 16 for both electrical and structural purposes.
  • Fig. 7 illustrates a perspective-view of the male-connector 18 from Fig. 1 .
  • the male electrical-terminal 16 includes the planar blade-shaped portion 54 that is formed of an electrically conductive material (e.g. copper-based alloy) and has two exposed-edges 56 of the planar blade-shaped portion 54 formed of a dielectric material 58.
  • the dielectric material 58 is configured prevent an electrical-shock if a human finger were to contact the exposed-edge 56.
  • the dielectric material 58 formed into the male-connector 18, being integrally formed with a header-wall 60 and a base 62 of the male-connector 18 to increase a strength and a structural rigidity of the dielectric material 58, with the added benefit of increasing a surface area of electrical connection surfaces without increasing a package-size of the male-connector 18.
  • the integration of the dielectric material 58 to the header-wall 60 is possible due to an open-distal-end 64 of the female electrical-terminal 14 (see Fig. 3 ).
  • Figure 8 illustrates an alternative embodiment of a female electrical-terminal 114.
  • the female electrical-terminal 114 further includes a third-sidewall 166 that extends from a medial-edge 168 of the first-sidewall 120 to the medial-zone 130 of the second-sidewall 122 such that the third-sidewall 166 is in electrical and physical communication with the medial-zone 130 of the first-sidewall 120.
  • the third-sidewall 166 provides a more rigid structure to the female electrical-terminal 114 and further provides an additional conductive path, both of which may enable the use of thinner material stock than needed for the female electrical-terminal 14 of Fig. 3 to carry an equivalent electrical current.
  • the third-sidewall 166 may be joined to the medial-zone 130 by a single clinch-rivet 170.
  • Alternative embodiments of the female electrical-terminal 114 may be formed using any of the other known joining methods.
  • the location of the single clinch-rivet 170 in the medial-zone 130 is advantageous because the placement reduces a distortion of the proximal-end 128 of the second-sidewall 122.
  • Fig. 9 illustrates yet another embodiment of a female electrical-terminal 214.
  • the female electrical-terminal 214 is formed of a single piece of electrically conductive material and has a first-sidewall 220, a second-sidewall 222, and a third-sidewall 266.
  • the second-sidewall 222 defines a distal-end 226, a proximal-end 228, and a medial-zone 230 disposed between the distal-end 226 and the proximal-end 228.
  • the first-sidewall 220 is opposite and parallel at the distal-end 226 to the second-sidewall 222.
  • the third-sidewall 266 extends from a medial-edge 268 of the first-sidewall 220 and contacts the second-sidewall 222 from the medial-zone 230 to the proximal-end 228.
  • the third-sidewall 266 is in electrical and physical communication with the first-sidewall 220.
  • the third-sidewall 266 defines a plurality of weld-slots 272 longitudinally extending from the medial-zone 230 to the proximal-end 228.
  • the weld-slots 272 are configured to interface with an electrical-cable (not shown) sonically welded to the female electrical-terminal 214.
  • the weld-slots 272 expose a surface of the second-sidewall 222 and enable the electrical-cable to be sonically welded to both the third-sidewall 266 and the second-sidewall 222.
  • the quantity of the plurality of weld-slots 272 and a dimension of the weld-slots 272 may be varied based on a diameter of the electrical-cable and the material thickness of the female electrical-terminal 214.
  • a high-current electrical connector 10 is provided.
  • the connector 10 is beneficial because the connector 10 increases the number of contact-points 40 between the female electrical-terminal 14 and the male electrical-terminal 16, which may enable a reduction in resistive-heating of the connector 10 during high-current operation.

Landscapes

  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Connector Housings Or Holding Contact Members (AREA)

Claims (7)

  1. Ein elektrischer Hochstromverbinder (10), welcher eine Buchse (12) und einen Steckverbinder (18) umfasst, wobei der Verbinder (10) umfasst:
    einen Buchsenanschluss (14, 114) in der Buchse (12), der dazu ausgebildet ist, einen Steckverbinderanschluss (16) des Steckverbinders (18) aufzunehmen, wobei der Buchsenanschluss (14, 114) aus einem Einzelstück aus einem elektrisch leitenden Material gebildet ist, wobei der Buchsenanschluss (14, 114) eine erste Seitenwand (20, 120) und eine zweite Seitenwand (22, 122) aufweist, wobei die zweite Seitenwand (22, 122) ein distales Ende (26, 126), ein proximales Ende (28, 128) und einen medialen Bereich (30, 130), welcher dazwischen angeordnet ist, definiert, wobei die erste Seitenwand (20, 120) am distalen Ende (26, 126) gegenüber der zweiten Seitenwand (22, 122) und parallel dazu angeordnet ist;
    der Steckverbinderanschluss (16) ein planares blattförmiges Teil (54) umfasst, das aus einem elektrisch leitenden Material gebildet ist; und
    eine Kontaktfeder (32), die aus einem Einzelstück aus einem elektrisch leitenden Material gebildet ist und im Buchsenanschluss (14, 114) zwischen der ersten Seitenwand (20, 120) und der zweiten Seitenwand (22, 122) angeordnet ist, wobei die Kontaktfeder (32) eine Vielzahl von paarweise gegenüberliegenden Kontaktträgern (36) definiert, wobei jeder Kontaktträger aus der Vielzahl von paarweise gegenüberliegenden Kontaktträgern (36) eine Vielzahl von Außenkontaktpunkten (38) und eine Vielzahl von Innenkontaktpunkten (42) aufweist, wobei die Vielzahl von Außenkontaktpunkten (38) im elektrischen und physischen Kontakt mit dem Buchsenanschluss (14, 114) ist, und wobei die Vielzahl von Innenkontaktpunkten (42) im elektrischen und physischen Kontakt mit gegenüberliegenden Seiten des Steckverbinderanschlusses (16) ist, so dass ein elektrischer und physischer Kontakt zwischen dem Kontaktträger (36), dem Buchsenanschluss (14, 114) und dem Steckverbinderanschluss (16) an mindestens vier verschiedenen Stellen gebildet ist;
    dadurch gekennzeichnet, dass der Steckverbinderanschluss (16) zwei sichtbare Kanten (56) des planaren blattförmigen Teils (54) aufweist, die aus einem dielektrischen Material gebildet sind, wobei das dielektrische Material (58) mit einer Kopfwand (60) und einem Boden (62) des Steckverbinders (18) einstückig gebildet ist.
  2. Der elektrische Hochstromverbinder (10) gemäß Anspruch 1, wobei die Vielzahl von paarweise gegenüberliegenden Kontaktträgern (36) dadurch gekennzeichnet ist, dass sie einen sinusförmigen Querschnitt aufweist.
  3. Der elektrische Hochstromverbinder (10) gemäß einem der Ansprüche 1 oder 2, wobei die Vielzahl von Innenkontaktpunkten (42) und die Vielzahl von Außenkontaktpunkten (38) dadurch gekennzeichnet sind, dass sie eine gerundete Form (46) aufweisen.
  4. Der elektrische Hochstromverbinder (10) gemäß einem der Ansprüche 1 bis 3, wobei die Kontaktfeder (32) weiter ein Paar von gegenüberliegenden Führungsrippen (48) umfasst, welche in Vorderkanten der Kontaktfeder (32) gebildet sind, wobei das Paar von gegenüberliegenden Führungsrippen (48) dazu ausgebildet ist, beim Einführen in den Buchsenanschluss (14) in den Steckverbinderanschluss (16) einzugreifen und diesen auszurichten, und dadurch eine Querbewegung des Steckverbinderanschlusses (16) zu reduzieren, wenn der Steckverbinderanschluss (16) in einer Sitzposition (52) ist.
  5. Der elektrische Hochstromverbinder (10) gemäß einem der Ansprüche 1 bis 4, wobei die Kontaktfeder (32) dadurch gekennzeichnet ist, dass sie eine U-Form (34) aufweist.
  6. Der elektrische Hochstromverbinder (10) gemäß einem der Ansprüche 1 bis 5, wobei der Buchsenanschluss (14) weiter eine dritte Seitenwand (166) umfasst, welche sich von einer medialen Kante (168) der ersten Seitenwand (120) bis zum medialen Bereich (168) der zweiten Seitenwand (122) erstreckt, wobei die dritte Seitenwand (166) in elektrischer und physischer Verbindung mit dem medialen Bereich (130) der ersten Seitenwand (120) ist.
  7. Der elektrische Hochstromverbinder (10) gemäß Anspruch 6, wobei die dritte Seitenwand (166) durch einen einzelnen Pressniet (170) mit dem medialen Bereich (130) der zweiten Seitenwand (122) verbunden ist.
EP18198056.6A 2017-10-04 2018-10-01 Elektrischer hochstromverbinder Active EP3467949B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US15/724,682 US10230191B2 (en) 2017-08-01 2017-10-04 High-current electrical connector with multi-point contact spring

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EP3467949B1 true EP3467949B1 (de) 2021-04-21

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110265815A (zh) * 2019-06-21 2019-09-20 陈丽霞 一种弯头连接器插孔
CN113612050B (zh) * 2020-05-05 2023-01-10 泰连服务有限公司 具有相等法向力的多个接触点的电触头
CN112072358B (zh) * 2020-08-21 2022-05-20 乐清市八达光电科技股份有限公司 一种多重接触大电流弹性端子及具有其的连接器
US20230387619A1 (en) * 2022-05-24 2023-11-30 Aptiv Technologies Limited High voltage electrical terminal with compliant contact insert

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Publication number Priority date Publication date Assignee Title
US5588884A (en) * 1995-09-08 1996-12-31 Packard Hughes Interconnect Company Stamped and formed contacts for a power connector
US6416340B2 (en) * 2000-05-04 2002-07-09 Christopher E. Schaefer Single blade terminal power connector system
US6692316B2 (en) * 2002-04-16 2004-02-17 Delphi Technologies, Inc. High current terminal blade type sealed connection system
EP2451016B1 (de) * 2009-07-03 2018-11-21 Yazaki Corporation Buchsenanschlussstück
CN201498702U (zh) * 2009-08-31 2010-06-02 东莞大朗金准电器厂 一种改良的卤素灯座端子
US8419486B2 (en) * 2010-12-17 2013-04-16 Tyco Electronics Corporation Receptacle terminal with a contact spring

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CN109616808A (zh) 2019-04-12
EP3467949A1 (de) 2019-04-10

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