US20220368052A1 - High voltage (hv) terminal frame - Google Patents
High voltage (hv) terminal frame Download PDFInfo
- Publication number
- US20220368052A1 US20220368052A1 US17/741,938 US202217741938A US2022368052A1 US 20220368052 A1 US20220368052 A1 US 20220368052A1 US 202217741938 A US202217741938 A US 202217741938A US 2022368052 A1 US2022368052 A1 US 2022368052A1
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- Prior art keywords
- terminal frame
- spring
- terminal
- assembly
- bus bar
- Prior art date
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- 239000000463 material Substances 0.000 claims description 30
- 239000010935 stainless steel Substances 0.000 claims description 8
- 229910001220 stainless steel Inorganic materials 0.000 claims description 8
- 230000000712 assembly Effects 0.000 description 9
- 238000000429 assembly Methods 0.000 description 9
- 230000000717 retained effect Effects 0.000 description 4
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 238000003780 insertion Methods 0.000 description 3
- 230000037431 insertion Effects 0.000 description 3
- 229910000677 High-carbon steel Inorganic materials 0.000 description 2
- 238000007373 indentation Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
Images
Classifications
-
- 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
-
- 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
- H01R13/10—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
- 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
- H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
-
- 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
- H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
-
- 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
- H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
- H01R13/42—Securing in a demountable manner
Definitions
- the present disclosure is directed to a high voltage terminal frame and in particular to a two-piece high voltage terminal frame.
- High voltage terminal frames include a rigid outer housing and a more compliant contact spring.
- the rigid outer housing is separate from the more compliant contact spring, made of different materials, and requiring assembly at manufacture.
- This type of HV frame is a two-piece assembly.
- a conductive bus bar is crimped to the rigid outer housing, resulting in a three-piece assembly. It would be beneficial to develop a high voltage terminal frame that provides the same functionality but that does not require separate components for the rigid outer housing and the more compliant contact spring.
- a two-piece high voltage (HV) terminal frame includes a terminal frame and a contact spring.
- the terminal frame includes at least a top portion, a bottom portion, and a middle portion forming an opening for receiving a first bus bar and a second bus bar.
- the contact spring is configured to engage the top portion of the terminal frame, wherein the contact spring includes a spring portion that extends into the opening of the terminal frame.
- a header assembly includes a housing assembly, a two-piece terminal assembly, and a terminal position assurance (TPA).
- the housing assembly includes at least a first opening for receiving a bus bar.
- the two-piece terminal assembly includes a terminal frame and a contact spring engaged with the terminal frame, wherein the two-piece terminal assembly is positioned within the housing assembly.
- the terminal position assurance (TPA) positioned within the housing assembly adjacent to the two-piece terminal assembly.
- FIG. 1A is an isometric view of a high voltage (HV) terminal assembly according to some embodiments
- FIG. 1B is an isometric view of a high voltage (HV) terminal assembly with an outer covering removed illustrate a high voltage (HV) terminal frame according to some embodiments.
- FIG. 2 is a cross-sectional view of a header assembly associated with the HV terminal assembly according to some embodiments.
- FIG. 3A is an isometric view of a terminal assembly with installed spring contact according to some embodiments
- FIG. 3B is a side view of the terminal assembly with installed spring contact according to some embodiments.
- FIG. 4A is a cross-sectional view of a header assembly positioned to receive a header side bus bar according to some embodiments
- FIG. 4B is a cross-sectional view of the header assembly that includes the header side bus bar in the installed position according to some embodiments.
- FIGS. 5A and 5B are isometric views of a bi-directional pass-thru terminal assembly according to some embodiments.
- FIG. 6 is an exploded view of a bi-directional pass-thru header assembly that utilizes the bi-directional pass-thru terminal assembly shown in FIGS. 5A and 5B according to some embodiments.
- FIG. 7 is an isometric view of a bi-directional pass-thru header assembly according to some embodiments.
- the present invention is directed to a high voltage (HV) terminal assembly.
- the HV terminal assembly is a two-part assembly that includes a terminal frame and a spring contact, wherein the spring contact is configured to engage with the terminal frame.
- the terminal frame is fabricated from a first piece of material (e.g., stainless steel) having a first thickness and the spring contact is fabricated form a second piece of material (e.g., stainless steel) having a second thickness less than the first thickness.
- a first piece of material e.g., stainless steel
- the spring contact is fabricated form a second piece of material (e.g., stainless steel) having a second thickness less than the first thickness.
- a HV terminal assembly 100 that utilizes a pair of header assemblies 108 a , 108 b .
- the HV terminal assembly 100 is a right-angle assembly.
- Terminal ports 102 a , 102 b are configured to receive a corresponding terminal (not shown) in a first longitudinal or horizontal direction.
- Conductive bus bars 104 a , 104 b (referred to as a connector side bus bar) extends in a vertical direction at a right-angle to the direction of connection associated with the terminal ports 102 a , 102 b.
- a portion of the housing associated with the HV terminal assembly 100 is removed to expose the header assemblies 108 a , 108 b .
- a connector side bus bar 106 a , 106 b extends longitudinally from the header assemblies 108 a , 108 b , respectively.
- the header side bus bars 104 a , 104 b extend in a downward direction from the header assemblies 108 a , 108 b .
- the header side bus bars 104 a , 104 b are pass through bus bars that do not require crimping of the bus bars to the header assemblies 108 a , 108 b , respective.
- the connector side bus bar 106 a , 106 b is slid downward into the header assemblies 108 a , 108 b , respectively, and is pressed into contact with the header side bus bars 104 a , 104 b , respectively, by contact springs ( 126 , shown in FIGS. 3A and 3B ).
- each terminal assembly 114 is a two-piece assembly, including a terminal frame 116 and a contact spring 118 , described in more detail with respect to FIGS. 3A and 3B .
- header assembly 108 a includes a housing assembly 110 a , terminal assembly 114 a , and terminal position assurance (TPA) 112 a .
- terminal assembly 114 a is located within housing assembly 110 a .
- header side bus bar 104 a is positioned within housing assembly 110 a and is retained by terminal assembly 114 a .
- An opening or port 115 a is configured to receive the connector side bus bar 106 a (shown in FIG. 1A ), which is retained in place by terminal assembly 114 a .
- the contact spring 118 is configured to exert a normal force on the connector side bus bar 106 a that urges the connector side bus bar 106 a into contact with the header side bus bar 104 a .
- TPA 112 a is configured to be placed within the housing assembly 110 a , which engages with terminal assembly 114 a within housing assembly 110 a .
- TPA 112 a includes a lock feature (not shown) that engages with the housing assembly 110 a to lock the TPA 112 a into place within the housing assembly 110 a .
- the header assembly 108 b includes a housing assembly 110 b , terminal assembly 114 b , and terminal position assurance (TPA) 112 b.
- FIGS. 3A and 3B illustrate the terminal assembly 114 a , which is a two-piece assembly that includes terminal frame 116 and contact spring 118 .
- Terminal assembly 114 a includes an opening.
- the spring portion 126 of contact spring 118 extends into the opening, wherein the opening is configured to receive header side bus bar 104 a and connector side bus bar 106 a (as shown in FIGS. 1A and 1B ).
- the spring portion 126 of contact spring 118 is brought into contact with the connector side bus bar 106 a and urges the connector side bus bar 106 a into contact with the header side bus bar 104 a (as shown in more detail in FIGS. 4A and 4B ).
- terminal frame 116 is fabricated from a single piece of material having a first uniform thickness folded into the desired shape.
- contact spring 118 is fabricated from a single piece of material having a second uniform thickness folded into a desired shape, wherein the second thickness is less than the first thickness.
- the terminal frame 116 and the contact spring 118 are fabricated from the same material (e.g., stainless steel), wherein characteristics such as rigidity of the terminal frame 116 and the contact spring 118 are selected based on the thickness of the respective components.
- the terminal frame 116 and the contact spring 118 may be fabricated using different materials.
- the terminal frame 116 may be fabricated from a high carbon steel, wherein the contact spring 118 may be fabricated from stainless steel.
- the terminal frame 116 is “C-shaped” and includes a top portion 132 , a middle portion 134 , and a bottom portion 136 , wherein the top portion 132 and the bottom portion 136 are parallel to one another.
- the middle portion 134 is transverse to the top portion 132 and the bottom portion 136 and connects the top portion 132 and the bottom portion 136 .
- the top portion 132 , the middle portion 134 and the bottom portion 136 form the opening configured to receive the connector side bus bar 106 and the header side bus bar 104 .
- the top portion 132 is configured to receive and capture the contact spring 118 , wherein the spring portion 126 extends into the opening and is configured to exert a normal force on the connector side bus bar 106 to urge the connector side bus bar 106 into contact with the header side bus bar 104 .
- the bottom portion 136 of the terminal frame 116 includes a stop feature 142 , a front guide feature 138 and a side guide feature 140 .
- the stop feature 142 defines the maximum extent the header side bus bar 104 can extend into the terminal frame 116 .
- the side guide feature 140 and the front guide feature 138 aid in guiding the header side bus bar 104 into the opening of the terminal frame 116 .
- the front guide feature 138 interacts with an overlapping feature 150 (shown in FIGS. 4A and 4B ) of the TPA 112 a to ensure the terminal frame 116 is properly positioned within the housing 110 .
- contact spring 118 is also “C-shaped” having a first portion 120 , a middle portion 122 and a second portion 124 .
- the first portion 120 and the second portion 124 are configured to engage with the terminal frame 116 , wherein the spring portion 126 extends into an opening provided within the terminal assembly 114 a .
- the first portion 120 and the second portion 124 wrap around the top portion 132 of terminal frame 116 , and prevent the contact spring 118 from moving forward or backward relative to the terminal frame 116 .
- contact spring 118 also includes a cut-out portion 128 located within the middle portion 122 and a spring 130 formed within the cut-out portion 128 .
- the spring 130 bends or flexes toward the terminal frame 116 .
- the spring 130 bends or flexes against the top surface of the terminal frame 116 .
- a groove or channel (not shown) formed on the top surface of the terminal frame 116 is configured to receive and capture the spring 130 when the contact spring 118 is fully engaged with the terminal frame 116 . The engagement of the spring 130 with the groove or channel (not shown) of the terminal frame 116 prevents the contact spring 118 from sliding relative to the terminal frame 116 .
- FIGS. 4A and 4B are cross-sectional views that illustrate insertion of a header side bus bar 104 b into the header assembly 108 b .
- the contact spring 118 is installed on the terminal frame 116
- the terminal assembly 114 b is installed within the housing assembly 110 b .
- TPA 112 b is installed within the housing assembly 110 b and pushed into engagement with the terminal frame 116 to ensure the terminal frame 116 is properly positioned (e.g., seated) within the housing assembly 110 b .
- an overlapping feature 152 associated with the TPA 112 b engages with the front guide feature 138 of the terminal frame 116 to ensure terminal frame 116 is properly positioned/seated within the housing assembly 110 b .
- TPA 112 b includes a locking feature (not shown) that engages with the housing assembly 110 b to ensure the TPA 112 b (as well as terminal assembly 114 b ) is properly positioned/seated within the housing assembly 110 b.
- the header side bus bar 104 b is inserted within the header assembly 108 b .
- the front guide feature 138 and the side guide feature 140 associated with the terminal frame 116 act to guide the header side bus bar 104 b into place within the terminal frame 116 .
- the stop feature 142 associated with the terminal frame 116 is configured to receive the header side bus bar 104 b . Having positioned the header side bus bar 104 b within the header assembly 108 b , a connector side bus bar 106 b may be inserted into the opening 115 b on the header assembly 108 b .
- the connector side bus bar 106 b interacts with and compresses spring portion 126 of contact spring 118 .
- the compression of the spring portion 126 generates a normal force on the connector side bus bar 106 b that presses the connector side bus bar 106 b into contact with the header side bus bar 104 b.
- FIGS. 5A and 5B illustrate the terminal assembly 514 , which is a two-piece assembly that includes terminal frame 516 and contact spring 518 .
- Terminal assembly 514 includes an opening for receiving connector side bus bars 606 a and 606 b (shown in FIG. 6 ).
- terminal assembly 514 is configured to receive one of connector side bus bar 606 a or 606 b , not both simultaneously.
- the contact spring 518 includes first spring portion 526 a and second spring portion 526 b that each extend into the opening of the terminal assembly 514 .
- At least one of the spring portions 526 a and 526 b of contact spring 518 is brought into contact with one of the respective connector side bus bars 606 a and/or 606 b and urges the particular connector side bus bar 606 a and/or 606 b into contact with the header side bus bar 604 (as shown in more detail in FIGS. 6 and 7 ).
- a benefit of this design is that the header assembly 608 (shown in FIG. 6 ) may receive connector side bus bars from more than one direction, making the header assembly 608 capable of use in different applications requiring different orientations of the connector side bus bar.
- terminal frame 516 is fabricated from a single piece of material having a first uniform thickness folded into the desired shape.
- contact spring 518 is fabricated from a single piece of material having a second uniform thickness folded into a desired shape, wherein the second thickness is less than the first thickness.
- One benefit of a two-piece terminal assembly wherein the thickness of the material forming the terminal frame 516 is greater than the thickness of the material forming the contact spring 518 is the greater thickness of the terminal frame 516 provides improved rigidity as compared with the contact spring 518 .
- the contact spring 518 and in particular the spring portions 526 a and 526 b — is more flexible due to the thickness of the contact spring.
- the terminal frame 516 and the contact spring 518 are fabricated from the same material (e.g., stainless steel), wherein characteristics such as rigidity of the terminal frame 516 and the contact spring 518 are selected based on the thickness of the respective components.
- the terminal frame 516 and the contact spring 518 may be fabricated using different materials.
- the terminal frame 516 may be fabricated from a high carbon steel, wherein the contact spring 518 may be fabricated from stainless steel.
- the terminal frame 516 is “C-shaped” and includes a top portion 532 , a middle portion 534 , and a bottom portion 536 , wherein the top portion 532 and the bottom portion 536 are parallel to one another.
- the middle portion 534 is transverse to the top portion 532 and the bottom portion 536 and connects the top portion 532 and the bottom portion 536 .
- the top portion 532 , the middle portion 534 and the bottom portion 536 form the opening configured to receive one or both of the connector side bus bars 606 a and 606 b and the header side bus bar 604 (shown in FIGS. 6 and 7 ).
- the terminal frame 516 includes an aperture 535 formed along the bottom portion 536 that is configured to receive the header side bus bar 604 (shown in FIGS. 6 and 7 ).
- the header assembly is uni-directional in that the connector side bus bar is affixed to the header assembly 108 from only a single direction.
- the terminal frame 116 is oriented such that the opening of the terminal frame 116 accepts both the connector side bus bar 106 and the header side bus bar 104 .
- the terminal frame 516 in the bi-directional design shown in FIGS. 5A, 5B, 6, and 7 is oriented to allow bi-directional connection of connector side bus bars 606 a and 606 b .
- the terminal frame 516 includes aperture 535 to allow the header side bus bar 604 to be positioned within the terminal frame 516 .
- the top portion 532 is configured to receive and capture the contact spring 518 , wherein the spring portions 526 a and 526 b extend into the opening and are configured to exert a normal force on the connector side bus bars 606 a and 606 b , respectively, to urge the respective connector side bus bars 606 a and 606 b into contact with the header side bus bar 604 .
- the contact spring 518 includes only a single spring portion 526 rather than two sprint portions 526 a , 526 b . That is, in some embodiments regardless of the direction of the connector side bus bar 606 the single sprint portion 526 is brought into contact with the connector side bus bar 606 .
- the bottom portion 636 of the terminal frame 616 may include a stop feature (not shown), a front guide feature (not shown) and a side guide feature (not shown) similar to that described with respect to FIGS. 3A and 3B .
- contact spring 518 is also “C-shaped” having a first portion 520 , a middle portion 522 and a second portion 524 .
- the first portion 520 and the second portion 524 are configured to engage with the terminal frame 516 and in particular with the top portion 532 of the terminal frame 516 .
- the spring portions 526 a , 526 b extends into an opening provided within the terminal assembly 514 . As described above, in some embodiments only a single spring portion 526 is utilized rather than two separate spring portions 526 a , 526 b . As shown in FIGS.
- contact spring 518 also includes a cut-out portion 528 located within the middle portion 522 and a spring 530 formed within the cut-out portion 528 .
- the spring 530 bends or flexes toward the terminal frame 516 .
- a groove or channel (not shown) formed on the top surface 532 of the terminal frame 516 is configured to receive and capture the spring 530 when the contact spring 518 is fully engaged with the terminal frame 516 .
- the engagement of the spring 530 with the groove or channel (not shown) of the terminal frame 516 prevents the contact spring 518 from sliding relative to the terminal frame 516 .
- terminal frame 516 is configured for use in a bi-directional HV terminal assembly, in which connector side bus bars 606 a and 606 b may be positioned from either side of the HV terminal assembly.
- the spring portions 526 a and 526 b are configured to extend toward the middle portion 534 of the terminal frame 516 .
- the orientation of the spring portions 526 a and 526 b within the opening of the terminal frame 516 allows the connector side bus bars 506 a and 506 b to be inserted vertically (i.e., from the top) into the terminal frame 516 (as shown in FIGS. 6 and 7 ).
- FIGS. 6 and 7 exploded and assembly views of the bi-directional header assembly 608 are provided.
- the exploded view shown in FIG. 6 illustrates assembly of the housing 610 , the terminal assembly 514 and the terminal retainer 612 as part of the bi-directional header assembly 608 , with the assembled version shown in FIG. 7 .
- the contact spring 518 is installed on the terminal frame 516
- the terminal assembly 514 is installed within the housing assembly 610 .
- terminal retainer 612 is installed within the housing assembly 610 and pushed into engagement with the terminal frame 516 to ensure the terminal frame 516 is properly positioned (e.g., seated) within the housing assembly 610 .
- an overlapping feature (not shown) associated with the terminal retainer 612 engages with the terminal frame 516 to ensure terminal frame 516 is properly positioned/seated within the housing assembly 610 .
- terminal retainer 612 includes a locking feature (not shown) that engages with the housing assembly 610 to ensure the terminal retainer 612 (as well as terminal assembly 514 ) is properly positioned/seated within the housing assembly 610 .
- the terminal frame 516 is retained in place by the terminal retainer 612 , wherein the terminal frame 516 does not require features to retain the terminal frame 516 within the housing assembly 610 .
- the header side bus bar 604 is inserted within the header assembly 608 .
- the header side bus bar 604 is inserted from below the header assembly 608 and is inserted through the terminal retainer 612 and into the terminal frame 514 . In some embodiments, this allows the header assembly 608 to be mounted over the top of a header side bus bar 604 , wherein the header side bus bar 608 is then moved into position within the header assembly 608 . In some embodiments, the header side bus bar 604 is retained and locked in place by the terminal retainer 612 .
- the position of the header side bus bar 604 is maintained by the terminal retainer 612 , but is not locked in place by the terminal retainer 612 .
- connector side bus bars 606 a and 606 b may be inserted into the opening 615 on the header assembly 608 .
- connector side bus bar 606 a is provided from a first direction and connector side bus bar 606 b is provided from a second direction opposite the first. In this way, the header assembly 608 is bi-directional.
- the insertion of the connector side bus bar 606 a into the opening 615 causes compression of the spring portion 526 a , which in response generates a normal force on the connector side bus bar 606 a that presses the connector side bus bar 606 a into contact with the header side bus bar 604 .
- the insertion of the connector side bus bar 606 b into the opening 615 causes compression of the spring portion 526 b , which in response generates a normal force on the connector side bus bar 606 b that presses the connector side bus bar 606 b into contact with the header side bus bar 604 .
- connector side bus bars 606 a and 606 b include indentations 620 a and 620 b , respectively, for receiving the spring portions 526 a and 526 b , respectively. Engagement of the indentations 620 a and 620 b with the spring portions 526 a and 526 b prevents the connector side bus bars 606 a and 606 b from moving within the header assembly 608 .
- the terminal assembly 514 shown in FIGS. 6 and 7 are oriented to allow connector side bus bars 606 a and 606 b to extend bi-directionally from the header assembly 608 .
- wires 622 a and 622 b and corresponding connector side bus bars 606 a and 606 b extend in opposite directions from the header assembly 608 .
Abstract
Description
- This patent application claims the benefit of U.S. Provisional Application No. 63/187,588, filed May 12, 2021 and U.S. Provisional Application No. 63/195,785 filed Jun. 2, 2021, both of which are incorporated by reference in their entirety.
- The present disclosure is directed to a high voltage terminal frame and in particular to a two-piece high voltage terminal frame.
- High voltage terminal frames include a rigid outer housing and a more compliant contact spring. Typically, the rigid outer housing is separate from the more compliant contact spring, made of different materials, and requiring assembly at manufacture. This type of HV frame is a two-piece assembly. In some embodiments, a conductive bus bar is crimped to the rigid outer housing, resulting in a three-piece assembly. It would be beneficial to develop a high voltage terminal frame that provides the same functionality but that does not require separate components for the rigid outer housing and the more compliant contact spring.
- According to one aspect, a two-piece high voltage (HV) terminal frame includes a terminal frame and a contact spring. The terminal frame includes at least a top portion, a bottom portion, and a middle portion forming an opening for receiving a first bus bar and a second bus bar. The contact spring is configured to engage the top portion of the terminal frame, wherein the contact spring includes a spring portion that extends into the opening of the terminal frame.
- According to another aspect, a header assembly includes a housing assembly, a two-piece terminal assembly, and a terminal position assurance (TPA). The housing assembly includes at least a first opening for receiving a bus bar. The two-piece terminal assembly includes a terminal frame and a contact spring engaged with the terminal frame, wherein the two-piece terminal assembly is positioned within the housing assembly. The terminal position assurance (TPA) positioned within the housing assembly adjacent to the two-piece terminal assembly.
-
FIG. 1A is an isometric view of a high voltage (HV) terminal assembly according to some embodiments; andFIG. 1B is an isometric view of a high voltage (HV) terminal assembly with an outer covering removed illustrate a high voltage (HV) terminal frame according to some embodiments. -
FIG. 2 is a cross-sectional view of a header assembly associated with the HV terminal assembly according to some embodiments. -
FIG. 3A is an isometric view of a terminal assembly with installed spring contact according to some embodiments;FIG. 3B is a side view of the terminal assembly with installed spring contact according to some embodiments. -
FIG. 4A is a cross-sectional view of a header assembly positioned to receive a header side bus bar according to some embodiments;FIG. 4B is a cross-sectional view of the header assembly that includes the header side bus bar in the installed position according to some embodiments. -
FIGS. 5A and 5B are isometric views of a bi-directional pass-thru terminal assembly according to some embodiments. -
FIG. 6 is an exploded view of a bi-directional pass-thru header assembly that utilizes the bi-directional pass-thru terminal assembly shown inFIGS. 5A and 5B according to some embodiments. -
FIG. 7 is an isometric view of a bi-directional pass-thru header assembly according to some embodiments. - According to some aspects, the present invention is directed to a high voltage (HV) terminal assembly. In some embodiments, the HV terminal assembly is a two-part assembly that includes a terminal frame and a spring contact, wherein the spring contact is configured to engage with the terminal frame. In some embodiments, the terminal frame is fabricated from a first piece of material (e.g., stainless steel) having a first thickness and the spring contact is fabricated form a second piece of material (e.g., stainless steel) having a second thickness less than the first thickness. As a result, the terminal frame provides more rigidity as compared with the spring contact, as desired.
- Referring now to
FIGS. 1A-1B , aHV terminal assembly 100 is provided that utilizes a pair ofheader assemblies HV terminal assembly 100 is a right-angle assembly.Terminal ports Conductive bus bars terminal ports - In the embodiment shown in
FIG. 1B , a portion of the housing associated with theHV terminal assembly 100 is removed to expose theheader assemblies side bus bar header assemblies side bus bars header assemblies side bus bars header assemblies side bus bar header assemblies side bus bars FIGS. 3A and 3B ). - Referring now to
FIGS. 2 through 4B , various views of theheader assemblies terminal assemblies respective header assemblies terminal frame 116 and acontact spring 118, described in more detail with respect toFIGS. 3A and 3B . - In the embodiment shown in
FIG. 2 ,header assembly 108 a includes ahousing assembly 110 a,terminal assembly 114 a, and terminal position assurance (TPA) 112 a. Referring toheader assembly 108 a,terminal assembly 114 a is located withinhousing assembly 110 a. In the embodiment shown inFIG. 2 , headerside bus bar 104 a is positioned withinhousing assembly 110 a and is retained byterminal assembly 114 a. An opening orport 115 a is configured to receive the connectorside bus bar 106 a (shown inFIG. 1A ), which is retained in place byterminal assembly 114 a. In particular, as described with respect toFIGS. 3A and 3B , thecontact spring 118 is configured to exert a normal force on the connectorside bus bar 106 a that urges the connectorside bus bar 106 a into contact with the headerside bus bar 104 a. In some embodiments, TPA 112 a is configured to be placed within thehousing assembly 110 a, which engages withterminal assembly 114 a withinhousing assembly 110 a. In some embodiments, TPA 112 a includes a lock feature (not shown) that engages with thehousing assembly 110 a to lock theTPA 112 a into place within thehousing assembly 110 a. Likewise, theheader assembly 108 b includes ahousing assembly 110 b,terminal assembly 114 b, and terminal position assurance (TPA) 112 b. -
FIGS. 3A and 3B illustrate theterminal assembly 114 a, which is a two-piece assembly that includesterminal frame 116 andcontact spring 118.Terminal assembly 114 a includes an opening. Thespring portion 126 ofcontact spring 118 extends into the opening, wherein the opening is configured to receive headerside bus bar 104 a and connectorside bus bar 106 a (as shown inFIGS. 1A and 1B ). As described above, thespring portion 126 ofcontact spring 118 is brought into contact with the connectorside bus bar 106 a and urges the connectorside bus bar 106 a into contact with the headerside bus bar 104 a (as shown in more detail inFIGS. 4A and 4B ). - In some embodiments,
terminal frame 116 is fabricated from a single piece of material having a first uniform thickness folded into the desired shape. In some embodiments,contact spring 118 is fabricated from a single piece of material having a second uniform thickness folded into a desired shape, wherein the second thickness is less than the first thickness. One benefit of a two-piece terminal assembly wherein the thickness of the material forming theterminal frame 116 is greater than the thickness of the material forming thecontact spring 118 is the greater thickness of theterminal frame 116 provides improved rigidity as compared with thecontact spring 118. Likewise, thecontact spring 118—and in particular thespring portion 126—is more flexible due to the thickness of the contact spring. In some embodiments, theterminal frame 116 and thecontact spring 118 are fabricated from the same material (e.g., stainless steel), wherein characteristics such as rigidity of theterminal frame 116 and thecontact spring 118 are selected based on the thickness of the respective components. In other embodiments, theterminal frame 116 and thecontact spring 118 may be fabricated using different materials. For example, theterminal frame 116 may be fabricated from a high carbon steel, wherein thecontact spring 118 may be fabricated from stainless steel. In some embodiments, theterminal frame 116 is “C-shaped” and includes atop portion 132, amiddle portion 134, and abottom portion 136, wherein thetop portion 132 and thebottom portion 136 are parallel to one another. Themiddle portion 134 is transverse to thetop portion 132 and thebottom portion 136 and connects thetop portion 132 and thebottom portion 136. Thetop portion 132, themiddle portion 134 and thebottom portion 136 form the opening configured to receive the connector side bus bar 106 and the header side bus bar 104. In some embodiments, thetop portion 132 is configured to receive and capture thecontact spring 118, wherein thespring portion 126 extends into the opening and is configured to exert a normal force on the connector side bus bar 106 to urge the connector side bus bar 106 into contact with the header side bus bar 104. In some embodiments, thebottom portion 136 of theterminal frame 116 includes astop feature 142, afront guide feature 138 and aside guide feature 140. Thestop feature 142 defines the maximum extent the header side bus bar 104 can extend into theterminal frame 116. Theside guide feature 140 and thefront guide feature 138 aid in guiding the header side bus bar 104 into the opening of theterminal frame 116. In addition, thefront guide feature 138 interacts with an overlapping feature 150 (shown inFIGS. 4A and 4B ) of theTPA 112 a to ensure theterminal frame 116 is properly positioned within the housing 110. - In some embodiments,
contact spring 118 is also “C-shaped” having afirst portion 120, amiddle portion 122 and asecond portion 124. Thefirst portion 120 and thesecond portion 124 are configured to engage with theterminal frame 116, wherein thespring portion 126 extends into an opening provided within theterminal assembly 114 a. As shown inFIG. 3B , thefirst portion 120 and thesecond portion 124 wrap around thetop portion 132 ofterminal frame 116, and prevent thecontact spring 118 from moving forward or backward relative to theterminal frame 116. In some embodiment,contact spring 118 also includes a cut-outportion 128 located within themiddle portion 122 and aspring 130 formed within the cut-outportion 128. In some embodiments, thespring 130 bends or flexes toward theterminal frame 116. During installation of thecontact spring 118 onto theterminal frame 116—which requires sliding thecontact spring 118 over theterminal frame 116—thespring 130 bends or flexes against the top surface of theterminal frame 116. A groove or channel (not shown) formed on the top surface of theterminal frame 116 is configured to receive and capture thespring 130 when thecontact spring 118 is fully engaged with theterminal frame 116. The engagement of thespring 130 with the groove or channel (not shown) of theterminal frame 116 prevents thecontact spring 118 from sliding relative to theterminal frame 116. -
FIGS. 4A and 4B are cross-sectional views that illustrate insertion of a headerside bus bar 104 b into theheader assembly 108 b. As shown inFIG. 4A , thecontact spring 118 is installed on theterminal frame 116, and theterminal assembly 114 b is installed within thehousing assembly 110 b. In some embodiments,TPA 112 b is installed within thehousing assembly 110 b and pushed into engagement with theterminal frame 116 to ensure theterminal frame 116 is properly positioned (e.g., seated) within thehousing assembly 110 b. In some embodiments, an overlapping feature 152 associated with theTPA 112 b engages with thefront guide feature 138 of theterminal frame 116 to ensureterminal frame 116 is properly positioned/seated within thehousing assembly 110 b. In some embodiments,TPA 112 b includes a locking feature (not shown) that engages with thehousing assembly 110 b to ensure theTPA 112 b (as well asterminal assembly 114 b) is properly positioned/seated within thehousing assembly 110 b. - Having inserted the
terminal assembly 114 b and theTPA 112 b within thehousing assembly 110 b, the headerside bus bar 104 b is inserted within theheader assembly 108 b. In some embodiments, thefront guide feature 138 and theside guide feature 140 associated with theterminal frame 116 act to guide the headerside bus bar 104 b into place within theterminal frame 116. Likewise, the stop feature 142 associated with theterminal frame 116 is configured to receive the headerside bus bar 104 b. Having positioned the headerside bus bar 104 b within theheader assembly 108 b, a connectorside bus bar 106 b may be inserted into theopening 115 b on theheader assembly 108 b. Once inserted, the connectorside bus bar 106 b interacts with and compressesspring portion 126 ofcontact spring 118. The compression of thespring portion 126 generates a normal force on the connectorside bus bar 106 b that presses the connectorside bus bar 106 b into contact with the headerside bus bar 104 b. -
FIGS. 5A and 5B illustrate theterminal assembly 514, which is a two-piece assembly that includesterminal frame 516 andcontact spring 518.Terminal assembly 514 includes an opening for receiving connector side bus bars 606 a and 606 b (shown inFIG. 6 ). Typically,terminal assembly 514 is configured to receive one of connectorside bus bar contact spring 518 includesfirst spring portion 526 a andsecond spring portion 526 b that each extend into the opening of theterminal assembly 514. As described above, at least one of thespring portions contact spring 518 is brought into contact with one of the respective connector side bus bars 606 a and/or 606 b and urges the particular connectorside bus bar 606 a and/or 606 b into contact with the header side bus bar 604 (as shown in more detail inFIGS. 6 and 7 ). A benefit of this design is that the header assembly 608 (shown inFIG. 6 ) may receive connector side bus bars from more than one direction, making theheader assembly 608 capable of use in different applications requiring different orientations of the connector side bus bar. - In some embodiments,
terminal frame 516 is fabricated from a single piece of material having a first uniform thickness folded into the desired shape. In some embodiments,contact spring 518 is fabricated from a single piece of material having a second uniform thickness folded into a desired shape, wherein the second thickness is less than the first thickness. One benefit of a two-piece terminal assembly wherein the thickness of the material forming theterminal frame 516 is greater than the thickness of the material forming thecontact spring 518 is the greater thickness of theterminal frame 516 provides improved rigidity as compared with thecontact spring 518. Likewise, thecontact spring 518—and in particular thespring portions terminal frame 516 and thecontact spring 518 are fabricated from the same material (e.g., stainless steel), wherein characteristics such as rigidity of theterminal frame 516 and thecontact spring 518 are selected based on the thickness of the respective components. In other embodiments, theterminal frame 516 and thecontact spring 518 may be fabricated using different materials. For example, theterminal frame 516 may be fabricated from a high carbon steel, wherein thecontact spring 518 may be fabricated from stainless steel. In some embodiments, theterminal frame 516 is “C-shaped” and includes atop portion 532, amiddle portion 534, and abottom portion 536, wherein thetop portion 532 and thebottom portion 536 are parallel to one another. Themiddle portion 534 is transverse to thetop portion 532 and thebottom portion 536 and connects thetop portion 532 and thebottom portion 536. Thetop portion 532, themiddle portion 534 and thebottom portion 536 form the opening configured to receive one or both of the connector side bus bars 606 a and 606 b and the header side bus bar 604 (shown inFIGS. 6 and 7 ). In some embodiments, theterminal frame 516 includes anaperture 535 formed along thebottom portion 536 that is configured to receive the header side bus bar 604 (shown inFIGS. 6 and 7 ). In the embodiments shown inFIGS. 2-4B , the header assembly is uni-directional in that the connector side bus bar is affixed to the header assembly 108 from only a single direction. As a result of being uni-directional, theterminal frame 116 is oriented such that the opening of theterminal frame 116 accepts both the connector side bus bar 106 and the header side bus bar 104. In contrast, theterminal frame 516 in the bi-directional design shown inFIGS. 5A, 5B, 6, and 7 is oriented to allow bi-directional connection of connector side bus bars 606 a and 606 b. Theterminal frame 516 includesaperture 535 to allow the headerside bus bar 604 to be positioned within theterminal frame 516. - In some embodiments, the
top portion 532 is configured to receive and capture thecontact spring 518, wherein thespring portions side bus bar 604. In some embodiments, thecontact spring 518 includes only a single spring portion 526 rather than twosprint portions FIGS. 3A and 3B . - In some embodiments,
contact spring 518 is also “C-shaped” having afirst portion 520, amiddle portion 522 and asecond portion 524. Thefirst portion 520 and thesecond portion 524 are configured to engage with theterminal frame 516 and in particular with thetop portion 532 of theterminal frame 516. In some embodiments, thespring portions terminal assembly 514. As described above, in some embodiments only a single spring portion 526 is utilized rather than twoseparate spring portions FIGS. 5A and 5B , thefirst portion 520 and thesecond portion 524 wrap around thetop portion 532 ofterminal frame 516, and prevent thecontact spring 518 from moving forward or backward relative to theterminal frame 516. In some embodiment,contact spring 518 also includes a cut-outportion 528 located within themiddle portion 522 and aspring 530 formed within the cut-outportion 528. In some embodiments, thespring 530 bends or flexes toward theterminal frame 516. During installation of thecontact spring 518 onto theterminal frame 516—which requires sliding thecontact spring 518 over theterminal frame 516—thespring 530 bends or flexes against thetop surface 532 of theterminal frame 516. A groove or channel (not shown) formed on thetop surface 532 of theterminal frame 516 is configured to receive and capture thespring 530 when thecontact spring 518 is fully engaged with theterminal frame 516. The engagement of thespring 530 with the groove or channel (not shown) of theterminal frame 516 prevents thecontact spring 518 from sliding relative to theterminal frame 516. - In some embodiments,
terminal frame 516 is configured for use in a bi-directional HV terminal assembly, in which connector side bus bars 606 a and 606 b may be positioned from either side of the HV terminal assembly. To accommodate connector side bus bars 606 a and 606 b extending in either direction from theterminal frame 516, thespring portions middle portion 534 of theterminal frame 516. The orientation of thespring portions terminal frame 516 allows the connector side bus bars 506 a and 506 b to be inserted vertically (i.e., from the top) into the terminal frame 516 (as shown inFIGS. 6 and 7 ). - Referring now to
FIGS. 6 and 7 , exploded and assembly views of thebi-directional header assembly 608 are provided. The exploded view shown inFIG. 6 illustrates assembly of thehousing 610, theterminal assembly 514 and theterminal retainer 612 as part of thebi-directional header assembly 608, with the assembled version shown inFIG. 7 . As shown inFIG. 6 , thecontact spring 518 is installed on theterminal frame 516, and theterminal assembly 514 is installed within thehousing assembly 610. In some embodiments,terminal retainer 612 is installed within thehousing assembly 610 and pushed into engagement with theterminal frame 516 to ensure theterminal frame 516 is properly positioned (e.g., seated) within thehousing assembly 610. In some embodiments, an overlapping feature (not shown) associated with theterminal retainer 612 engages with theterminal frame 516 to ensureterminal frame 516 is properly positioned/seated within thehousing assembly 610. In some embodiments,terminal retainer 612 includes a locking feature (not shown) that engages with thehousing assembly 610 to ensure the terminal retainer 612 (as well as terminal assembly 514) is properly positioned/seated within thehousing assembly 610. In some embodiments, theterminal frame 516 is retained in place by theterminal retainer 612, wherein theterminal frame 516 does not require features to retain theterminal frame 516 within thehousing assembly 610. - Having inserted the
terminal assembly 514 and theterminal retainer 612 within thehousing assembly 610, the headerside bus bar 604 is inserted within theheader assembly 608. The headerside bus bar 604 is inserted from below theheader assembly 608 and is inserted through theterminal retainer 612 and into theterminal frame 514. In some embodiments, this allows theheader assembly 608 to be mounted over the top of a headerside bus bar 604, wherein the headerside bus bar 608 is then moved into position within theheader assembly 608. In some embodiments, the headerside bus bar 604 is retained and locked in place by theterminal retainer 612. In other embodiments, the position of the headerside bus bar 604 is maintained by theterminal retainer 612, but is not locked in place by theterminal retainer 612. Having positioned the headerside bus bar 604 within theheader assembly 608, connector side bus bars 606 a and 606 b may be inserted into theopening 615 on theheader assembly 608. In some embodiments, connectorside bus bar 606 a is provided from a first direction and connectorside bus bar 606 b is provided from a second direction opposite the first. In this way, theheader assembly 608 is bi-directional. In some embodiments, the insertion of the connectorside bus bar 606 a into theopening 615 causes compression of thespring portion 526 a, which in response generates a normal force on the connectorside bus bar 606 a that presses the connectorside bus bar 606 a into contact with the headerside bus bar 604. Likewise, the insertion of the connectorside bus bar 606 b into theopening 615 causes compression of thespring portion 526 b, which in response generates a normal force on the connectorside bus bar 606 b that presses the connectorside bus bar 606 b into contact with the headerside bus bar 604. In some embodiments, connector side bus bars 606 a and 606 b includeindentations spring portions indentations spring portions header assembly 608. - In contrast with the header assembly 108 shown in
FIG. 2 in which the terminal assembly 114 is oriented to only allow the connector side bus bar to extend away in a single direction, theterminal assembly 514 shown inFIGS. 6 and 7 are oriented to allow connector side bus bars 606 a and 606 b to extend bi-directionally from theheader assembly 608. As shown inFIG. 7 ,wires header assembly 608. - While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (20)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US17/741,938 US20220368052A1 (en) | 2021-05-12 | 2022-05-11 | High voltage (hv) terminal frame |
EP22173082.3A EP4089847A3 (en) | 2021-05-12 | 2022-05-12 | High voltage (hv) terminal frame |
CN202210517650.8A CN115347396A (en) | 2021-05-12 | 2022-05-12 | High-voltage terminal rack |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US202163187588P | 2021-05-12 | 2021-05-12 | |
US202163195785P | 2021-06-02 | 2021-06-02 | |
US17/741,938 US20220368052A1 (en) | 2021-05-12 | 2022-05-11 | High voltage (hv) terminal frame |
Publications (1)
Publication Number | Publication Date |
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US20220368052A1 true US20220368052A1 (en) | 2022-11-17 |
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ID=81603834
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US17/741,938 Pending US20220368052A1 (en) | 2021-05-12 | 2022-05-11 | High voltage (hv) terminal frame |
Country Status (3)
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US (1) | US20220368052A1 (en) |
EP (1) | EP4089847A3 (en) |
CN (1) | CN115347396A (en) |
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CN117039486A (en) * | 2023-06-28 | 2023-11-10 | 昆山沪光汽车电器股份有限公司 | Composite terminal for high-voltage connection |
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2022
- 2022-05-11 US US17/741,938 patent/US20220368052A1/en active Pending
- 2022-05-12 CN CN202210517650.8A patent/CN115347396A/en active Pending
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Also Published As
Publication number | Publication date |
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EP4089847A3 (en) | 2023-02-22 |
EP4089847A2 (en) | 2022-11-16 |
CN115347396A (en) | 2022-11-15 |
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