US3493034A

US3493034A - Method of making an electrical connector

Info

Publication number: US3493034A
Application number: US710829A
Authority: US
Inventors: Clarence B Haegert
Original assignee: Individual
Current assignee: Individual
Priority date: 1968-03-06
Filing date: 1968-03-06
Publication date: 1970-02-03
Anticipated expiration: 1987-02-03
Also published as: DE1902756C3; DE1902756B2; GB1241383A; DE1902756A1

Description

Feb. 3, 1970 c. BQHAEGERT 3,493,o34

METHOD OF MAKING AN ELECTRICAL CONNECTOR Filed March 6. 1968 INVENTOR ChWe/Me i/qgemi ATTORNEYS United States Patent 3,493,034 METHOD OF MAKING AN ELECTRICAL CONNECTOR Clarence B. Haegert, P.O. Box 318, Coifeyville, Kans. 67337 Filed Mar. 6, 1968, Ser. No. 710,829 Int. Cl. B22d 23/00 US. Cl. 164-47 9 Claims ABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION The present invention relates to electrical connectors of various types. Electrical connectors of this type including means for securing an electrical member thereto have in the past been generally formed of a brass-lead alloy or a copper alloy. Such prior art connectors are relatively expensive and are subject to excessive corrosion. This excessive cost arises due to the materials employed in the connectors as well as the method of making the connectors.

SUMMARY OF THE INVENTION The present invention comprises an electrical connector wherein the body means thereof is formed of a zinc base alloy. The utilization of the zinc base alloy of the present invention substantially reduces the cost of the connector since the materials involved are cheaper, and furthermore the connector can be readily manufactured.

In the present invention, the method includes the step of sandcasting or die casting the electrical connector, and this provides a most practical and economical manner of manufacturing an electrical connector of this type.

Also, surprisingly enough, it has been found that electrical connectors made of such a zinc base alloy according to the present invention have better electrical conductivity than prior art connectors made of a brass lead alloy or a copper alloy, and also exhibit good tensile strength. Additionally, the connector of the present invention has very good resistance to corrosion.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a top perspective view illustrating a first form of electrical connector according to the present invention;

FIG. 2 is a top perspective view illustrating a second form of electrical connector according to the present invention;

FIG. 3 is a top perspective view of a further electrical connector according to the present invention;

FIG. 4 is a top perspective view of still another elec trical connector according to the present invention; and

FIG. 5 is a top perspective exploded view of the structure illustrated in FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings wherein like reference characters designate corresponding parts throughout the several views, a first form of electrical connector is illus- 3,493,034 Patented Feb. 3, 197( trated in FIG. 1 wherein the connector is indicated gen erally by reference numeral 12.

This connector includes a body means 14 having a1 integral hollow cylindrical portion 16 for receiving 21 electrical cable or the like. The body means also include a pair of spaced

integral leg portions

18 and 20 having a tapered bore 24 defined therein for receiving a batter1 terminal whereby the device is adapted to operate as 1 conventional battery terminal connector.

A bolt 30 extends through aligned holes provided it the outer ends of

arms

18 and 20, the bolt 30 having ar enlarged head portion 32 received within a cutout 3: provided in leg portion 20 of the body means. A nut 3! is threaded on the far end of the bolt as seen in FIG. 1 for clamping the connector on a battery terminal.

A small screw 40 is adapted to be threaded into 2 tapped hole provided in enlarged head 32 for securing 2 lug 42 to the connector. This lug has a suitable hole provided therein for receiving the threaded shank portion of screw 40. The end portion 44 of lug 42 is 110110 for receiving a suitable electrical member which is crimped thereto.

A threaded stud 50 extends upwardly from portior 16 of the connector and has a tapped hole formed therein for receiving a small screw 52 which is employed fol holding lug 54 in place, lug 54 being of substantially the same construction 'as lug 42.

Referring now to FIG. 2 of the drawing, a modified electrical connector is indicated generally by reference numeral 60 and may also comprise a battery terminal connector. This connector includes a body means 62 having "a hollow cylindrical portion 64 for receiving an electrical cable or the like. The body means also includes a pair of spaced

leg portions

66 and 68 having aligned

holes

70 and 72 formed therethrough for receiving a suitable nut and bolt assembly for clamping the connector on a battery terminal.

A tapered bore 75 is formed between

spaced legs

66 and 68 for receiving a conventional battery terminal.

Referring now to FIG. 3, a further modified form of electrical connector according to the present invention is illustrated. The electrical connector is indicated generally by reference numeral and includes a body means including a flat end portion 82 having a hole 84 formed therethrough. The opposite end portion 86 of the body means is of generally cylindrical configuration and is hollow for receiving a cable or the like, the bared end of the cable being crimped in position within such hollow end portion of the body means.

Referring now to FIGS. 4 and 5, a still further modified form of electrical connector is illustrated. The connector is indicated generally by reference numeral 90 and includes a three-part body means, the body means including a bolt 92 having an enlarged hex head 94 at one end thereof and having a longitudinally extending slot 96 formed therein. The external portion of the lower part of the bolt is provided with threads 98.

The body means includes an intermediate member 100 the main portion of which is adapted to slide within the slot 96 formed in bolt 92. Member 100 includes depending

leg portions

102 and 104 which are spaced apart and which are adapted to be inserted through a threaded bore 106 provided in a nut 108 and then turned upwardly as indicated in phantom lines in FIG. 5 so as to retain

members

100 and 108 in assembled relationship as seen in FIG 4. The threaded bore 106 is adapted to be threaded on the external threads 98 provided on the bolt 92.

As seen most clearly in FIG. 5, the upper surface of member 100 is provided with a central generally V-shaped groove 110. A pair of lugs 112 extend outwardly in opposite directions from one end of member 100 and a similar pair of lugs 114 extend outwardly in opposite ditions from the opposite end of member 100. The por- 1 of member 100 between

lugs

112 and 114 is adapted fit within the slot 96 provided in bolt member 92, lugs l and 114 serving to retain member 100 in position and guide its movement in a vertical direction as seen in drawings. [t is apparent that when the electrical connector is in the embled relationship shown in FIG. 4, rotation of nut t with respect to bolt 92 will cause member 100 to be sed and lowered within the slot 96 in the bolt member ereby a suitable electrical member may be clamped be- :en the upper surface of member 100 and the underface of the hex head 94 of the bolt. The body means of each of the electrical connectors described in connection with FIGS. 1 through 5 inclue is formed of a Zinc base alloy having a particular mposition. The following three examples represent compositions table for use as the body means of an electrical conctor according to the present invention.

EXAMPLE I Percent uminum 3.9-4.3.

vpper .75-1.25. agnesium .03.06. )n Up to .075 maximum. :ad Up to .003 maximum. \dmium Up to .003 maximum. n Up to .002 maximum. nc Balance.

EXAMPLE II Percent uminum 3.5-4.5.

)pper 2.5-3.5. agnesium .02-.10. 5n Up to .100 maximum. :ad Up to .007 maximum. admium Up to .005 maximum. 11 Up to .005 maximum. nc Balance.

EXAMPLE III Percent luminum 3.9-4.3. opper Up to .10 maximum. Iagnesium 0.3-0.6. on Up to .075 maximum. ead Up to .003 maximum. admium Up to .003 maximum. in Up to .002 maximum. inc Balance.

In each of the above examples, the percentages are by eight of the composition, and it will be noted that in lCh case the major portion of the composition comprises nc which is the balance of the composition in each of re three examples.

In carrying out the method of the present invention, ne of the aforementioned zinc base alloys is provided nd heated until it is in a molten state. The molten metal then either sandcast or die cast to form one or more )mponents of the electrical connector which includes body means having means for securing an electrical rember thereto.

It is apparent from the foregoing that there is provided new and novelmethod of making an electrical conector body means having means for securing an elecfical connector member thereto and wherein the body leans is formed of a zinc base alloy which enables the onnector to be manufactured at a lower cost with good lectrical conductivity, good tensile strength, and good orrosion resistance characteristics.

As this invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, and since the scope of the invention is defined by the appended claims, all changes that fall within the metes and bounds of the claims or that form their functional as wall as conjointly cooperative equivalents are therefore intended to be embraced by those claims.

I claim:

1. The method of making an electrical connector comprising providing a zinc base alloy consisting essentially of about 3.9 to 4.3% aluminum, about .75 to 1.25% copper, about .03 to .06% magnesium, up to about .075% iron, up to about .003% lead, up to about 003% cadmium, up to about .002% tin, the balance being Zinc, all of said percentages being by weight of the composition, heating said alloy until it is in a molten condition, and then casting said molten alloy to form an electrical connector including a body means having means for securing an electrical member thereto.

2. The method as defined in claim 1 wherein said casting step is a sandcasting procedure.

3. The method as defined in claim 1 wherein said casting step is a die casting procedure.

4. The method of making an electrical connector comprising providing a zinc base alloy consisting essentially of about 3.5 to 4.5% aluminum, about 2.5 to 3.5% copper, about .02 to .10% magnesium, up to about .100% iron, up to about .007% lead, up to about .005% cadmium, up to about .005% tin, the balance being zinc, all of said percentages being by weight of the composition, heating said alloy until it is in a molten condition, and then casting said molten alloy to form an electrical connector including a body means having means for securing an electrical member thereto.

5. The method as defined in claim 4 wherein said casting step is a sandcasting procedure.

6. The method as defined in claim 4 wherein said casting step is a die casting procedure.

7. The method of making an electrical connector comprising providing a zinc base alloy consisting essentially of about 3.9 to 4.3% aluminum, up to about .10% copper, 0.3 to 0.6% magnesium, up to about .075% iron, up to about .003% lead, up to about 003% cadmium, up to about .002% tin, the balance being zinc, all of said percentages being by weight of the composition, heating said alloy until it is in a molten condition, and then casting said molten alloy to form an electrical connector including a body means having means for securing an electrical member thereto.

8. The method as defined in claim 7 wherein said casting step is a sandcasting procedure.

9. The method as defined in claim 7 wherein said casting step is a die casting procedure.

References Cited FOREIGN PATENTS 2/ 1935 Australia.

OTHER REFERENCES J. SPENCER OVERHOLSER, Primary Examiner I. E. ROETHEL, Assistant Examiner U.S. Cl. X.R. 164-113; 339278