US3766442A

US3766442A - Electrical component terminal

Info

Publication number: US3766442A
Application number: US00223634A
Authority: US
Inventors: G Pearce; W Breeden
Original assignee: PR Mallory and Co Inc
Current assignee: Duracell Inc USA; Electrolytics Inc
Priority date: 1972-02-04
Filing date: 1972-02-04
Publication date: 1973-10-16
Anticipated expiration: 1990-10-16
Also published as: AU5097473A; DE2304688A1; JPS5718336B2; GB1415099A; BR7300849D0; JPS4888465A; CA983591A

Abstract

An electrical component terminal is provided utilizing a concentric extension foot and a cooperating fluted rivet whereby integral mechanical and electrical contact is achieved between the foot and the fluted rivet through the seal member in the component.

Description

limited States Patent [1 1 Pearce et a1.

1 41 ELECTRICAL COMPONENT TERMINAL [75] lnventors: Godfrey R. Pearce; William .1. Breeden, both of Glasgow, Ky.

[73] Assignee: P. R. Mallory & Co. Inc.,

' Indianapolis, Ind.

[22] Filed: Feb. 4, 1972 [21] Appl. No.: 223,634

[52] US. Cl 317/230, 174/52 S, 339/214 C,

339/220 R, 339/220 C, 339/276 C [51] Int. Cl I-I0lg 9/10, H01r 9/14 [58] Field of Search 174/50.56, 52 S,

174/153 R; 317/230; 339/147 C, 214 R, 214 C, 218 C, 220 C, 275 A, 276 C, 277 C, 278 A, 219 R, 220 R, 220 L, 220 T; 200/166 B,

1 Oct. 16, 1973 2,225,801 12/1940 Schnoll 174/52 S UX 2,465,654 3/1949 Millard 339/214 R 3,439,232 4/1969 Van Buskirk et a1 174/52 S X 3,548,264 12/1970 Carino et a1 174/52 S X FOREIGN PATENTS OR APPLICATIONS 1,186,529 2/1965 Germany 339/219 R 1,028,657 2/1953 France 339/214 R 1,065,157 12/1953 France 339/214 R 1,147,809 6/1957 France 317/230 556,689 2/1957 Italy 174/52 S Primary Examiner-Laramie E. Askin Attorney-Richard H. Childress et a1.

[5 7] ABSTRACT An electrical component terminal is provided utilizing a concentric extension foot and a cooperating fluted rivet whereby integral mechanical and electrical contact is achieved between the foot and the fluted rivet through the seal member in the component.

12 Claims, 3 Drawing Figures 1 ELECTRICAL COMPONENT TERMINAL A significant problem has arisen in the connection of tabs from an electrical component body (including, for example, capacitors, resistors and semi-conductor devices) to terminals for connecting the device into an electrical circuit. Particularly in the case of capacitors, a number of failures have been observed in the connection between thetabs and the terminal involving a rivet member and these failures have been particularly recurrent where high current and/or heavy duty cycle applications have been involved.

One proposed solution to this problem is described in Van Buskirk et al. U.S. Pat. No. 3,439,232. In this patent, a hollow bushing is utilized through which the rivet connector member passes. However, failures have still occurred and the use of the hollow bushing involves a significant outlay.

Another technique which has been utilized to connect the tab members to the terminals is described in US. Pat. No. 2,225,801. In this technique, the tab member is inserted into a hollow stud member. After insertion of the tab, the lower portion of the stud is pinched to hold the lower portion of the stud in engagement with the tab.

The terminal member is pierced through the phenolic disc so that the teeth on the terminal member engage the disc. Thus, the disc forms an integral part of the support structure for the electrical connection between the pin portion of the stud and the hole in the terminal member. Since the searated teeth are flared outwardly, there is not as much surface area available for contact as desired between the pin and the hole. Thus, overheating may occur when high currents or heavy duty cycles are utilized in operation.

Thus, it is apparent that there is a need for an electrical component terminal connection assembly which avoids the over-heating and resulting open circuiting of terminal connections, particularly where high currents and/or heavy duty cycles are encountered.

It is therefore an object of the present invention to provide a terminal structure which is easy to manufacture and assemble.

It is another object of the present invention to provide a terminal construction at low cost.

- Other objects will be apparent from the following description and drawings wherein:

FIG. 1 is an exploded view in perspective of the terminal construction of the present invention;

FIG. 2 is a sectional view illustrating the terminal construction after assembly; and

FIG. 3 is a view of an assembled capacitor utilizing the terminal connection assembly of the present invention.

As can be seen from FIG. 1, the assembly of the present invention comprises a terminal member indicated generally as having an external connection portion 11 and an internal connection portion 12, preferably at 90 with respect to said external connection portion. The internal connection portion has an opening 13, and an extension or foot 14, preferably perpendicular to the body of the internal connection portion.

The extension or foot is adapted to enter into the upper portion of a seal member 20. The seal member comprises an upper member 21 of relatively hard plastic or thermosetting material such as phenolic or BAKELITE and a lower member 22 made of soft rubher which may be of any of the known soft natural or synthetic rubbers. Each of the

members

21 and 22 has an opening therein, respectively, 23 and 24. As can be seen from FIG. 2, the foot 14 enters into at least a portion of the upper seal member 21.

A very important aspect of the present invention is the rivet which is shown generally at 30 in FIG. 1. This rivet comprises a base portion 31, preferably having on the upper or contacting surface thereof, a plurality of dimples 32. The rivet also comprises a longitudinal shank portion 33 (with respect to base 31), preferably cylindrical and preferably having thereon a plurality of flutes 34. Generally from two to eight such flutes may conveniently be utilized. More flutes than eight do not improve the device significantly. One flute generally does not provide sufficient contact around the circumference to achieve the full benefit of the use of flutes. Longitudinal portion or shank portion 33 also preferably has an opening 35 which extends down to from about one-third to onerhalf of the distance from the top of the shank to the base.

The other parts of the assembly include a plurality of tabs 40 connected to the component body. As mentioned above, the component may be a capacitor, a re sistor, a semiconductor device, inductance or combination of the foregoing. For example, as shown in FIG. 3, tabs 40 may be connected to capacitor electrodes 71, 72 of the capacitor body 70. Each of the tabs has opening 41 placed in engagement with the rivet base portion 31; and a washer 50 having an opening 51 is used to hold the tabs in place upon base portion'31.

The method of assembly of the terminal assembly is as follows: First, the tab 40 is placed upon rivet 30 and the tab is pulled down sufficiently to engage the base portion 31 and preferably engage the dimples 32. Next, washer 50 is placed over tab 40 so that the lower surface 52 engages the upper surface 43 of tab 40.

Next, terminal member 10 is placed upon the disc 20 with the extension foot 14 in place within opening 23 of the disc. Then the shank portion 33 of rivet 30 with tab 40 and washer 50 in place is brought up through the disc 20 and opening 13 in terminal 10 so that at least a riveting portion 36 extends through and above internal connection portion 12.

. It will be noted that the

openings

23 and 24 in the disc are of greater diameter than the diameter of the rivet shank 33.

As shown in FIG. 2, the riveting operation results in engagement of shank portion 36 with internal contacting portion 12 of terminal 10 at 61. Engagement also is achieved by the rivet shank 33 with the internal surface of the extension foot 14 at 62. Furthermore, the riveting operation-results in flutes 34 being driven outwardly and upwardly so that a substantial amount of engagement is achieved between flutes 34 and the under surface 15 of foot 14 at 63.

As mentioned previously, a very important problem with prior assemblies is achieving sufficient contact area so that in handling high currents (above about 5 amps) or heavy duty cycles (such as a current of about 5 amps or higher is used for more than milliseconds for more than 5, for example, 6 to 12, times per hour) sufficient heat being generated at the contact area to melt a portion of one or more of the members will be avoided. In general, the terminal member 10 is made of steel and all of the other members of the assembly including rivet 30, tab 40, and washer 50 are made of aluiron or steel could be used for other members of the assembly in addition to terminal number 10.

The present invention is particularly adapted to the connecting assemblies in A.C. motor start capacitors where currents of about 20-25 amps and higher at up to 100 volts and higher are utilized and the duty cycle is heavy during the period the operator is starting the device. For example, the duty cycle may be above 100 milliseconds 8-15 times per hour or higher.

However, with the construction of the present invention wherein good mechanical and electrical contact and engagement is obtained at 61, 62 and 63, the problem of heating and melting is largely overcome in terminal assemblies even where high currents and/or heavy duty cycles are involved.

Another important advantage of the present invention is that the assembly is relatively independent of deterioration of the disc member 20. All the contacting points are integrally engaged after the riveting opera tion so that deterioration of anyportion of the disc 20 does not lessen the integral bond and electrical contact of the assembly.

An example of a completed device is shown in FIG. 3. The device illustrated is a capacitor, but the component body could just as well be one of the other components or combinations thereof mentioned above. Wound metal conducting electrodes 71 and 72 are separated by a separator or spacer member 73 made of paper or plastic. Preferably an electrolyte is impregnated into the spacer in a known manner. Tabs 40 contact the electrodes 71 and 72 and contact rivet base portion 31 and .washer 50-of the terminal assembly as described above. A metal or plastic case 80'is used to house the assembly. A material such as tar 81 may be provided to protect the capacitor body against camming and vibration.

What is claimed is:

1. A terminal assembly adapted to project through an opening in seal means closing an open end of a housing for an electrical component, the terminal assembly comprising terminalmember means including an external connection portion and an internal connection portion, an opening in the internal connection portion and extension means concentric with the opening of the internal connection portion projecting from the internal connection portion, the extension means adapted to project into the opening of the seal means, and means projecting through the opening of the internal connection portion including a portion adapted to assist in retaining tab means of the electrical component, the means including shank means having flute means, the extension means of the internal connection portion in contact with the flute means by moving the extension means relative to the flute means to drive at least some of the flute means outwardly from the shank means, a flanged portion of the shank means engaging with the internal connection portion to lock the means including the shank means to the terminal member means.

2, The terminal assembly of claim 1, wherein the flute means is a plurality of flutes integral with and elongated in the direction of the longitudinal axis of the shank means.

3. The terminal assembly of claim 2, wherein the extension means is made from a metal harder than the metal of the flutes.

4. The terminal assembly 'of claim 3, wherein the extensionmeans is metal selected from the group including iron and steel, and the flutes are a metal selected from the group including aluminum, aluminum alloys, and copper, silver, gold and their alloys.

5. The terminal assembly of claim 1, wherein the extension means is adapted to engage with the wall of the opening of the seal means.

6. The terminal assembly of claim 5, wherein the.

means including the shank means is a rivet-like means including base means having a contact surface with a plurality of dimples, and washer means adjacent the contact surface of the base means, the contact surface and washer means adapted to grip and assist in retaining the tab means of the electrical component.

7. The terminal assembly of claim 6, wherein the external connection portion of the terminal member means is at an angle of about with respect to the internal connection portion.

8. The terminal assembly of claim'l, wherein the internal connection portion and the external connection portion are at an angle with respect to each other, the means including the shank means is a rivet-like means including a base means having a contact surface with dimple means adapted to assist in retaining the tab means, the shank means projecting from the base means-and having the flu-te means integral with and elongated in the direction of the longitudinal axis of. the shank means, the extension means of the internal connection portion in contact with the flute means by moving the extension means relative to the flute means to.

drive the flute means toward the base means and outwardlyfrom the shank means to occupy more of the opening of the seal means. j

' 9.. The terminal assembly of claim 8, wherein the extension means is a hard metal and the flute means is a soft metal.

10. The terminal assembly of claim8, including a washer cooperatively associated with the contact surface of the base of the rivet-like means to assist in retaining the tab means.

11. The terminal assembly of claim 10, wherein the extension means is adapted to engage with the wall of the opening of the seal means.

12. A capacitor including anode electrode means and cathode electrode means, dielectric means between the anode electrode means and the cathode electrode means, electrolyte means cooperatively associated with the anode electrode means and the cathode electrode means, tab means contacting one of the electrode means and having a portion retained by the terminal assembly of claim 1.

H UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PatentNo msmmiz Dated 10/1 /73 Inventor(s) Godfrey R. Pearce; William J. Breeden It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3, line 2, change "66 to ---66O Signed and sealed this 9th day of April 1971+.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. c. MARSHALL DANN Attesting Officer Commissioner of Patents FORM PO-105O (10-69) USCOMM-DC 60376-P69 fi u.s. GOVERNMENT PRINTING OFFICE: 1969 0-366-334 UNITED STATES PATENT OFFICE TI ATE OF CORRECTION Patent No 3 Z66 ,L;) 2 v Dated /73 Inventor(s) Godfrey R. Pearce; William J. Breeden It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Colwnn 3, line 2, change "66" to ---660---- Signed and sealed this 9th day of April 197b,.

(SEAL) Attest: I

EDWARD M.FLETCHER,JR. or. MARSHALL, DANN Attesting Officer 7 Commissioner of Patents FORM PO-1050 (10-69) u c 60376.p69

- u.s. sovsnnmsm PRINTING omcz I969 o-ass-au

Claims

1. A terminal assembly adapted to project through an opening in seal means closing an open end of a housing for an electrical component, the terminal assembly comprising terminal member means including an external connection portion and an internal connection portion, an opening in the internal connection portion and extension means concentric with the opening of the internal connection portion projecting from the internal connection portion, the extension means adapted to project into the opening of the seal means, and means projecting through the opening of the internal connection portion including a portion adapted to assist in retaining tab means of the electrical component, the means including shank means having flute means, the extension means of the internal connection portion in contact with the flute means by moving the extension means relative to the flute means to drive at least some of the flute means outwardly from the shank means, a flanged portion of the shank means engaging with the internal connection portion to lock the means including the shank means to the terminal member means.

2. The terminal assembly of claim 1, wherein the flute means is a plurality of flutes integral with and elongated in the direction of the longitudinal axis of the shank means.

4. The terminal assembly of claim 3, wherein the extension means is metal selected from the group including iron and steel, and the flutes are a metal selected from the group including aluminum, aluminum alloys, and copper, silver, gold and their alloys.

6. The terminal assembly of claim 5, wherein the means including the shank means is a rivet-like means including base means having a contact surface with a plurality of dimples, and washer means adjacent the contact surface of the base means, the contact surface and washer means adapted to grip and assist in retaining the tab means of the electrical component.

7. The terminal assembly of claim 6, wherein the external connection portion of the terminal member means is at an angle of about 90* with respect to the internal connection portion.

8. The terminal assembly of claim 1, wherein the internal connection portion and the external connection portion are at an angle with respect to each other, the means including the shank means is a rivet-like means including a base means having a contact surface with dimple means adapted to assist in retaining the tab means, the shank means projecting from the base means and having the flute means integral with and elongated in the direction of the longitudinal axis of the shank means, the extension means of the internal connection portion in contact with the flute means by moving the extension means relative to the flute means to drive the flute means toward the base means and outwardly from the shank means to occupy more of the opening of the seal means.

9. The terminal assembly of claim 8, wherein the extension means is a hard metal and the flute means is a soft metal.

10. The terminal assembly of claim 8, including a washer cooperatively associated with the contact surface of the base of the rivet-like means to assist in retaining the tab means.