US3922050A - Blind, shank expanding electrical terminal structure - Google Patents

Blind, shank expanding electrical terminal structure Download PDF

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Publication number
US3922050A
US3922050A US453200A US45320074A US3922050A US 3922050 A US3922050 A US 3922050A US 453200 A US453200 A US 453200A US 45320074 A US45320074 A US 45320074A US 3922050 A US3922050 A US 3922050A
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United States
Prior art keywords
sleeve
shank
region
cylindrical
sheet
Prior art date
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Expired - Lifetime
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US453200A
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English (en)
Inventor
Michael J Lettini
Howard P Stock
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Boeing Co
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Boeing Co
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Priority to US453200A priority Critical patent/US3922050A/en
Priority to FR7508814A priority patent/FR2265194B1/fr
Priority to GB1167375A priority patent/GB1470272A/en
Priority to BE160066A priority patent/BE833449A/fr
Application granted granted Critical
Publication of US3922050A publication Critical patent/US3922050A/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B19/00—Bolts without screw-thread; Pins, including deformable elements; Rivets
    • F16B19/04—Rivets; Spigots or the like fastened by riveting
    • F16B19/08—Hollow rivets; Multi-part rivets
    • F16B19/10—Hollow rivets; Multi-part rivets fastened by expanding mechanically
    • F16B19/1027—Multi-part rivets
    • F16B19/1036—Blind rivets
    • F16B19/1045—Blind rivets fastened by a pull - mandrel or the like
    • F16B19/1054—Blind rivets fastened by a pull - mandrel or the like the pull-mandrel or the like being frangible
    • 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
    • H01R4/58—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 characterised by the form or material of the contacting members
    • H01R4/64—Connections between or with conductive parts having primarily a non-electric function, e.g. frame, casing, rail

Definitions

  • the method of the invention comprises the steps of: drilling a cylindrical hole through said sheet or into said body; inserting a blind, shank expanding terminal comprising an elongated cylindrical shank and a cylindrical. radially expandable sleeve axially mounted on said shank into said drilled hole; and.
  • the apparatus of the invention comprises an improved electrical terminal structure comprising a sheet or body of electrically conducting material and a blind shank expanding terminal formed of an elongated cylindrical shank and a radially expandable cylindrical sleeve axially mounted on said shank in a manner such that said radially expandable sleeve radially expands when said shank is axially displaced in one direction with respect to said sleeve.
  • Said radially expandable cylindrical sleeve is formed of a material that is electrically compatible with said sheet or body of electrically conducting material.
  • This invention is directed to electrical terminal structures and more particularly to electrical terminal structures including an electrical terminal and a body of electrically conductive material.
  • Electrical terminal structures and in particular electrical grounding terminal structures, have found widespread use. These terminal structures are generally adapted to create a point wherein electrical contact is made between one or more electrical conductors and a body of electrically conductive material. Such contact may be necessary for one or more of a variety of reasons. Generally, these reasons fall into two different groups-safety and electrical.
  • the safety group includes safety of the personnel operating the related equipment and safety of the equipment itself.
  • the electrical group includes the electrical requirements of the related equipment.
  • the safety group may, for example, include the prevention of sparks which could cause an explosion if explosive gases exist in the surrounding environment.
  • the safety group may include lightning protection and electrostatic charge dissipation.
  • the safety group reasons for making electrical contact to a body of electrically conducting material are related either to the direct personnel or equipment harm or the associated personnel or equipment harm that can be caused by electrical energy.
  • the electrical group reasons for making electrical contact to a body of conductive material relate to the use of the electrical equipment involved.
  • the chassis of electrical equipment is often used to provide electrical return paths.
  • the chassis or a surrounding shield is used for electromagnetic interference control.
  • a conductive body of material is utilized to create a particular electrical function, such as a ground plane for an antenna, for example.
  • electrical terminals make contact with the body and electrical conductors are attached to the terminals.
  • electrical terminal structure defines the terminal per se and the surrounding body of electrically conductive material to which the terminal is physically and electrically attached.
  • the most common prior art electrical terminal used to form an electrical terminal structure comprises a stud in combination with a plurality of washers and nuts.
  • the overall electrical terminal structure using such an electrical terminal is formed by drilling a hole through the body of electrically conductive material to which the terminal is to be attached. Thereafter, the surface of the body of material, around the hole and on one or both sides thereof, is cleaned to remove any nonelectrical coatings.
  • nonconductive electrical coatings may comprise a variety of layers of materials or may just consist of a primer coat of paint.
  • a washer and a lock washer are assembled on the stud and the assembly is installed through the hole from the back side of the body of material.
  • a washer and a nut (usually formed of brass) are attached to the stud on the "front" side of the structure.
  • the terminal becomes affixed to the body of electrically conductive material.
  • the exposed surfaces of the body of electrically conductive material are recoated or reprimed with care being taken to prevent the recoating or the repriming material from impinging on the brass nut and the portion of the stud extending outwardly from the brass nut.
  • electrical terminals are installed on the stud and a further washer and locknut are added. Finally, an inspection of the overall terminal is performed.
  • both sides of the body to which the terminal is to be attached must be accessible at the time of attachment because the stud head and the brass nut are installed from opposite sides and because both the stud head and the brass nut must be gripped during tightening of the nut on the stud.
  • This initial requirement is not only a disadvantage in and of itself but may also cause problems during the operative life of the terminal structure. Specifically, if the terminal structure loosens during its lifetime, and if the head side is then inaccessible, retightening of the terminal structure becomes extremely difficult.
  • the electrical terminal described in this patent comprises a stud having a head and a cylindrical collar located adjacent to the head on the threaded side of the stud.
  • the terminal is mounted in a hole formed in an electrically conductive material from the back side thereof. Thereafter, a frustoconical region extending outwardly from the cylindrical region on the side remote from the head is bent downwardly. Electrical contact is made where the sides of the hole and the sides of the cylindrical collar meet.
  • the resultant electrical terminal structure overcomes some of the disadvantages described above.
  • this terminal must be inserted from the back side of the body of electrically conductive material.
  • the disadvantages attendant to this method of installation remain.
  • the size of the hole and the size of the cylindrical collar must be precisely related (unless the surface is previously cleaned with its related disadvantages) or else the resultant electrical contact is inadequate.
  • the knurled collar proposed by Gulistan can overcome some of the precision disadvantages such a collar creates other disadvantages. Specifically. such a collar has been found to cause irregularities on the inside of the hole. The stresses built up around these irregularities can cause cracks to radiate out from the edge of the hole. Such cracks are undesirable to say the least and in some industries, such as the aircraft industry, for example. are completely unacceptable.
  • a method of forming an electrical terminal structure by attaching an electrical terminal to a body of electrically conductive material having a flat surface which may be coated with a generally nonconductive material so that said electrical terminal makes an electrically low resistance contact with said body of electrically conductive material is provided.
  • the method of the invention comprises the steps of: drilling a cylindrical hole through said generally nonconductive material into said body of electrically conductive material; inserting a blind shank expanding terminal comprising a cylindrical shank and a radially expandable cylindrical sleeve axially mounted on said shank into said drilled hole; and, causing said sleeve to radially expand and come into low resistance electrical contact with said body of electrically conductive material in the region where the cylindrical periphery of said hole meets said cylindrical sleeve.
  • the shank and sleeve of the blind shank expanding terminal are formed such that said sleeve radially expands when said shank is axially displaced in one direction with respect to said sleeve.
  • the method of the invention comprises the further step of axially moving said shank with respect to said sleeve.
  • the body of electrically conductive material is a sheet having a front side and a back side and the sleeve includes a collar lying on the front side whereby the method of the invention also comprises the step of causing a portion of the sleeve residing on the back side of said body to expand outwardly as said shank is axially moved with respect to said sleeve so as to form a collar having a diameter greater than the diameter of said hole.
  • an improved electrical terminal structure comprises a body of electrically conductive material having a hole therein and a blind shank expanding terminal mounted in said hole.
  • the blind shank expanding terminal comprises a cylindrical shank including a head and a radially expandable sleeve axially mounted on said shank adjacent to said head, said radially expandable sleeve being adapted to radially expand when said shank is axially displaced in one direction with respect to said sleeve.
  • the sleeve is formed of a material that is electrically compatible with said body of electrically conductive material such that the galvanic emf across the materials is less than a predetermined amount such as 0.250 volts, for example.
  • one end of the sleeve of said blind shank expanding terminal comprises a collar end and the other end comprises a thin wall.
  • the thin wall end is adjacent to the head and when the shank is axially displaced in said one direction, the thin wall rolls outwardly. If the body of electrically conductive material is a sheet of such material this outward rolling forms a collar that presses the sheet against the collar forming the other end of said sleeve.
  • the body of electrically conductive material is formed of aluminum and the sleeve is formed of either tin coated naval brass or alodine 600 coated aluminum.
  • the diameter of said head is substantially the same as the outer diameter of said thin wall end of said sleeve.
  • said shank includes a splined cylindrical region separated from said head by an undercut region. The diameter of said splined cylindrical region is smaller than the diameter of said head.
  • a threaded stud extends outwardly from said splined cylindrical region; said head, said splined cylindrical region and said stud being coaxial.
  • extending outwardly from said threaded region on the end of said stud remote from said splined region is a coaxial breakaway member.
  • Located between said breakaway member and said stud is an undercut region whereat said breakaway member breaks away from said stud when the force creating the axial movement of said shank with respect to said sleeve reaches a predetermined level, said force being applied to said breakaway member of said shank only.
  • said sleeve comprises a cylindrical axial aperture having a diameter slightly less than the diameter of said splined cylindrical region of said shank between said splined cylindrical region and said collar of said sleeve and slightly greater than the diameter of said splined cylindrical region where said sleeve surrounds said splined cylindrical region, all diameters being prior to the axial movement of said shaft with respect to said sleeve.
  • the electrical terminal structure of the invention comprises a body of electrically conductive material which may be coated with a nonconductive coating and a blind shank expanding electrical terminal mounted in a hole formed in the body of electrically conductive material.
  • the electrical terminal comprises a shank with a head and a sleeve with a perforated collar.
  • the shank is axially moved outwardly with respect to the sleeve (and the body of electrically conductive material). This movement causes radial expansion of the sleeve where it lies in the hole and, if the body is a sheet, a collar-like expansion of the sleeve on the side of the body remote from the direction of pull.
  • the sheet is pressed between the preformed collar and a collar formed by expansion. Electrical contact is made radially, where the sleeve and the side of the hole meet, as opposed to where the surface of the body and a collar or washer meet.
  • the nonconductive material need not be removed prior to attachment of the blind shank expanding terminal. Yet, even though such material is not removed, a good resistance electrical contact is formed between the terminal and the body or sheet of electrically conductive material.
  • the invention overcomes the abovedescribed disadvantages of prior art electrical terminal structures. Specifically, only a minimum number of installation steps are required by the invention. Thus, the cost of installation is considerably less than is the cost of installing prior art terminals, particularly those that utilize a stud/washer/nut arrangement. In fact, in one instance, it was found that up to a percent reduction in cost without loss of electrical terminal benefits can be achieved using the invention. In addition, access to both sides of the body of electrically conductive material is not required. Further, the terminal can be easily removed and replaced by merely driving the shank in the direction opposite to the pulling direction, drilling out the remaining sleeve and reinstalling a similar terminal in the same hole. Also installation of the terminal does not create irregularities around the hole which could. after installation, create radial cracks extending out from the hole.
  • the electrical terminal structure of the invention has torque and axial load characteristics comparable with prior art structures utilizing a stud/washer/nut arrangement.
  • the sleeve material can be chosen so as to have good (i.e., 0.250 volts or lower) galvanic compatibility with the body of electrically conductive material.
  • the sleeve can be formed of tin coated naval brass or alodine 600 coated aluminum.
  • the thermal shock, current cycling, humidity and vibration characteristics of the inventive terminal structure are as good as, or better than, prior art terminal structures.
  • the oxidation characteristics (which relate to shelf life) of the terminal structure are good, assuming suitable materials are utilized. such as tin coated naval brass or alodine 600 coated aluminum.
  • FIG. I is an exploded view illustrating one of the most common prior art electrical terminal structures in use
  • FIG. 2 is an exploded view illustrating the basic concept of the invention
  • FIG. 3 is a side view illustrating a preferred embodiment of an electrical terminal formed in accordance with the invention.
  • FIG. 4 is a side view partially in section illustrating an electrical terminal of the type illustrated in FIG. 3 being installed in a body of electrically conductive material;
  • FIG. 5 is a side view partially in section illustrating an electrical terminal structure formed in accordance with the invention.
  • FIG. 6 is a side view partially in section illustrating in side-by-side relationship an electrical terminal formed in accordance with the invention both prior to and subsequent to installation in a sheet of electrically conductive material;
  • FIG. 7 is a side view partially in section illustrating an alternate electrical terminal structure formed in accordance with the invention.
  • FIG. 8 is a split side view partially in section illustrating a still further alternate electrical terminal structure formed in accordance with the invention.
  • FIG. I is an exploded side view illustrating one of the most common prior art electrical terminal structures. and in particular an electrical terminal grounding structure.
  • the structure illustrated in FIG. 1 comprises a body of electrically conductive material ll.
  • the body of electrically conductive material may be a thin sheet of aluminum, titanium or tin, for example.
  • One or both of the front and rear surfaces may be coated with a layer 13 and 15 formed of a nonconductive material. such as a paint primer, for example.
  • a cylindrical aperture (hole) 17 is first punched. drilled or in some other manner formed in the body of electrically conductive material 11. Thereafter, the portion of the nonconductive layers in the areas 19 and 2! surrounding the hole 17 on the front and rear surfaces I3 and I5 are removed by any suitable means. Alternatively. and in fact more frequently, a portion of the nonconductive layer surrounding the hole on only one side is removed. In any event, thereafter the electrical terminal is actually installed.
  • the prior art electrical terminal illustrated in FIG. 1 comprises: a bolt 23; a lock washer 25; a first flat washer 27; a second flat washer 29; a nut 3], preferably formed of brass; one or more electrical terminals 33; a third flat washer and a self-locking retaining nut 37.
  • the lock washer 25 followed by the first flat washer 27 are passed over the shank 39 so as to lie adjacent to the head 41 of the stud 23. Thereafter, this assembly is inserted through the hole 17, upwardly as viewed in FIG. I so that the upper surface of the first flat washer 27 lies in the previously cleaned lower area 21 surrounding the hole 17.
  • the first flat washer is brought into electrical contact with the body of electrically conductive material.
  • the second flat washer 29 is mounted about the threaded shank 39 and the brass nut 31 is applied to the shank and tightened.
  • the mounting is such that the second flat washer is also in electrical contact with the body of electrically conductive material 11 because it lies in the upper cleaned area 19 surrounding the hole 17.
  • the remaining exposed cleaned area must then be repainted or reprimed and allowed to dry, being careful not to get paint on the nut or threaded shank.
  • the resultant terminal structure illustrated in FIG. I and described above has a variety of disadvantages. For example, because it includes a multitude of components, it is expensive to install. This factor becomes of particular significance when a large number of terminal structures are to be formed. In addition, after partial installation. repriming is required to prevent corrosion and other undesired detri mental effects from occuring. Moreover, a structure of the type illustrated in FIG. I has the disadvantage that access to both sides of the body of electrically conductive material 11 is required during installation of the terminal. In this regard, it should also be noted that if the electrical terminal loosens during use. and if both 8 sides of the body ll are not accessible, it is extremely difficult to retighten the terminal. One way of retightening the structure is to double nut" the threaded shank 39 of the bolt 23 to prevent movement of the bolt and then retighten the brass nut 31. Because such a procedure is time consuming, it is also expensive.
  • an electrical terminal arrangement of the type illustrated in FIG. 1 has a number of desirable characteristics. For example, it normally has high torque and axial load strength.
  • the materials used can be chosen to be galvanically compatible with the body of electrically conductive material. Further, it has high thermal shock, current cycling, humidity, vibration and oxidation characteristics. Finally, the overall thermal structure has low electrical resistance. The herein described invention overcomes the above-noted disadvantages of this structure, and related structures, without loss of these desirable advantages.
  • FIG. 2 illustrates, in exploded form, the basic concept of this invention.
  • the electrical terminal structure illustrated in FIG. 2 comprises a body of electrically conductive material 43, which may be a thin sheet of material.
  • the body or sheet 43 may be coated on one or both sides with a nonconductive coating 44 or 45, such as primer paint, for example.
  • the terminal structure also includes a blind shank expanding terminal 47.
  • the blind shank expanding terminal 47 includes a sleeve 46 axially mounted about an elongated shank 48.
  • the sleeve 46 comprises a cylindrical region 49 (prior to installation) that terminates in a preformed collar 50.
  • the elongated shank comprises a head region 51 and a threaded stud 52.
  • the sleeve 46 includes a cylindrical central aperture which allows it to be mounted about the elongated shank 48 in a manner such that the collar is remote from the head region 51.
  • a blind shank expanding terminal 47 of the type generally illustrated in FIG. 2 is inserted from one side (above as viewed in FIG. 2) into a cylindrical aperture drilled, punched or in some other manner formed in the sheet of electrically conducting material 43 so that the collar 50 lies against the side from which the terminal is inserted.
  • the sleeve is expanded outwardly by moving the shank 48 upwardly (as viewed in FIG. 2) in the direction of the arrow 53. This expansion presses the outer surface of the sleeve against the sides of the hole where they meet in the region 54. Electrical contact between the sheet 43 and the sleeve 46 occurs in this region 54.
  • the portion of the cylindrical region 49 lying on the back or remote side expands or rolls outwardly to some degree.
  • the sheet of electrically conductive material is pressed between the outwardly rolled portion and the preformed collar 50.
  • Located above the preformed collar 50 is one or more electrical contacts and located above the electrical contact(s) is a flat washer 56 and a self-locking retaining nut 57. The nut presses the contact(s) against the preformed collar 50 to create electrical contact therebetween.
  • the terminal is, inserted from one side of the sheet or body of electrically conductive material. Hence, access to both sides is not necessary.
  • the terminal is a blind terminal. Because of this advantage the electrical terminal can be easily replaced should it loosen in the hole. Replacement merely requires driving the shank 48 in the direction opposite to the arrow 53. After the shank has been removed, the sleeve 46 can be easily removed by drilling it out in a conventional manner. Thereafter, a similar shank expanding terminal is easily replaced in the same aperture. It will be appreciated that no step of this entire replacement procedure requires access to the back side of the sheet 43.
  • FIG. 2 One more important advantage of the inventive electrical terminal structure illustrated in FIG. 2 should be noted. Specifically, the formation of this structure does not require the removal of any nonconducting material from either surface of the sheet (body) of electrically conducting material 43. Thus, there is no requirement that these surfaces be recoated after the terminal is formed.
  • FIG. 3 illustrates a preferred embodiment of a blind, shank expanding electrical terminal 59 formed in accordance with the invention prior to insertion into an aperture in a body of electrical conducting material.
  • the blind shank expanding electrical terminal 59 comprises an elongated shank 63 and a sleeve 61.
  • the sleeve 61 includes a preformed collar 67 and the shank includes a threaded stud 69 and a head 65.
  • the sleeve includes a central aperture and is mounted about the elongated shank such that the collar 67 is remote from the head 65 and the cylindrical portion 66 is adjacent to the head.
  • a breakaway portion 81 Extending outwardly from, and coaxial with, the threaded stud 69 on the side remote from the head 65 is a breakaway portion 81.
  • An undercut region 83 is formed where the breakaway portion 81 and the threaded stud meet.
  • the other end of the breakaway region 81 includes a gripping region 85.
  • the breakaway portion 81 is preferably cylindrical and has a diameter smaller than the diameter of the threaded stud 69.
  • the undercut region is formed such that when a sufficient coaxial force between the stud 69 and the breakaway portion is created, the breakaway portion 81 breaks away from the stud.
  • FIG. 4 illustrates a device for creating such a force.
  • the sleeve 61 is inserted into the aperture in the body, which aperture has a diameter generally similar to, or slightly larger than, the outer diameter of the cylindrical portion 66 of the sleeve 61, and condiderably less than the diameter of the collar 67.
  • the collar 67 lies above (as illustrated in FIG. 4) the upper surface of the sheet of electrically conductive material 43.
  • the head 65 of course, lies on the other side (lower) of the sheet.
  • a suitable tool 9] which includes a cylindrical housing 93 and an axially movable head 95 slidably located inside of the housing is used to attach the electrical terminal 69 to the sheet of electrically conductive material 43.
  • the axially movable head 95 includes an aperture surrounded by means (not shown) adapted to grip the gripping region 85 of the breakaway portion 81, and the lower tip of the cylindrical housing is adapted to press against the upper surface of the preformed collar 67.
  • the electrical terminal is mounted in the tool 91 in this manner before the sleeve is inserted into the aperture in the sheet.
  • the tool is energized.
  • Such energization causes the tool head 95 to move upwardly in the direction of the arrow 70, as viewed in FIG. 4, while housing 93 remains stationary against the preformed collar 67. This axial force causes the elongated shank 63 to move upwardly.
  • the head 65 causes the cylindrical portion 66 of the sleeve 61 to expand radially outwardly in the region where the cylindrical portion is planar with the sheet of electrically conductive material 43.
  • the cylindrical portion rolls outwardly.
  • the continuing tool force causes the breakaway portion 81 to separate from the threaded stud at the undercut region 83.
  • the end result is the electrical terminal structure illustrated in FIG. 5.
  • the rolled portion 99 ofthe sleeve is located on the back side of the sheet 43 and the breakaway portion 81 is not shown. Good electrical conduction between the sleeve and the sheet occurs in the peripheral meeting region designated 10].
  • the collar compressive forces as well as the radial force prevents axial rotation of the terminal.
  • the head can include a suitable depression which allows it to be held against rotation by a suitable means such as a Phillips screwdriver 102 (FIG. 4), for example.
  • FIG. 6 illustrates. in a side-by side manner, the electrical terminal structure of the invention both prior to the radial and roll expansion of the cylindrical portion 66 of the sleeve 61 and subsequent thereto.
  • the internal structure of the sleeve and shank is illustrated. More specifically, the left-hand side of FIG. 6 illustrates in cross-section the internal structure of the shank 63 and sleeve 61 prior to radial and roll expansion.
  • Located adjacent to the head 65 of the shank 63 is an undercut region 103.
  • Located above the undercut region 103 is a knurled cylindrical section 105.
  • the knurled cylindrical region 105 has a diameter slightly greater than the diameter of the undercut region 103.
  • the end of the knurled cylindrical section 105 adjacent to the undercut region 103 is relatively planar whereby a'sharp generally right-angle corner 106 is formed.
  • the end 107 of the knurled cylindrical section 105 remote from the undercut region 103 tapers inwardly. Projecting outwardly from the knurled cylindrical section 105 is the threaded stud 69.
  • the diameter of the threaded stud is less than the diameter of the knurled cylindrical section 105.
  • the inner surface of the sleeve 61 has two different diameter regions 108 and 109 and an inwardly curved tip 111.
  • the inwardly curved tip is on the end of the sleeve opposite to the collar 67 and lies in the undercut region 105.
  • the first diameter region 108 is the same or slightly larger than the knurled cylindrical section 103 of the shank 63 and surrounds that portion of the shank.
  • the second diameter region 109 has a diameter slightly smaller than the diameter of the knurled cylindrical section 105 and substantially larger than the diameter of the threaded stud 69.
  • the second diameter region lies between the end of the first diameter region and the prefomed collar end of the sleeve.
  • the head causes the lower portion (as viewed in FIG. 6) of the sleeve to roll outwardly to form the collar 99, as previously described.
  • the movement of the knurled cylindrical section 105 causes the second diameter region 109 to expand the sleeve outwardly, as it moves into this region. This outward expansion creates a tight ra dial force against the aperture side walls whereby the previously described electrical contact region 101 is formed.
  • the breakaway portion 81 breaks away, as previously described.
  • FIG. 7 illustrates an alternate embodiment of the in vention wherein one or more electrical contacts 112 are located between the preformed collar 67 and the upper surface of the electrical conductive material 43 rather than above the collar, and no threaded stud is included. Rather, the breakaway portion is located next to the knurled cylindrical section.
  • the electrical contacts are mounted in the illustrated position prior to axial movement of the shank. Axial movement of the shank creates the above-described forces.
  • the FIG. 7 embodiment results in a permanent attachment arrangement, rather than such an arrangement that allows electrical contact to be made and broken. However, the benefits of the invention are not lost. In this case, a low resistance electrical path exists between the cylindrical peripheral contact region 101, and between the electrical contact 112 and the collar 67 where they meet in the region 115.
  • FIG. 8 illustrates a further alternate embodiment of the invention.
  • the body of electrically conductive material 117 is relatively thick.
  • a nonconductive coating 119 (such as primer paint) may be located on one surface.
  • a dead end cylindrical aperture 121 passes through the nonconductive coating 119 and enters the body 117.
  • the sleeve end of the electrical terminal device is inserted into this aperture so that the collar lies surface-to-surface with the coating 119. Thereafter, the shank is moved upwardly in the direction of the arrow 123. This action creates a radial force which maintains the overall structure in the dead end cylindrical aperture 121. Obviously, no rollover of the sleeve occurs.
  • the greater radial contact surface which creates a greater radial force, to some extent compensates for this lack.
  • the invention provides an electrical terminal structure which overcomes the above-described problems of prior art electrical terminal structures.
  • the apparatus of the invention uncomplicated, its insertion is also uncomplicated and, therefore, inexpensive.
  • a simple well known tool is then utilized to move a shank outwardly with respect to a sleeve. This movement causes the sleeve to radially expand. If the remote end of the sleeve is free, it rolls outwardly.
  • the end result is a tight electrical terminal structure which has good electrical conductivity.
  • the structure also has axial and torque characteristics as good as, or better than, prior art structures, and in particular such structures of the type illustrated in FIG. 1.
  • good galvanic compatibility is provided.
  • good galvanic compatibility preferably, means a galvanic emf of less than 0.250 volts.
  • a sleeve made of tin coated naval brass (Brass AMS 46l lC /H] will have good galvanic compatibility with an aluminum sheet or body ofelectrically conductive material.
  • an Alodine 600 coating on a 606l-T6 aluminum substrate sleeve can be utilized with a body or sheet of the same nature, if desired.
  • other materials can be utilized depending upon the nature of the body or sheet of electrically conductive material.
  • an A151 302 series stainless steel sleeve can be used with a titanium sheet or body.
  • the shank is formed of a heat treated steel coated cadmium.
  • a blind shank expanding threaded electrical grounding terminal structure :
  • a sheet of material having an electrically conductive center and cove red on its first and second sides with generally non-conductive layers, said sheet of material having a cylindrical aperture therein extending through said electrically conductive center and said generally non-conductive layers whereby said electrically conductive center is exposed in the region defined by the periphery of said cylindrical aperture;
  • a head located on one end. said head adapted to cause a collar to be formed in a radially expandable sleeve on the second side of said sheet of material in bearing engagement with the nonconductive layer located on said second side;
  • a sleeve expanding region located adjacent to said head, said sleeve expanding region adapted to radially press a radially expandable sleeve into low resistance electrical contact with the portion of said electrically conductive center exposed in the region defined by the periphery of said cylindrical aperture;
  • a radially expandable sleeve mounted about said elongated shank and extending through said sheet of material so as to generally surround said sleeve expanding region, said radially expandable sleeve being in low resistance electrical contact with the portion of said electrically conductive center exposed in the region defined by the periphery of said cylindrical aperture and in low resistance electrical contact with said sleeve expanding region of said elongated shank, said radially expandable sleeve including:
  • a pre-formed collar located in bearing, but nonelectrical, engagement with the non-conductive layer located on the first side of said sheet of material;
  • a blind shank expanding threaded electrical grounding terminal suitable for mounting in an aperture formed in a body of electrically conductive material to provide a means for electrically connecting ground wires to said body of electrically conductive material in a low galvanic emf manner, said blind shank expanding terminal comprising:
  • a cylindrical longitudinally splined region located adjacent to said head, but spaced therefrom by a narrow undercut region, said splined region adapted to cause a radially expandable sleeve to expand radially outwardly when said sleeve surrounds said splined region and said splined region is axially moved in one direction with respect to said sleeve;
  • a cylindrical aperture coaxial with said cylindrical region and separated into two regions having different diameters the first of said diameters being approximately the same as the diameter of said splined region of said elongated shank and surrounding said splined region of said elongated shank prior to the expansion of said radially ex pandable sleeve into low resistance electrical contact, the second of said diameters being slightly smaller than the diameter of said splined region and surrounding said splined region after the expansion of said radially expandable sleeve into low resistance contact with the adjacent surface of said aperture in said body of electrically conductive material.
  • expansion means integrally formed with said threaded shaft, at one end thereof, for radially expanding a radially expandable sleeve when said sleeve surrounds said expansion means and said expansion means is moved in a predetermined direc tion with respect to said sleeve; and a radially expandable sleeve, including a collar formed at one end, mounted about said expansion means in a position such that said collar is located inwardly of the end of said expansion means nearest said threaded shaft, said radially expandable sleeve further including a cylindrical region integral with said collar, said cylindrical region formed so as to radially expand outwardly when said elongated shank is moved in said predetermined direction with respect to said radially expandable sleeve.
  • the improved electrical terminal structure claimed in claim 5 further including a breakaway region integrally formed with and extending axially outwardly from the end of said threaded shaft remote from the end integrally formed with said expansion means.
  • a method of creating a threaded electrical terminal in a sheet of material having an electrically conductive center and covered on both sides with generally non-conductive layers comprising the steps of:
  • blind shank expanding electrical terminal comprising an elongated shank threaded at one end, and a radially expandable cylindrical sleeve surrounding the other end of said shank, said shank and said sleeve formed such that axial movement of said shank with respect to said sleeve along their common axis in a predetermined direction causes said radially expandable sleeve to expand radially outwardly.
  • said sleeve being formed of a metallic material that is electrically compatible with the electrically conductive center of said sheet of material. said sleeve having an outer diameter sized such that it is surrounded by. but spaced slightly from.
  • said sleeve when centered in said cylindrical aperture prior to said axial movement, said sleeve including a collar having a diameter greater than the outer diameter of said sleeve surrounding the end of said sleeve nearest said threaded end of said shank, said blind shank expanding electrical terminal being inserted into said cylindrical aperture to a position such that said collar rests against one side of said sheet of material; and.
  • a method of creating a threaded electrical terminal in a body of material having an electrically conductive center and covered on one side with a generally non-conductive layer comprising the steps of:
  • blind shank expanding electrical terminal comprising an elongated shank threaded at one end, and a radially expandable cylindrical sleeve surrounding the other end of said shank, said shank and said sleeve formed such that axial movement of said shank with respect to said sleeve along their common axis in a predetermined direction causes said radially expandable sleeve to expand radially outwardly, said sleeve being formed of a metallic material that is electrically compatible with the electrically conductive center of said body of material, said sleeve having an outer diameter sized such that it is surrounded by.
  • said sleeve including a collar having a diameter greater that the outer diameter of said sleeve surrounding the end of said sleeve nearest said threaded end of said shank.
  • said blind shank expanding electrical terminal being inserted into said cylindrical aperture to a position such that said collar rests against said generally non-conductive layer;
US453200A 1974-03-21 1974-03-21 Blind, shank expanding electrical terminal structure Expired - Lifetime US3922050A (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US453200A US3922050A (en) 1974-03-21 1974-03-21 Blind, shank expanding electrical terminal structure
FR7508814A FR2265194B1 (fr) 1974-03-21 1975-03-20
GB1167375A GB1470272A (en) 1974-03-21 1975-03-20 Electrical terminal structures
BE160066A BE833449A (fr) 1974-03-21 1975-09-16 Borne electrique et son procede de fabrication

Applications Claiming Priority (1)

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US453200A US3922050A (en) 1974-03-21 1974-03-21 Blind, shank expanding electrical terminal structure

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US3922050A true US3922050A (en) 1975-11-25

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US (1) US3922050A (fr)
BE (1) BE833449A (fr)
FR (1) FR2265194B1 (fr)
GB (1) GB1470272A (fr)

Cited By (24)

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US4710133A (en) * 1986-06-19 1987-12-01 Trw Inc. Electrical connectors
FR2612836A2 (fr) * 1985-06-06 1988-09-30 Aerospatiale Materiau de protection contre la foudre
US5004427A (en) * 1986-06-19 1991-04-02 Labinal Components And Systems, Inc. Electrical connectors
EP0540030A2 (fr) * 1991-10-31 1993-05-05 PROFIL-Verbindungstechnik GmbH & Co. KG Vis de mise à la terre
EP0640404A1 (fr) * 1993-08-24 1995-03-01 NEDSCHROEF PLETTENBERG GmbH Couvercle
US5597313A (en) * 1986-06-19 1997-01-28 Labinal Components And Systems, Inc. Electrical connectors
US5672062A (en) * 1991-01-30 1997-09-30 Labinal Components And Systems, Inc. Electrical connectors
EP1017129A2 (fr) * 1998-12-31 2000-07-05 Emhart Inc. Goujon de fixation électrique
US6125524A (en) * 1994-03-25 2000-10-03 Multifastener Corporation Rivetable element, assembly, method of assembly and riveting die
US6547573B1 (en) 1999-06-17 2003-04-15 The Boeing Company Method and apparatus for producing a grounding path on a structure
FR2833110A1 (fr) * 2001-12-03 2003-06-06 Gobin Daude Dispositif de fixation perfectionne
US20040077105A1 (en) * 1999-03-15 2004-04-22 Lei Wu Individually addressable micro-electromagnetic unit array chips in horizontal configurations
US20050153586A1 (en) * 2004-01-08 2005-07-14 Airbus France Electrical connection device to make a metallisation point, support equipped with such a connection device and aircraft equipped with such a support
WO2005067100A1 (fr) * 2003-12-23 2005-07-21 Daimlerchrysler Ag Dispositif de contact de masse dans le domaine automobile
US20060000813A1 (en) * 2004-05-18 2006-01-05 Airbus Deutschland Gmbh Laser-assisted coating removal method
FR2879836A1 (fr) * 2004-12-21 2006-06-23 Peugeot Citroen Automobiles Sa Dispositif et procede de mise a la masse d'un fil electrique sur une structure metallique, notamment un carter en aluminium pour vehicule automobile
WO2006069997A1 (fr) * 2004-12-30 2006-07-06 Airbus España, S.L. Dispositif pour metalliser des blindages de cables electriques sur des structures composites
DE102008041263B4 (de) * 2008-08-14 2014-01-02 Airbus Operations Gmbh Masseanbindung mindestens eines Kabels
US20150180178A1 (en) * 2013-12-20 2015-06-25 Jac Products, Inc. Fastener Assembly For Use With Vehicle Article Carrier
US20160156115A1 (en) * 2013-07-16 2016-06-02 Phoenix Contact Gmbh & Co. Kg Contact device for establishing an electrical connection to a contact point of a printed circuit board
EP3133303A1 (fr) * 2015-08-18 2017-02-22 Profil Verbindungstechnik GmbH & Co. KG Élément de rivet aveugle
KR200490658Y1 (ko) * 2019-03-04 2019-12-13 주식회사 신우산업 블라인드 리벳
WO2021034908A1 (fr) * 2019-08-19 2021-02-25 Carlisle Interconnect Technologies, Inc. Connecteur électrique et système de liaison
WO2022207295A1 (fr) * 2021-03-31 2022-10-06 Brose Sitech Gmbh Boulon de fixation

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FR2466110A2 (fr) * 1979-09-24 1981-03-27 Joux Jean Claude Perfectionnement a un rivet aveugle utilisable comme borne de connexion electrique
EP0010055A1 (fr) * 1978-10-03 1980-04-16 Jean-Claude Joux Rivet aveugle utilisable comme borne de connexion électrique
DE3176798D1 (en) * 1981-09-30 1988-07-28 Boeing Co Fastening device and method for composite structures
WO1984000255A1 (fr) * 1982-06-30 1984-01-19 Boeing Co Dispositif de fixation et procede permettant de realiser des structures composites
DE3420960C2 (de) * 1984-06-06 1986-06-12 ESGE-MARBY GmbH + Co KG, 4800 Bielefeld Elektrische Kontaktierungseinrichtung für sandwichartig aufgebaute Radkotschützer
IT1215911B (it) * 1988-02-18 1990-02-22 Cembre Srl Contatto elettrico permanente applicabile sull'anima di rotaie esimili.

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US2061629A (en) * 1933-07-20 1936-11-24 Huxon Holding Corp Rivet

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Cited By (36)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2612836A2 (fr) * 1985-06-06 1988-09-30 Aerospatiale Materiau de protection contre la foudre
US5597313A (en) * 1986-06-19 1997-01-28 Labinal Components And Systems, Inc. Electrical connectors
US5004427A (en) * 1986-06-19 1991-04-02 Labinal Components And Systems, Inc. Electrical connectors
US4710133A (en) * 1986-06-19 1987-12-01 Trw Inc. Electrical connectors
US5704795A (en) * 1991-01-30 1998-01-06 Labinal Components And Systems, Inc. Electrical connectors
US5672062A (en) * 1991-01-30 1997-09-30 Labinal Components And Systems, Inc. Electrical connectors
EP0540030A3 (fr) * 1991-10-31 1994-03-02 Profil Verbindungstechnik Gmbh
EP0540030A2 (fr) * 1991-10-31 1993-05-05 PROFIL-Verbindungstechnik GmbH & Co. KG Vis de mise à la terre
EP0640404A1 (fr) * 1993-08-24 1995-03-01 NEDSCHROEF PLETTENBERG GmbH Couvercle
US6125524A (en) * 1994-03-25 2000-10-03 Multifastener Corporation Rivetable element, assembly, method of assembly and riveting die
EP1017129A2 (fr) * 1998-12-31 2000-07-05 Emhart Inc. Goujon de fixation électrique
EP1017129A3 (fr) * 1998-12-31 2000-11-15 Emhart Inc. Goujon de fixation électrique
US20040077105A1 (en) * 1999-03-15 2004-04-22 Lei Wu Individually addressable micro-electromagnetic unit array chips in horizontal configurations
US6547573B1 (en) 1999-06-17 2003-04-15 The Boeing Company Method and apparatus for producing a grounding path on a structure
FR2833110A1 (fr) * 2001-12-03 2003-06-06 Gobin Daude Dispositif de fixation perfectionne
WO2005067100A1 (fr) * 2003-12-23 2005-07-21 Daimlerchrysler Ag Dispositif de contact de masse dans le domaine automobile
US6991478B2 (en) 2004-01-08 2006-01-31 Airbus France Electrical connection device to make a metallisation point, support equipped with such a connection device and aircraft equipped with such a support
US20050153586A1 (en) * 2004-01-08 2005-07-14 Airbus France Electrical connection device to make a metallisation point, support equipped with such a connection device and aircraft equipped with such a support
US20060000813A1 (en) * 2004-05-18 2006-01-05 Airbus Deutschland Gmbh Laser-assisted coating removal method
US7525065B2 (en) * 2004-05-18 2009-04-28 Airbus Deutschland Gmbh Laser-assisted coating removal method
FR2879836A1 (fr) * 2004-12-21 2006-06-23 Peugeot Citroen Automobiles Sa Dispositif et procede de mise a la masse d'un fil electrique sur une structure metallique, notamment un carter en aluminium pour vehicule automobile
WO2006069997A1 (fr) * 2004-12-30 2006-07-06 Airbus España, S.L. Dispositif pour metalliser des blindages de cables electriques sur des structures composites
US20100089608A1 (en) * 2004-12-30 2010-04-15 Eduardo Orgaz Villegas Device for Electrical Bonding of Electrical Cables Shielding on Composite Structures
US8263864B2 (en) 2004-12-30 2012-09-11 Airbus Operations S.L. Device for electrical bonding of electrical cables shielding on composite structures
DE102008041263B4 (de) * 2008-08-14 2014-01-02 Airbus Operations Gmbh Masseanbindung mindestens eines Kabels
US9640881B2 (en) * 2013-07-16 2017-05-02 Phoenix Contact Gmbh & Co. Kg Contact device for establishing an electrical connection to a contact point of a printed circuit board
US20160156115A1 (en) * 2013-07-16 2016-06-02 Phoenix Contact Gmbh & Co. Kg Contact device for establishing an electrical connection to a contact point of a printed circuit board
US20150180178A1 (en) * 2013-12-20 2015-06-25 Jac Products, Inc. Fastener Assembly For Use With Vehicle Article Carrier
EP3133303A1 (fr) * 2015-08-18 2017-02-22 Profil Verbindungstechnik GmbH & Co. KG Élément de rivet aveugle
CN106468301A (zh) * 2015-08-18 2017-03-01 形状连接技术有限公司及两合公司 盲铆钉元件
CN106468301B (zh) * 2015-08-18 2019-11-19 形状连接技术有限公司及两合公司 盲铆钉元件
KR200490658Y1 (ko) * 2019-03-04 2019-12-13 주식회사 신우산업 블라인드 리벳
WO2021034908A1 (fr) * 2019-08-19 2021-02-25 Carlisle Interconnect Technologies, Inc. Connecteur électrique et système de liaison
US20210057832A1 (en) * 2019-08-19 2021-02-25 Carlisle Interconnect Technologies, Inc. Electrical Connector And Bonding System
US11695225B2 (en) * 2019-08-19 2023-07-04 Carlisle Interconnect Technologies, Inc. Electrical connector and bonding system
WO2022207295A1 (fr) * 2021-03-31 2022-10-06 Brose Sitech Gmbh Boulon de fixation

Also Published As

Publication number Publication date
FR2265194B1 (fr) 1983-03-25
GB1470272A (en) 1977-04-14
FR2265194A1 (fr) 1975-10-17
BE833449A (fr) 1976-01-16

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