Electrical terminal assembly with increased contact area

Abstract

The present application relates to an electrical terminal assembly with an increased contact area. An electrical terminal assembly includes a contact member and a spring member. The contact member has a base and a contact arm, which extends from the base in an arm direction on opposite sides of the terminal plane. The spring member is supported on the contact member and includes a spring base and a spring arm, which extends from the spring base in an arm direction. The spring arms are located on opposite sides of the terminal plane and engage corresponding ones of the contact arms at corresponding spring contact portions. The spring member also includes a shield connected to the spring base and having an end shield extending beyond the arm. The shield includes side shields, which are located on opposite sides of the contact arm and connect the end shield to the spring base. The shield arm also connects the end shield to the spring base.

Description

Background of the Invention

[0001] The present invention relates to electrical terminal assemblies. More particularly, the present invention relates to an electrical terminal assembly that allows for a larger contact area with a mating terminal.

[0002] An electrical terminal assembly typically includes a female terminal and a corresponding male terminal that can cooperate to establish an electrical connection. It is known to provide a spring member for the female terminal to increase the compressive force between the male terminal and the female terminal. An example of such a terminal assembly is shown in U.S. Patent No. 10,396,482. The spring member is typically made of a material that is less conductive but less prone to relaxation than the material of the contact member. The spring member maintains the desired compressive force without increasing the size of the contact member and allows the female terminal assembly to maintain the desired contact area with the male terminal even when the temperature of the female terminal increases.

[0003] The terminal assembly shown in the '482 patent includes a spring member with an integral front end protection. The spring member includes a cage that extends around and beyond the contact arm. The cage protects the contact arm from damage during transportation, handling, installation, and use. Because the cage is part of the spring member, no additional parts are added to the female terminal assembly. It is desirable to have a terminal assembly that allows for a larger contact area with the corresponding male terminal. SUMMARY OF THE INVENTION

[0004] The present invention relates to an electrical terminal assembly. The electrical terminal assembly includes a contact member. The contact member has a contact base and a plurality of contact arms extending from the contact base in an arm direction. The contact arms are arranged on opposite sides of a terminal plane. The electrical terminal assembly also includes a spring member. The spring member is supported on the contact member. The spring member includes a spring base and a plurality of spring arms extending from the spring base in an arm direction. The spring arms are arranged on opposite sides of the terminal plane and engage corresponding contact arms of the plurality of contact arms at a spring contact portion. The spring member also includes a shield connected to the spring base. The shield extends around and beyond the contact arms. The shield has an end shield positioned to exceed the contact arm in the arm direction. The shield also has a side shield located on opposite sides of the contact arm and connecting the end shield to the spring base. The shield also includes a shield arm connecting the end shield to the spring base.

[0005] In another embodiment, an electrical terminal assembly includes an end shield reinforcement.

[0006] In another embodiment, an electrical terminal assembly includes terminal guides extending from an end shield along an arm direction and toward a terminal plane. The terminal guides are spaced apart from each other to define crenels between adjacent terminal guides.

[0007] Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a perspective view of a first embodiment of an electrical terminal assembly.

[0009] Figure 2 yes Figure 1 An exploded perspective view of the electrical terminal assembly shown in FIG.

[0010] Figure 3 Is from Figure 1 and Figure 2 A plan view of a spring member of an electrical terminal assembly is shown.

[0011] Figure 4 is a front view of the elastic member.

[0012] Figure 5 It is along Figure 3 A cross-sectional view of the spring member taken along line 5-5.

[0013] Figure 6 is a perspective view of an electrical terminal assembly connected to a busbar.

[0014] Figure 7 It is along Figure 6 A cross-sectional view taken along line 7-7 in FIG. 1 illustrates the connection of the electrical terminal assembly to the busbar.

[0015] Figure 8 is similar to Figure 7 sectional view illustrating the connection of a second embodiment of an electrical terminal assembly to a second busbar.

[0016] Detailed Description of the Preferred Embodiments

[0017] Now referring to the drawings, Figure 1 A perspective view of a first embodiment of an electrical terminal assembly, generally designated 10, is illustrated in FIG. The electrical terminal assembly 10 includes some features similar to the electrical terminal assembly with a locking spring member described and illustrated in U.S. Patent No. 10,396,482, the disclosure of which is hereby incorporated by reference. Figure 2 is an exploded perspective view of the electrical terminal assembly 10 showing the contact member, generally designated 12 , the spring member, generally designated 14 , and the retainer, generally designated 16 , respectively.

[0018] The illustrated contact member 12 is made from a single copper sheet that has been stamped and folded into the illustrated shape. However, the contact member 12 can be made from any desired material and can be manufactured using any desired process. The contact member 12 includes a connecting portion 18, which will be described in detail below. The contact member 12 also includes a contact base 20 that is connected to the connecting portion 18. The illustrated contact base 20 has a substantially rectangular cross-sectional shape. However, the contact base 20 can have any desired shape.

[0019] The contact member 12 includes a plurality of contact arms 24 extending from the contact base 20 in an arm direction 26. In the illustrated embodiment, the connecting portion 18 and the contact arms 24 are located on opposite sides of the contact base 20, but these components may have any desired relative orientation. In the illustrated embodiment, the contact member 12 includes eight pairs of contact arms 24, but the contact member 12 may have any desired number and arrangement of contact arms 24. The members of each pair of contact arms 24 are arranged on opposite sides of the terminal plane 28.

[0020] The contact member 12 also includes a plurality of spring spaces 30 that are used to position the spring member 14 relative to the contact member 12, as will be described below. The illustrated contact member 12 includes four spring spaces 30 on each side of the terminal plane 28. However, the contact member 12 may include any desired number of spring spaces 30. In the illustrated embodiment, the spring spaces 30 are located between adjacent pairs of contact arms 24 and extend into the contact base 20. However, the spring spaces 30 may be located in any desired position on the contact member 12.

[0021] The illustrated spring member 14 is made from a single sheet of material that has been stamped and folded into the illustrated configuration. However, the spring member 14 may be made by any desired process. The illustrated spring member 14 is made from stainless steel, but may be made from any desired material. Preferably, the spring member 14 is made from a material that exhibits good spring properties even at relatively high temperatures.

[0022] The spring member 14 includes a spring base 32. The illustrated spring base 32 includes two bridge portions 34, each connected to a plurality of U-shaped legs 36. However, the spring base 32 may have any desired shape. The illustrated spring base 32 includes four legs 36, but may include any desired number. The spring member 14 includes a plurality of spring arms 38 extending from the spring base 32 in the arm direction 26. In the illustrated embodiment, the spring member 14 includes four pairs of spring arms 38 extending from the spring base 32 and arranged on opposite sides of the terminal plane 28. However, the spring member 14 may include any desired number and arrangement of spring arms 38.

[0023] Each spring arm 38 extends from the spring base 32 to a respective spring end 40. Each spring arm 38 includes a spring contact 42 that engages the contact arm 24 when the electrical terminal assembly 10 is assembled. Each illustrated spring arm 38 includes two spring contacts 42 that extend from opposite sides of the spring arm 38. When the electrical terminal assembly 10 is assembled, each spring contact 42 engages a different contact arm 24, such that each illustrated spring arm 38 engages two contact arms 24.

[0024] like Figure 5 As best shown, each spring arm 38 includes a spring arm deflection portion 44 between the spring base portion 32 and the spring contact portion 42. Each illustrated spring arm deflection portion 44 is a V-shaped portion of the corresponding spring arm 38 that bends toward the terminal plane 28. Figure 1 When assembled as shown, the arm deflection portion 44 is located between adjacent contact arms 24 .

[0025] like Figure 2 As best shown, the spring member 14 includes a shield, generally designated 46. The shield 46 includes an end shield 48 positioned further in the arm direction 26 than the spring arm 38. The end shield 48 is connected to the spring base 32 by two side shields 50. The side shields 50 are located on opposite sides of the spring arm 38, and the terminal plane 28 passes through each of the illustrated side shields 50. In the illustrated embodiment, each side shield 50 includes a dovetail lock 52 that holds the spring member 14 in the illustrated shape. However, the spring member 14 may include any desired type of retainer. The illustrated shield 46 is substantially symmetrical about the terminal plane 28, but may have any desired shape.

[0026] The spring member 14 includes a plurality of shield arms 54 extending from the spring base 32 to the end shields 48. The shield arms 54 are shown extending substantially parallel to the terminal plane 28. However, the shield arms 54 may have any desired orientation. The shield arms 54 are located between the side shields 50. Figure 3 As best shown, each illustrated cover arm 54 is located between adjacent pairs of spring arms 38. However, the cover arms 54 may be disposed in any desired location.

[0027] The spring member 14 also includes an end shield reinforcement 56. The end shield reinforcement 56 is shown as an embossed portion of the end shield 48, but may be, for example, an additional layer of material applied to the end shield 48. Figure 5 As best shown, the end shield reinforcement 56 extends from the end shield 48 toward the terminal plane 28. Thus, the illustrated end shield reinforcement 56 increases the strength of the end shield 48 without increasing the outer dimensions of the spring member 14. However, the end shield reinforcement 56 may be provided at any desired location.

[0028] When the electrical terminal assembly 10 is as Figure 1 As shown assembled, the end shield 48 is positioned further in the arm direction 26 than the contact arm 24, and the side shield 50 is located on the opposite side of the contact arm 24. Thus, the shield 46 extends from the spring base 32 around the contact arm 24 and extends beyond the contact arm 24 in the arm direction 26.

[0029] The spring member 14 includes a terminal guide 58 extending from the end shield 48 in the arm direction 26. The terminal guide 58 is used to protect the contact arm 24 from damage during mating with a corresponding male terminal (not shown). In order to mate with the electrical terminal assembly 10, the corresponding male terminal is inserted through the insertion opening 60 of the spring member 14. The insertion opening 60 is defined by the end shield 48 and the side shield 50 of the shield 46. In order to prevent damage to the contact arm 24, it is desirable that the corresponding terminal be inserted in a desired orientation and posture relative to the terminal assembly 10. The terminal guide 58 extends from the end shield 48 toward the terminal plane 28 to reduce the size of the insertion opening 60, thereby preventing the corresponding male terminal from stubbing against the contact arm 24.

[0030] The terminal guide 58 shown is not continuous. Figure 3 , a series of terminal guides 58 extend from the end shield 48 and are spaced apart from one another to define a series of crenels 62 between adjacent terminal guides 58. The crenels 62 are gaps between the terminal guides 58, and each crenel 62 defines a portion of a corresponding tool space 64 that extends parallel to the arm direction 26. The tool spaces 64 extend opposite the arm direction 26, and a portion of at least one spring arm 38 extends into each tool space 64. In the illustrated embodiment, the tool space 64 is also located between the side shield 50 and the terminal guides 58.

[0031] refer to Figure 4 , a portion of each spring contact 42 on each spring arm 38 is located in the tool space 64. In addition, each spring contact 42 on a single spring arm 38 is located in a different tool space 64. This allows a tool, such as an arbor (not shown), to be inserted through the insertion opening 60 and engage the spring arm 38 to push the spring arm 38 further away from the terminal plane 28 than the terminal guide 58 might allow. In the illustrated embodiment, the tool space 64 extends through the terminal plane 28 between the two end shields 48. However, if desired, the tool spaces 64 on either side of the terminal plane 28 can be positioned differently from each other.

[0032] To attach the assembled spring member 14 to the assembled contact member 12, a tool is used to push the spring arms 38 apart, away from the terminal plane 28. The spring member 14 is then moved relative to the contact member 12 in a direction opposite to the arm direction 26 so that each leg 36 on the spring member 14 is received within one of the spring spaces 30. The spring arms 38 are then released and allowed to recoil, so that the spring contacts 42 engage the contact arms 24 and the spring arm deflections 44 are positioned between adjacent contact arms 24, which helps to properly position the spring member 14 relative to the contact member 12. This allows the spring member 14 to be attached to the contact member 12 after the spring member 14 has been assembled (including the side covers 50 being connected via corresponding dovetail locks 52).

[0033] Compared to the electrical terminal assembly described in U.S. Patent No. 10,396,482, the electrical terminal assembly 10 is wider and includes a greater number of contact arms 24. This provides a greater contact area between the electrical terminal assembly 10 and the corresponding terminal. The shield arms 54 and the end shield reinforcement 56 provide additional strength to the shield 46 and prevent the end shield 48 from deflecting relative to the spring base 32.

[0034] Reference again Figure 2 , the illustrated connecting portion 18 is part of the contact member 12 and is made of two layers of material that are stacked one on top of the other. However, the connecting portion 18 can be made of any desired type and arrangement of materials. The connecting portion 18 includes a connecting surface 66. The illustrated connecting surface 66 is substantially planar and is located on the connecting portion 18 facing the terminal plane 28. However, the connecting surface 66 can have any desired shape and can be located in any desired position.

[0035] The connecting portion 18 includes a mounting hole 68. The mounting hole 68 is generally located at the center of the connecting surface 66 and extends through both layers of material of the connecting portion 18. In the illustrated embodiment, the retainer 16 is a swaged nut. Figure 1 When assembled as shown, the shaft 70 of the retainer 16 is inserted into the mounting hole 68 .

[0036] refer to Figure 6 , which illustrates something similar to Figure 1 , in which the electrical terminal assembly is shown attached to a busbar 72. The busbar 72 engages the electrical terminal assembly 10 to allow current to flow between the busbar 72 and the electrical terminal assembly 10. Screws 74 are threaded into the retainer 16 and engage the busbar 72 to hold the busbar 72 in the position shown against the connection surface 66.

[0037] refer to Figure 7 , showing the Figure 67. As shown, the screw 74 engages the retainer 16, and the connecting portion 18 and the busbar 72 are trapped between the retainer 16 and the screw 74. This maintains contact between the electrical terminal assembly 10 and the busbar 72. In the illustrated embodiment, the shaft 70 of the retainer 16 extends into the mounting hole 68 a distance approximately equal to the thickness of a layer of material of the connecting portion 18. However, the shaft 70 can extend into the mounting hole 68 any desired distance.

[0038] refer to Figure 8 , which illustrates something similar to Figure 7 , showing a second embodiment of the electrical terminal assembly 110 attached to the second busbar 172. The second embodiment of the electrical terminal assembly 110 is substantially similar to the first embodiment of the electrical terminal assembly 10 previously described, and like features are identified by like element numerals increased by 100. Figure 8 As shown, the second electrical terminal assembly 110 includes a mounting hole 168, which includes two different cross-sectional sizes. The mounting hole 168 includes a first portion 176 and a second portion 178. In the illustrated embodiment, both the first portion 176 and the second portion 178 have a circular cross-sectional shape relative to the connecting surface 166. However, the first portion 176 and the second portion 178 can have any desired cross-sectional shape. As shown, the second portion 178 is positioned closer to the connecting surface 166 than the first portion 176. The second portion 178 also has a larger diameter than the first portion 176. In the illustrated embodiment, the first portion 176 of the mounting hole 168 passes through the first layer of material of the connecting portion 118, and the second portion of the mounting hole 168 passes through the second layer of material of the connecting portion 118.

[0039] As shown, the shaft 170 of the retainer 116 extends through the first portion 176 into the mounting hole 168. The larger second portion 178 provides a deflection space 180 between the retainer 116 and the busbar 172. The deflection space 180 provides room for deformation of the material of the connecting portion 118 during attachment of the electrical terminal assembly 110 to the busbar 172.

[0040] The illustrated embodiments have been described using swaged nuts as retainers 16 and 116, but any desired type of connector may be used with the electrical terminal assemblies 10 and 110. For example, the electrical terminal assembly 10 may not include the mounting holes 68 and may be welded to the busbar 72. Additionally, the illustrated embodiments have been described in conjunction with the busbars 72 and 172, but the electrical terminal assemblies 10 and 110 may be connected to any desired type of conductor.

[0041] The principles and modes of operation of the present invention have been explained and illustrated in its preferred embodiments. However, it must be understood that the present invention may be practiced in ways other than as specifically explained and illustrated without departing from the spirit or scope of the invention.

Claims

1. An electrical terminal assembly, comprising: a contact member including a contact base having contact arms extending from the contact base in an arm direction and arranged on opposite sides of a terminal plane; and A spring member supported on the contact member, the spring member comprising a spring base, at least two spring arms and a shield, the at least two spring arms extending from the spring base in the arm direction on opposite sides of the terminal plane to engage with the contact arm at corresponding spring contacts, the shield being connected to the spring base and extending around the contact arm and extending beyond the contact arm in the arm direction, the shield comprising an end shield, a side shield and a shield arm, the end shield being positioned beyond the contact arm in the arm direction, the side shield being located on opposite sides of the contact arm, the side shield connecting the end shield to the spring base, and the shield arm connecting the end shield to the spring base, wherein each of the shield arms is located between a pair of adjacent spring arms of the at least two spring arms.

2. The electrical terminal assembly according to claim 1, wherein The cover arm extends substantially parallel to the terminal plane.

3. The electrical terminal assembly according to claim 1, wherein The cover arms are located between the side covers.

4. The electrical terminal assembly according to claim 1, wherein The cover arms are located on opposite sides of the terminal plane.

5. The electrical terminal assembly according to claim 1, wherein The end shield includes an end shield reinforcement.

6. The electrical terminal assembly according to claim 5, wherein: The end shield reinforcement portion extends from the end shield toward the terminal plane.

7. The electrical terminal assembly according to claim 6, wherein: The shroud includes terminal guides extending from the end shroud along the arm direction and toward the terminal plane, and wherein the terminal guides are spaced apart from one another to define crenels between adjacent terminal guides.

8. The electrical terminal assembly according to claim 7, wherein: The crenel defines tool spaces extending parallel to the arm directions, and wherein each spring arm is at least partially located in one of the tool spaces.

9. An electrical terminal assembly comprising: a contact member including a contact base having contact arms extending from the contact base in an arm direction and arranged on opposite sides of a terminal plane; and a spring member supported on the contact member, the spring member comprising a spring base, at least two spring arms extending from the spring base in the arm direction on opposite sides of the terminal plane to engage the contact arms at corresponding spring contacts, and a shield connected to the spring base and extending around the contact arms and beyond the contact arms in the arm direction; The shield includes an end shield and a shield arm, wherein the end shield is positioned to exceed the contact arm in the arm direction and includes an end shield reinforcement portion, and the shield arm connects the end shield to the spring base, wherein each of the shield arms is located between a pair of adjacent spring arms of the at least two spring arms.

10. The electrical terminal assembly according to claim 9, wherein The end shield reinforcement portion extends from the end shield toward the terminal plane.

11. The electrical terminal assembly according to claim 10, wherein: The shroud includes terminal guides extending from the end shroud along the arm direction and toward the terminal plane, and wherein the terminal guides are spaced apart from one another to define crenels between adjacent terminal guides.

12. The electrical terminal assembly according to claim 11, wherein The crenel defines tool spaces extending parallel to the arm directions, and wherein each spring arm is at least partially located in one of the tool spaces.

13. An electrical terminal assembly comprising: a contact member including a contact base having contact arms extending from the contact base in an arm direction on opposite sides of a terminal plane; and a spring member supported on the contact member, the spring member comprising a spring base, at least two spring arms extending from the spring base in the arm direction on opposite sides of the terminal plane to engage the contact arms at corresponding spring contacts, and a shield connected to the spring base and extending around the contact arms and beyond the contact arms in the arm direction; wherein the shield comprises an end shield, a terminal guide and a shield arm, the end shield being positioned beyond the contact arm in the arm direction, the terminal guide extending from the end shield along the arm direction and toward the terminal plane, the shield arm connecting the end shield to the spring base, and wherein the terminal guides are spaced apart from each other to define a crenel between adjacent terminal guides, and wherein each of the shield arms is located between adjacent pairs of spring arms of the at least two spring arms.

14. The electrical terminal assembly according to claim 13, wherein The crenel defines tool spaces extending parallel to the arm directions, and wherein each spring arm is at least partially located in one of the tool spaces.

15. The electrical terminal assembly according to claim 14, wherein The shield includes side shields located on opposite sides of the contact arm, the side shields connecting the end shield to the spring base.

16. The electrical terminal assembly according to claim 13, wherein The cover arm extends substantially parallel to the terminal plane.

17. The electrical terminal assembly according to claim 15, wherein The cover arms are located between the side covers.

18. The electrical terminal assembly according to claim 13, wherein The cover arms are located on opposite sides of the terminal plane.

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