Anti-friction / multi-contact terminal using knurling pattern

Abstract

The female electrical terminal (100) includes a fixed end (103) and a mating end (101) coupled to the fixed end (103) along a longitudinal axis. The mating end (101) includes a housing (102) provided with an opening (115) configured to receive a male contact (105). A contact pad (130) located within the housing (102) is oriented to contact the male contact (105) received within the opening (115), wherein a surface of the contact pad (130) includes a plurality of protrusions (142) extending from the surface.

Description

[0001] Cross-references to related applications

[0002] This application claims the priority benefit of U.S. Patent Application No. 16 / 985,595, filed August 5, 2020, the entire contents of which are incorporated herein by reference. Background Technology

[0003] Electrical contact between terminals typically relies on the generation of high contact forces between the components providing the contact. The surface area of ​​the corresponding electrical contacts can be relatively large; however, due to process variations and other factors, only a few electrical contact points are provided between the corresponding electrical contacts. Furthermore, mechanical vibrations between the corresponding components can induce friction at the contact points, eventually causing the conductive material to wear away at one or two contact points, resulting in a loss of electrical contact. To address this issue, complex geometries associated with the electrical contacts can be used to ensure additional contact points. However, this additional complexity increases the time and cost associated with manufacturing the electrical contacts.

[0004] It would be beneficial to develop an electrical contact that provides a cost-effective system for increasing the number of contact points between corresponding terminals while maintaining electrical contact in the presence of mechanical vibration / friction. Summary of the Invention

[0005] According to some aspects, a female electrical terminal includes a fixed end, a mating end located opposite to the fixed end along a longitudinal connecting axis, and a contact pad. The mating end further includes a housing having an opening configured to receive a male contact or terminal. The contact pad is positioned within the housing to contact the male terminal or contact received within the opening, wherein the surface of the contact pad includes a plurality of protrusions extending from the surface.

[0006] According to another aspect, the connection assembly may include a female electrical terminal and a male electrical terminal. The female electrical terminal may include a first end and a second end, the first end having an opening and a contact pad located within the first end, wherein the surface of the contact pad is knurled to provide a plurality of protrusions. The male electrical terminal includes a male contact element received into the opening of the female electrical terminal and positioned to contact the contact pad, wherein one or more of the protrusions provide an electrical contact point with the male contact element.

[0007] According to another aspect, the male electrical contact includes a first surface and a second surface opposite to the first surface. The first or second surface may include a contact surface comprising a plurality of protrusions extending from the surface. Attached Figure Description

[0008] Figure 1 This is an isometric view of the terminals according to some embodiments.

[0009] Figure 2 This is a top view of the terminals according to some embodiments.

[0010] Figure 3 This is a side view of a terminal according to some embodiments.

[0011] Figure 4 According to some embodiments Figure 2 The diagram shows a cross-sectional view of the terminal cut by line 2-2.

[0012] Figure 5 According to some embodiments Figure 3 The diagram shows a cross-sectional view of the terminal cut by line 3-3.

[0013] Figure 6 This is an enlarged view of a knurled pattern formed on a contact pad according to some embodiments.

[0014] Figure 7 This is a cross-sectional view of the contact pad taken along line 6-6, which shows the protrusions created by the grooves made on the contact pad according to some embodiments.

[0015] Figure 8 This is a graph showing the height of the contact pad along the plane axis according to some embodiments.

[0016] Figure 9 This is an isometric view of a male electrical terminal having a male contact including a knurled surface, according to some embodiments. Detailed Implementation

[0017] According to some aspects, contact pads used to form electrical contacts with corresponding terminals can utilize knurling patterns to increase the number of contact points between the corresponding terminals. In some embodiments, the knurling pattern comprises indentations of multiple recesses on the contact pad, wherein the multiple recesses formed in the contact pad result in multiple protrusions or ridges (i.e., the knurling pattern) abutting the recesses. Each of the multiple protrusions provides a possible electrical contact point between the contact pad and the mating terminal. Furthermore, friction between one or more contact points associated with the contact pad can cause new electrical contact points to be generated along the contact pad at different protrusions. In this way, friction does not cause a loss of electrical contact between the corresponding terminals. In some embodiments, the multiple recesses used to form the knurling can have various geometries, such as diamond-shaped recesses. Furthermore, a cost-effective and simple stamping process can be used to form the multiple recesses (and thus the knurling pattern), so that the knurling pattern does not significantly increase the cost of the terminals.

[0018] Reference Figure 1-3 A female electrical terminal 100 is provided, which includes a contact pad 130 with a knurled surface (in... Figure 4-8(As shown in the figure). The female electrical terminal 100 includes a mating end 101 and a stationary end 103. The mating end 101 is configured to receive a compatible male electrical terminal (e.g., a blade contact 105), and the stationary end 103 is configured to receive and retain a wire / conductor (not shown). A longitudinal connection axis is defined between the mating end 101 and the stationary end 103 in the connection direction indicated by arrow 109. The mating end 101 includes a housing 102 comprising a plurality of walls, including a first side wall 104 and a second side wall 108, a bottom wall 106, and a top wall 110. The housing extends longitudinally toward the stationary end 103, and the plurality of walls define an opening 115 configured to receive and retain the blade contact 105. In some embodiments, the portion of the blade contact 105 received within the opening 115 is held by a contact force spring 116. In some embodiments, the contact force spring 116 provides a contact force to ensure engagement between a portion of the leaf-type contact 105 and a contact pad 130 located on the inner surface of the housing and having a knurled surface (hereinafter referred to as...). Figure 4-7 (For more detailed description). A spring lock 117 is positioned on the bottom wall 106 to lock the terminal 100 into the connector housing. The fixed end 103 includes a conductor wing 112 and an insulating wing 114. The conductor (not shown) received at the fixed end 103 is secured to the female electrical terminal 100 by crimping the conductor wing 112 (at the conductive or exposed length of the conductor), and further secured by crimping the insulating wing 114 around a portion of the conductor. The terms “top” and “bottom” are used to distinguish the respective sidewalls; however, it should be understood that these terms do not require the top wall 110 to be positioned above the bottom wall 106. Depending on the mounting configuration of the female electrical terminal 100, the respective sidewalls may be positioned relative to each other in any orientation.

[0019] Now for reference Figure 4 and 5 A cross-sectional view of the female electrical terminal 100 is shown according to some embodiments. Figure 4 It is along Figure 2 The cross-sectional view of the female electrical terminal 100 taken by line 2-2 is shown. Figure 5 It is along Figure 3 The cross-sectional view of the female electrical terminal 100 taken by line 3-3 is shown.

[0020] exist Figure 4 In the cross-sectional view shown, the knurled contact pad 130 is located on the inner surface of the top wall 110. In some embodiments, the knurled contact pad 130 is located on a raised platform. For example, in Figure 5 In the cross-sectional view shown, contact pad 130 is situated on a raised platform that extends into housing 102 toward contact force spring 116. A male electrical terminal is inserted into opening 115, for example... Figure 1The blade connector, such as 105 shown, is forced into contact with the contact pad 130 under the contact force applied by the contact force spring 116. The knurled surface of the contact pad 130 ensures multiple contact points between the contact pad 130 and the blade connector 105. In some embodiments, the knurled surface of the contact pad 130 includes multiple recesses or indentations formed in the contact pad. As described below... Figure 6 and Figure 7 In detail, in some embodiments, multiple recesses are created using an imprinting operation. Each recess formed using the imprinting operation results in a corresponding protrusion (e.g., Figure 7 As shown, these protrusions point towards the contact force spring 116, opposite the contact pad 130. The blade connector 105 contacts one or more of these protrusions extending from the knurled surface of the contact pad 130. Subsequently, friction caused by mechanical vibration between the contact pad 130 and the blade contact 105 may cause the contact point between the blade contact 105 and the contact pad 130 to change from one or more protrusions in the first group to one or more protrusions in the second group.

[0021] In some embodiments, the contact pad 130 extends along most of the top wall 110. For example, in some embodiments, the contact pad 130 extends along at least 50% of the length of the top wall 110. In some embodiments, the contact pad 130 extends along at least 75% of the length of the top wall 110.

[0022] In some embodiments, the contact force spring 116 is connected via a spring retainer 120 located on the outer surface of the bottom wall 106 (e.g., ...). Figure 5 (As shown) It is fixed to the outer surface of the bottom wall 106. The first portion of the contact force spring 116 extends toward the opening 115, and then the second portion extends into the opening and toward the contact pad 130. When the blade contact 105 is inserted into the opening, the contact force spring 116 is bent, causing the contact force spring 116 to generate a contact force, causing the blade contact 105 to contact the contact pad 130.

[0023] Reference Figure 6 and 7 The knurled surface of the contact pad is discussed in more detail according to some embodiments. In particular, Figure 6 It is the partially knurled surface of contact pad 130 (part of 132, in Figure 4 (shown in the image) Enlarged view. Figure 7 It is along Figure 6 The image shows a cross-sectional view of the knurled surface taken by line 6-6. In some embodiments, the knurled surface includes a plurality of recesses 140 formed on the surface of the contact pad 130. Figure 6In the illustrated embodiment, the plurality of recesses 140 have a rhomboid geometry. In other embodiments, various other geometries can be used to form the recesses 140. In some embodiments, the knurled surface may include recesses having more than one size, depth, and / or geometry. Modifying one or more of the size, depth, and / or geometry of the recesses 140 may cause a plurality of protrusions 142 (e.g., ...) to form adjacent to the recesses 140 as the recesses are formed. Figure 7 (As shown) Changes. In some embodiments, the recess 140 is manufactured according to a stamping process for manufacturing the contact pad 130. In some embodiments, a knurled pattern is formed on the portion of the contact pad 130 intended to contact the male terminal. For example, in some embodiments, the male terminal is a blade connector, wherein the width of the knurled pattern will be equal to or greater than the width of the blade contact 105.

[0024] Figure 7 This is a cross-sectional view showing a plurality of recesses 140 and a plurality of corresponding protrusions 142 located near each of the plurality of recesses 140. In some embodiments, prior to the stamping process, the contact pad has a substantially flat surface defined by a plane P. In some embodiments, the plurality of recesses 140 are manufactured using a stamping process, the manufacture of the recesses resulting in a plurality of protrusions 142 in the vicinity of each of the plurality of recesses 140. The height of the plurality of protrusions 142 depends on the size, depth, and geometry of the plurality of recesses. Although Figure 7 The illustrated embodiment includes a plurality of recesses 140 with a generally uniform depth and a plurality of protrusions 142 with a generally uniform height; however, in some embodiments, the depth of the plurality of recesses 140 and the height of the plurality of protrusions 142 will vary. In some embodiments, variation in the height of the plurality of protrusions 142 is desirable to provide a plurality of initial contact points associated with a first plurality of protrusions located at a first height (i.e., maximum height) and a plurality of secondary contact points associated with a second plurality of protrusions. One or more of the first plurality of protrusions initially contact the male terminal, and friction thereunder causes one or more of the second plurality of protrusions to contact the male terminal. In this way, friction at the contact points does not result in a loss of electrical connection between the male terminal and the contact pad 130.

[0025] Figure 8This is a graph illustrating the heights of recesses 140 and protrusions 142 associated with a contact pad according to some embodiments. The flat surface of the contact pad 130 is designated as a reference height of zero. In some embodiments, the recesses 140 are defined by a depth of approximately -20 to -40 micrometers (μm), and the protrusions 142 are defined by a height of approximately 15 to 25 μm. In some embodiments, the depth of the recesses 140 is greater than the height of the protrusions 142. In some embodiments, this is the result of an imprinting operation, wherein the recesses 140 are formed using an imprinting machine comprising a plurality of protrusions. The protrusions 142 are formed by the movement of material during the formation of the recesses 140. One advantage of the contact pad 130 is the non-uniformity associated with the heights of the plurality of protrusions 142. For example, in Figure 8 In the illustrated embodiment, the protrusion 142 with the greatest height will create a first contact point between the contact pad 130 and the male terminal, while the protrusion with the smaller height will not (at least initially) contact the male terminal. When the protrusion 142 with the greatest height rubs and wears down to the point of losing contact with the male terminal, the protrusion with the smaller height will initially enter into contact with the male terminal. Thus, despite friction and wear, electrical contact can still be maintained between the contact pad 130 and the male terminal.

[0026] Figure 9 This is an isometric view of a blade-type contact 900 including a knurled contact area 902 according to some embodiments. Figure 4 and Figure 5 The illustrated embodiments are the opposite, for example, in Figure 9 In the illustrated embodiment, the knurled surface of the male blade connector 900 inserts into an opening associated with a female electrical terminal (not shown). In some embodiments, the knurled contact area 902 includes a plurality of protrusions formed along a first surface to provide the desired knurling. In some embodiments, both a first side of the blade contact 900 and a second side located opposite the first side can be knurled to ensure that the knurling contacts the contact pad of the female electrical terminal regardless of the orientation of the blade contact 900. As described above, in some embodiments, the knurled surface is created via the formation of a plurality of recesses on the surface of the blade connector 900, resulting in the formation of a plurality of protrusions on the surface that provide the desired knurling for the contact area 902. In some embodiments, if the male blade connector 900 includes the knurled contact area 902, the contact pad (not shown) located on the female terminal may not include a knurled surface. That is, in some embodiments, only one of the contact surfaces is knurled. In other embodiments, both the male blade connector and the contact pad, which is part of the female terminal, can include interacting knurled surfaces.

[0027] While the invention has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and its elements can be replaced by equivalents without departing from the scope of the invention. Furthermore, various modifications can be made to adapt specific situations or materials to the teachings of the invention without departing from its main scope. Therefore, the invention is not intended to be limited to the specific embodiments disclosed, but rather to include all embodiments falling within the appended claims.

[0028] Discussion of possible embodiments

[0029] The following is a non-exclusive description of possible embodiments of the present invention.

[0030] According to some aspects, a female electrical terminal includes a fixed end, a mating end located opposite to the fixed end along a longitudinal connecting axis, and a contact pad. The mating end further includes a housing with an opening configured to receive a male contact pad located within the housing, and the contact pad is oriented to contact a male contact received within the opening, wherein the surface of the contact pad includes a plurality of protrusions extending from the surface.

[0031] The female electrical terminals in the preceding paragraph may optionally include, additionally and / or alternatively include one or more of the following features, constructions and / or additional components.

[0032] For example, in some embodiments, the heights of the multiple protrusions may be uneven.

[0033] In some embodiments, one or more contact points may be formed between one or more of a plurality of protrusions and a male contact, and wherein the one or more contact points may shift over time in response to friction of the original contact points.

[0034] In some embodiments, the contact pad may include a plurality of recesses.

[0035] In some embodiments, a plurality of protrusions may be formed in response to the formation of a plurality of recesses.

[0036] In some embodiments, the plurality of recesses may be rhomboid in shape.

[0037] In some embodiments, the housing may include at least a bottom wall, a top wall, and two side walls extending between the bottom wall and the top wall, the side walls defining an opening for receiving a male contact, wherein a contact pad is located on the inner surface of the bottom wall or the top wall.

[0038] In some embodiments, the female electrical terminal may further include a spring attached to the top wall that extends into an opening within the housing, wherein the spring is positioned to contact the male contact to provide contact force between the male contact and the contact pad.

[0039] In some embodiments, the fixed end may include conductive wings and insulating wings.

[0040] According to another aspect, the connection assembly may include a female electrical terminal and a male electrical terminal. The female electrical terminal may include a first end and a second end, the first end having an opening and a contact pad located within the first end, wherein the surface of the contact pad is knurled to provide a plurality of protrusions. The male electrical terminal includes a male contact element received into the opening of the female electrical terminal and positioned to contact the contact pad, wherein one or more of the protrusions provide an electrical contact point with the male contact element.

[0041] The connecting components of the preceding paragraphs may optionally include, additionally and / or alternatively include one or more of the following features, constructions and / or additional components.

[0042] For example, in some embodiments, the first end may include a housing that defines an opening for receiving a male contact.

[0043] In some embodiments, the housing may include at least a top wall, a bottom wall, and two side walls extending between the top wall and the bottom wall, wherein the top wall, the bottom wall, and the two side walls form an opening for receiving a male contact, and wherein a contact pad is located on the inner surface of the bottom wall.

[0044] In some embodiments, the female electrical terminal may further include a spring fixed to the top wall that extends into the opening, wherein the spring provides contact force between the male contact and the contact pad.

[0045] In some embodiments, the heights of the multiple protrusions may be uneven.

[0046] In some embodiments, the contact pad may include a plurality of recesses.

[0047] In some embodiments, the plurality of recesses may be rhomboid in shape.

[0048] According to another aspect, the male electrical contact includes a first surface and a second surface opposite to the first surface. The first or second surface may include a contact surface comprising a plurality of protrusions extending from the surface.

[0049] The anode electrical contact in the preceding paragraph may optionally include, additionally and / or alternatively include one or more of the following features, constructions and / or additional components.

[0050] For example, in some embodiments, the heights of the multiple protrusions may be uneven.

[0051] In another embodiment, one or more contact points may be formed between one or more of the plurality of protrusions and a contact pad associated with the female terminal.

[0052] In another embodiment, the contact surface may include a plurality of recesses.

[0053] In another embodiment, the multiple protrusions may be formed in response to the formation of the multiple recesses.

Claims

1. A female electrical terminal (100), comprising: a fixed end (103); a mating end (101) coupled to the fixed end (103) along a longitudinal axis, the mating end (101) including a housing (102) provided with an opening (115) configured to receive a male contact (105); and a contact pad (130) located within the housing (102) having a planar surface for contacting the male contact (105) received within the opening (115), wherein the planar surface of the contact pad (130) includes a plurality of recesses (140) defined within the planar surface and a plurality of pointed protrusions (142) extending from the planar surface, the recesses (140) have a depth of about negative twenty to negative forty microns relative to the planar surface and the protrusions (142) have a height of fifteen to twenty-five microns relative to the planar surface, the plurality of protrusions (142) are formed from movement of material upon formation of the recesses, the plurality of protrusions includes a plurality of first protrusions of a first height and a plurality of second protrusions of a second height, the second height being less than the first height, a contact point is formed between one or more of the plurality of first protrusions and the male contact (105), and wherein the contact point is transferred over time to one or more of the plurality of second protrusions in response to friction of the first protrusions.

2. The female electrical terminal (100) of claim 1, characterized in that, the plurality of recesses (140) are diamond shaped.

3. The female electrical terminal (100) of claim 1, characterized in that, the housing (102) includes at least a bottom wall (106), a top wall (110), and two side walls (108) extending between the bottom wall (106) and the top wall (110) defining the opening (115) for receiving the male contact (105), wherein the contact pad (130) is located on an inner surface of the bottom wall (106) or the top wall (110).

4. The female electrical terminal (100) of claim 3, characterized in that, further comprising: a spring (120) affixed to the housing (102), the spring extending into the opening (115) within the housing (102), wherein the spring (120) is positioned in contact with the male contact (105) to provide a contact force between the male contact (105) and the contact pad (130).

5. The female electrical terminal (100) of claim 1, wherein, the fixed end (103) includes a conductive wing (112) and an insulative wing (114).

6. A connection assembly, the connection assembly comprising: A female electrical terminal (100) having a first end (101) and a second end (103), the first end (101) having an opening (115) and a contact pad (130) located within the first end (101), wherein a flat surface of the contact pad (130) is knurled to provide a plurality of recesses (140) defined within the flat surface of the contact pad (130) and a plurality of protrusions extending from the flat surface and being pointed, the recesses (140) having a depth of about negative twenty to negative forty microns relative to the flat surface, the protrusions (142) having a height of fifteen to twenty-five microns relative to the flat surface, the plurality of protrusions including a first plurality of protrusions of a first height and a second plurality of protrusions of a second height, the second height being less than the first height; and a male electrical terminal having a male contact (105) received within the opening (115) of the female electrical terminal (100) and placed in contact with the contact pad (130), wherein the plurality of protrusions includes a first plurality of protrusions of a first height and a second plurality of protrusions of a second height, the second height being less than the first height, a contact point being formed between one or more of the first plurality of protrusions of the first height and the male contact (105), and wherein the contact point migrates over time in response to friction of the first protrusions and is formed between one or more of the second plurality of protrusions of the second height and the male contact.

7. The connection assembly of claim 6, wherein, The first end (101) includes a housing (102) defining the opening (115) for receiving the male contact (105).

8. The connection assembly of claim 7, wherein, The housing (102) includes at least a top wall (110), a bottom wall (106), and two side walls (108) extending between the top wall (110) and the bottom wall (106), wherein the top wall (110), the bottom wall (106), and the two side walls (108) form the opening (115) for receiving the male contact (105), and wherein the contact pad (130) is located on an inner surface of the bottom wall (106).

9. The connection assembly of claim 8, wherein, The female electrical terminal (100) further includes a spring (120) affixed to the top wall (110), the spring extending into the opening (115), wherein the spring (120) provides a contact force between the male contact (105) and the contact pad (130).

10. The connection assembly of claim 6, wherein, The plurality of recesses (140) are diamond shaped.

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