Twist-lock electrical connector assembly

Abstract

The present invention relates to an electrical connector assembly, comprising a male terminal (100) having a first pivot feature (102) and a plurality of contact arms (104) extending from the first pivot feature (102). The assembly also comprises a female terminal (200) having a base (202) defining a second pivot feature (204) and a plurality of receiving features (206), the plurality of receiving features (206) being configured to receive free ends (112) of the plurality of contact arms (104) as the first pivot feature (102) engages the second pivot feature (204) and the plurality of contact arms (104) rotate about the first and second pivot features (102, 204).

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 086,893, filed on October 2, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to a twist-lock electrical connector assembly. Background Art

[0004] Conductive traces are formed on or in a vehicle window to complete an electrical circuit, such as an antenna or defroster. To electrically connect the conductive traces to the associated electronic device, electrical terminals, typically male terminals, are soldered to the glass in communication with the conductive traces. Female terminals at the ends of cables connected to the associated electronic device then mate with male terminals located on the glass.

[0005] In some applications, the male terminal has a male circular post, and the mating female terminal may have a cup-shaped female receptacle with a resilient contact tab that engages the post. The contact tab bends inward into the receptacle for a resilient engagement. The female terminal's cup-shaped receptacle is crimped to the conductor within the cable. This type of female receptacle is often used in low-power applications such as antennas but is unsuitable for higher-power devices such as rear window defrosters. Summary of the Invention

[0006] According to one or more aspects of the present disclosure, an electrical connector assembly includes a male terminal having a first pivot feature and a plurality of contact arms extending from the first pivot feature. The electrical connector assembly also includes a female terminal having a base plate defining a second pivot feature and a plurality of receiving features, the plurality of receiving features being configured to receive free ends of the plurality of contact arms as the first pivot feature engages the second pivot feature and the plurality of contact arms rotate about the first pivot feature and the second pivot feature.

[0007] In one or more embodiments of the electrical connector assembly according to the preceding paragraph, the first pivot feature can be a circular recess and the second pivot feature can be a circular protrusion received within the circular recess.

[0008] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the circular recess may be formed by a circular aperture extending through the male terminal.

[0009] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the first pivot feature may be formed by a relief in the form of a sector of a hollow ball.

[0010] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the plurality of receiver features may define a U-shaped gap in which the free end is received.

[0011] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, each arm of the plurality of contact arms may be offset from an adjacent arm of the plurality of contact arms by an angle of less than 180 degrees.

[0012] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, each arm of the plurality of contact arms may be offset from an adjacent arm of the plurality of contact arms by an angle of approximately 150 degrees.

[0013] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the plurality of contact arms define a stop feature that may extend vertically from the plurality of contact arms and proximate the free end, and the stop feature may be configured to engage the plurality of receiving portion features as the plurality of contact arms rotate about the first pivot feature and the second pivot feature, thereby limiting further rotation.

[0014] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the plurality of contact arms may define a contact protrusion extending proximate the free end and configured to contact the plurality of receiving features.

[0015] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the contact protrusion may be formed by a relief in the form of a spherical sector.

[0016] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the plurality of receptacle features may define contact recesses configured to receive the contact protrusions.

[0017] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the contact recess can be formed by a circular aperture extending through the plurality of receiving features.

[0018] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the contact recess may be formed by a relief in the form of a sector of a hollow sphere.

[0019] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the base plate can be generally planar and circular about the second pivot feature.

[0020] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the plurality of receiver features may be J-shaped tabs extending from an edge of the substrate.

[0021] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the male terminal may further include a wire attachment portion extending from the first pivot feature.

[0022] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the plurality of contact arms may include two arms.

[0023] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the substrate may include a solder layer on a surface opposite the second pivot feature.

[0024] According to one or more aspects of the present disclosure, a male electrical terminal includes a pivot feature. The pivot feature is a circular recess. The male electrical terminal also includes a plurality of contact arms extending from the pivot feature. Each of the plurality of contact arms is offset from an adjacent arm of the plurality of contact arms by an angle of approximately 150 degrees.

[0025] According to one or more aspects of the present disclosure, a female electrical terminal includes a base plate defining a pivot feature. The pivot feature is a circular protrusion formed by a spherical sector-shaped relief. The base plate is substantially planar and circular. The pivot feature is located in the center of the base plate. The female electrical terminal also includes a plurality of receiving features defining a U-shaped gap. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1A is a top view of a male electrical connector according to a first embodiment;

[0027] Figure 1B According to some embodiments Figure 1A A side view of a male electrical connector;

[0028] Figure 1C According to some embodiments Figure 1A A perspective view of a male electrical connector;

[0029] Figure 1D According to some embodiments, Figure 1A A cross-sectional view of a flat electrical conductor of a male electrical connector taken along section line 1D-1D;

[0030] Figure 2A is a top view of a female electrical connector according to some embodiments;

[0031] Figure 2B According to some embodiments Figure 2A The hatch line 2B-2B Figure 2A A side sectional view of a female electrical connector;

[0032] Figure 2C According to some embodiments Figure 2AA perspective view of a female electrical connector;

[0033] Figure 3A is in a pre-engaged position according to some embodiments Figure 1A Male electrical connector and Figure 2A A top view of a female electrical connector;

[0034] Figure 3B is rotated to an engaged position according to some embodiments Figure 1A Male electrical connector and Figure 2A A top view of a female electrical connector;

[0035] Figure 4A is a top view of a male electrical connector according to some embodiments;

[0036] Figure 4B According to some embodiments Figure 4A A side view of a male electrical connector;

[0037] Figure 4C According to some embodiments Figure 4A A perspective view of a male electrical connector; and

[0038] Figure 4D According to some embodiments, Figure 4A A cross-sectional view of the flat electrical conductor of the male electrical connector taken along the section line 4D-4D; DETAILED DESCRIPTION

[0039] A low-profile electrical connector assembly is presented herein in which a male terminal is locked into a female terminal by twisting a pivot point on the male terminal about a mating pivot point on the female terminal. The male terminal has a contact arm extending from its pivot point, and as the male terminal is twisted about the pivot point, the contact arm is received in a receptacle on the female terminal, thereby locking the male terminal to the female terminal. The electrical connector assembly is particularly suitable for making high-current electrical connections between wires attached to the male terminal and conductive traces on glass to which the female terminal is soldered, such as those used in automotive window defroster circuits.

[0040] Figures 1A-1D A non-limiting example of a male electrical terminal 100 of an electrical connector assembly is shown. The male terminal 100 has a first pivot feature 102 and a pair of contact arms 104 extending from the first pivot feature 102. The male terminal 100 also includes a wire attachment portion 106 extending from the first pivot feature 102. The wire attachment portion 106 has a pair of crimp wings 108 configured to attach the male terminal 100 to an electrical cable 10, such as Figures 3A-3B shown. Figures 1A-1CThe first pivot feature 102 shown in FIG. 1 is a circular aperture extending through the male terminal 100. The pair of contact arms 104 extend from the first pivot feature 102 at an angle of approximately 105 degrees to the centerline of the wire attachment portion 106 and at an angle of 150 degrees to each other. The contact arm 104 defines a contact protrusion 110 extending from a location near the free end 112 of the contact arm 104. The contact protrusion 110 has a spherical sector shape that is less than or equal to a hemisphere. The contact arm 104 further defines a stop feature 114 extending perpendicularly from the contact arm 104 and located near the free end 112 of the contact arm 104. The stop feature 114 on one contact arm 104 is located on opposite sides of the stop feature 114 on the other contact arm 104. The male terminal 100 can be formed from sheet metal, such as tinned copper, by stamping, punching, blanking, bending, and embossing methods known to those skilled in the art.

[0041] Figures 2A-2C A non-limiting example of a female electrical terminal 200 of an electrical connector assembly is shown. The female terminal 200 has a base plate 202 defining a second pivot feature 204 configured to mate with the first pivot feature 102 of the male terminal 100 and allow the male terminal 100 to pivot about the second pivot feature 204. The female terminal 200 also includes a pair of receiving features 206 configured to receive the free end 112 of the contact arm 104 as the first pivot feature 102 engages the second pivot feature 204 and the contact arm 104 twists or rotates about the first and second pivot features 102, 204. The base plate 202 has a generally planar and circular shape. The second pivot feature 204 protrudes from the base plate 202 and has a spherical sector shape that is less than or equal to a hemisphere. The receiving feature 206 is in the form of a J-shaped tab 208 extending from an edge of the base plate 202. The tab 208 forms a gap 210 with the substrate 202, in which the free end 112 of the contact arm 104 is received. The tab 208 defines a contact recess 212 that is configured to receive the contact protrusion 110. The contact recess 212 is formed by a circular aperture extending through the tab 208. The substrate 202 also includes a solder layer 214 on the side of the substrate 202 opposite the second pivot feature 204, which is used to attach the female terminal 200 to a conductive trace, such as a defroster circuit on a car window (not shown). The female terminal 200 can be formed from a sheet of metal, such as a tinned copper sheet, by stamping, punching, blanking, bending, and embossing methods known to those skilled in the art. This combination of the male terminal 100 and the female terminal 200 provides the advantage of a higher current carrying capacity than existing post and cup sockets and can therefore be used in higher current applications, such as window defrosters.

[0042] Figures 3A-3B FIG. 2 shows a process of connecting the male terminal 100 to the female terminal 200. Figure 3AIn the disengaged position 302 shown, the second pivot feature 204 of the female terminal 200 is received within the first pivot feature 102 of the male terminal 100, while the free end 112 of the contact arm 104 is offset from the receiving portion feature 206. The male terminal 100 is then rotated in a clockwise direction relative to the female terminal 200 to Figure 3B 206, and the stop feature 114 contacts or engages the receiving portion feature 206, thereby inhibiting further rotation of the male terminal 100. As the contact arm 104 rotates, the contact protrusion 110 will contact the tabs 208 and push them outward until the contact protrusion 110 is seated in the contact recess 212, at which point the tabs 208 will bend inward back to their original position. The size, shape, and arrangement of the contact arm 104, contact protrusion 110, tabs 208, and contact recess 212 are designed to be in a position to rotate when in engagement position. Figure 3B A normal force is generated between the male and female terminals when the terminals are in the engaged position.

[0043] The engagement of the contact protrusion 110 with the contact recess 212 and the contact of the stop feature 114 with the receptacle feature 206 provide tactile feedback to the assembler that the male terminal 100 and the female terminal 200 are fully engaged and electrically connected.

[0044] An alternative embodiment of the male terminal 400 is Figures 4A-4D , where the first pivot feature 402 is in the form of a hollow spherical sector. Other alternative embodiments of the electrical connector assembly are contemplated in which the male terminal is rotated counterclockwise relative to the female terminal, the first pivot feature is received within the second pivot feature, the second pivot feature has a cylindrical shape, or the contact arm defines a spring feature to engage the receiving portion feature. Other embodiments are also contemplated for use with a printed circuit board or including mounting studs protruding from the female terminal.

[0045] Although the present invention has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, various modifications may be made to adapt a particular situation or material to the teachings of the present invention without departing from its broad scope. Therefore, the present invention is not intended to be limited to the disclosed embodiment or embodiments, but is intended to include all embodiments falling within the scope of the appended claims.

Claims

1. An electrical connector assembly, comprising: a male terminal (100) having a first pivot feature (102) and a plurality of contact arms (104) extending from the first pivot feature (102); and A female terminal (200) having a base (202) defining a second pivot feature (204) and a plurality of receiving features (206), the plurality of receiving features (206) being configured to receive free ends (112) of the plurality of contact arms (104) as the first pivot feature (102) engages the second pivot feature (204) and the plurality of contact arms (104) rotate about the first pivot feature (102) and the second pivot feature (204), Wherein, the plurality of receiving features (206) are J-shaped tabs extending from an edge of the base plate (202).

2. The electrical connector assembly according to claim 1, wherein: The first pivot feature (102) is a circular recess and the second pivot feature (204) is a circular protrusion (204) received within the circular recess (102).

3. The electrical connector assembly according to claim 2, wherein: The circular recess is formed by a circular aperture extending through the male terminal (100).

4. The electrical connector assembly according to claim 1, wherein: The first pivot feature (102) is formed by a relief in the form of a sector of a hollow sphere.

5. The electrical connector assembly according to claim 1, wherein: The plurality of receiver features (206) define a U-shaped gap (210) in which the free ends (112) of the plurality of contact arms (104) are received.

6. The electrical connector assembly according to claim 1, wherein: Each arm (104) of the plurality of contact arms (104) is offset from an adjacent arm (104) of the plurality of contact arms (104) by an angle of less than 180 degrees.

7. The electrical connector assembly according to claim 6, wherein: Each arm (104) of the plurality of contact arms (104) is offset from the adjacent arm (104) of the plurality of contact arms (104) by an angle of approximately 150 degrees.

8. The electrical connector assembly according to claim 1, wherein: The plurality of contact arms (104) define a stop feature (114) extending perpendicularly from the plurality of contact arms (104) and proximate the free ends (112) of the plurality of contact arms (104), wherein the stop feature (114) is configured to engage the plurality of receiving portion features (206) as the plurality of contact arms (104) rotate about the first pivot feature (102) and the second pivot feature (204), thereby limiting further rotation.

9. The electrical connector assembly according to claim 1, wherein: The plurality of contact arms (104) define contact protrusions (110) extending proximate the free ends (112) of the plurality of contact arms (104) and configured to contact the plurality of receiver features (206).

10. The electrical connector assembly according to claim 9, wherein: The contact protrusion (110) is formed by a relief in the form of a spherical sector.

11. The electrical connector assembly according to claim 9, wherein: The plurality of receiver features (206) define a contact recess (212) configured to receive the contact protrusion (110).

12. The electrical connector assembly according to claim 11, wherein: The contact recess (212) is formed by a circular aperture extending through the plurality of receiving features (206).

13. The electrical connector assembly according to claim 11, wherein: The contact recess (212) is formed by a relief in the form of a hollow sphere sector.

14. The electrical connector assembly according to claim 1, wherein: The base plate (202) is substantially planar and circular about the second pivot feature (204).

15. The electrical connector assembly according to claim 1, wherein: The male terminal (100) also includes a wire attachment portion (106) extending from the first pivot feature (102).

16. The electrical connector assembly according to claim 1, wherein: The plurality of contact arms (104) is two arms.

17. The electrical connector assembly according to claim 1, wherein: The substrate (202) includes a solder layer on a surface opposite the second pivot feature (204).

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