Tuning fork mounting terminal with improved contact surface

Abstract

Embodiments of the present disclosure relate to improved tuning fork mounting terminals. In one example, the circuit protection device may be coupled to the PCB by a tuning fork mounting terminal that may include a base and a first pin separated from a second pin by a gap, where the first pin and the second pin each include a proximal end connected to the base and a distal end extending toward the circuit protection device. The distal end may include a rounded outer surface and a flat inner surface, where a plane defined by the flat inner surface is oriented at a non-zero angle relative to a central axis extending through the gap when the first pin and the second pin are in the relaxed configuration, and where the first pin and the second pin are in the relaxed configuration. The flat inner surface is oriented at a zero degree angle when a terminal of the circuit protection device is present between the first pin and the second pin.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the field of electrical protection. More specifically, the present disclosure relates to a tuning fork mounting terminal for fuses, relays, and the like. BACKGROUND

[0002] Fuses and relays used in the automotive, industrial, and electrical industries can include fuse terminals having a plurality of fingers or prongs. When connected via a corresponding tuning fork mounting terminal, a pair of terminals can typically be joined into a fuse block for two contact points with a circuit board. The insertion end of existing tuning fork mounting terminals is typically round, which causes wire contact contact areas and higher temperature rise during loading.

[0003] Accordingly, there is a need for improved tuning fork mounting terminals. SUMMARY

[0004] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the DETAILED DESCRIPTION. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is this Summary intended to be used to determine the scope of the claimed subject matter.

[0005] In one aspect, a power distribution module can include a circuit protection device coupled to a PCB by a tuning fork mounting terminal, the tuning fork mounting terminal can include a first prong separated by a gap from a second prong, wherein the first prong and the second prong each include a proximal end connected to a base and a distal end extending toward the circuit protection device. The distal end can include a rounded outer surface and a flat inner surface, wherein a plane defined by the flat inner surface is oriented at a non-zero angle relative to a central axis extending through the gap when the first prong and the second prong are in a relaxed configuration, and wherein the flat inner surface is oriented at a zero degree angle when a terminal of the circuit protection device is present between the first prong and the second prong.

[0006] In another aspect, a tuning fork mounting terminal can include a base for connection to a printed circuit board and a first prong separated by a gap from a second prong, wherein the first prong and the second prong each include a free end and a proximal end connected to the base, wherein the free end includes a rounded outer surface and a flat inner surface, wherein a plane defined by the flat inner surface is oriented at a non-zero angle relative to a central axis extending through the gap when the first prong and the second prong are in a relaxed configuration, and wherein the plane defined by the flat inner surface is oriented at a zero degree angle relative to the central axis when a terminal of a circuit protection device is present between the first prong and the second prong.

[0007] In yet another aspect, a method for increasing terminal electrical contact can include providing a printed circuit board (PCB) and coupling a circuit protection device to the PCB by a tuning fork mounted terminal, where the tuning fork mounted terminal includes a first prong separated from a second prong by a gap. The first prong and the second prong each include a proximal end connected to a base and a distal end extending toward the circuit protection device, where the distal end includes a rounded outer surface and a flat inner surface, and where, when the first prong and the second prong are in a first configuration, a plane defined by the flat inner surface is oriented at a non-zero angle relative to a central axis extending through the gap. The method can further include receiving a terminal of the circuit protection device between the first prong and the second prong, where, when the first prong and the second prong are in a second configuration, the plane defined by the flat inner surface is oriented at a zero degree angle relative to the central axis. BRIEF DESCRIPTION OF DRAWINGS

[0008] The accompanying drawings illustrate exemplary methods of the present disclosure, including the practical application of its principles, as follows:

[0009] Figure 1 is an exploded view of a power distribution module according to embodiments of the present disclosure;

[0010] Figure 2 is a side view of an example tuning fork mounted terminal according to embodiments of the present disclosure;

[0011] Figure 3 is a close-up side view of a portion of an example tuning fork mounted terminal according to embodiments of the present disclosure;

[0012] Figure 4 is a close-up side view of a portion of an example protection device and tuning fork mounted terminal according to embodiments of the present disclosure; and

[0013] Figure 5 shows a flowchart of a method for increasing terminal electrical contact according to embodiments of the present disclosure.

[0014] The drawings are not necessarily to scale. The drawings are merely schematic representations, not intended to portray specific parameters of the disclosure. The drawings are intended to depict only typical embodiments of the disclosure, and therefore should not be considered as limiting the scope of the disclosure. In the drawings, like numbering denotes like elements.

[0015] Furthermore, some of the elements in some of the figures can have been omitted or simplified for purposes of clarity. Cross-sectional views are shown as "cut away" or "near-sighted" cross-sectional views, with certain background lines omitted for clarity. Also, some of the drawings can have omitted certain reference numbers for clarity. DETAILED DESCRIPTION

[0016] The methods, apparatus, and systems according to this disclosure will now be described more fully below with reference to the accompanying drawings, in which various embodiments are illustrated. These methods, apparatus, and systems may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that the disclosure will be thorough and complete, and will fully convey the scope of these methods to those skilled in the art.

[0017] As will be described in more detail herein, the inventors of this application have designed an optimized tuning fork mounting terminal for use with circuit protection devices, such as fuses. The free end of each pin of the tuning fork mounting terminal may include a circular outer surface and a flat / planar inner surface configured to engage a fuse. In a first relaxed configuration of the first and second pins, the flat inner surface is angled relative to a centerline extending between the first and second pins. When the fuse terminal is inserted between the first and second pins, the first and second pins deflect slightly away from the centerline, such that the flat inner surface is coplanar with each corresponding outer surface of the fuse terminal. The optimized tuning fork mounting terminal achieves at least the following advantages: First, the contact area of ​​the tuning fork mounting terminal changes from a line to a surface, which reduces heat during operation. Second, the overall height of the tuning fork mounting terminal can be reduced. Third, alternative / cheaper materials can be used for the tuning fork mounting terminal, for example, in addition to copper alloys. Fourth, or, the friction generated by the planar contact area surface better holds the fuse in place. Fifth, it reduces resistance for the tuning fork mounting terminals.

[0018] Figure 1 One possible application of the optimized tuning fork mounting terminal is shown. It should be understood that the optimized tuning fork mounting terminal of this disclosure can be used with other devices and systems not shown or discussed for the sake of brevity. A power distribution module 10 is shown, which can be a flexible electrical center (“FLEC”) for vehicles such as automobiles, trucks, motorcycles, boats, surf bikes, heavy transport vehicles, all-terrain vehicles, etc. Module 10 houses replaceable fuses and other types of circuit protection devices.

[0019] like Figure 1As seen in the exploded view, module 10 includes a housing 12, a cover 50 attached to the housing 12, a printed circuit board (“PCB”) 70 with components and connector terminals (the PCB is inserted into the housing 12), and a base 60 removably attached to a bottom portion of the housing 12 for sealing and isolating the PCB from the external environment. The housing 12, cover 50, and base 60 may be made of the same or different materials, such as insulating plastics like nylon, glass-filled nylon, polyester, and polycarbonate. In one embodiment, the PCB 70 is made of FR-4 material. If additional rigidity is required, the PCB 70 may alternatively be made of ceramic.

[0020] The housing 12 in the illustrated embodiment is a molded plastic part having a centrally located component grid 14. The component grid 14 may have multiple cover area holes 16, forming multiple cover areas for multiple fuses or circuit protection devices (overcurrent or overvoltage) inserted into the component grid 14 of the housing 12 of the power distribution module 10. As shown, the holes 16 may form multiple fuses of the same type. Alternatively, the holes 16 may form different cover areas for different types of component cover areas. In the non-limiting example shown, the holes 16 form cover areas for multiple anode-type fuses.

[0021] In the illustrated embodiment, the housing 12 may also include or define a plurality of connector mounts or retainers 26 located around the component grid 14. The connector mounts 26 include walls 28 that guide the connectors to the correct position and orientation. Like the component coverage area via the aperture 16, the connector mounts 26 may also be sized as shown to accommodate connectors of different sizes and types and to accommodate any desired number of each connector. In one embodiment, the connector mount 26 includes or provides one or more locking mechanisms 32 that engage the connectors to lock them in place.

[0022] As further shown, one or more mounting terminals 72 with a tuning fork-like configuration can be attached to the PCB 70. In one embodiment, the mounting terminals 72 can be mechanically secured to the PCB 70 via through-holes provided in the PCB 70. Here, a small portion of the mounting terminal 72 extends below the PCB 70. In this arrangement, the mounting terminals 72 can be additionally soldered (e.g., wave soldered) to the PCB 70 or can be non-soldered (e.g., wave soldered) to the PCB 70. In an alternative embodiment, the mounting terminals 72 are surface-mounted to the PCB 70. In this case, the mounting terminals 72 do not extend through the PCB 70. Surface mounting is particularly advantageous for feedthrough embodiments, where the terminals extend from both sides of the PCB 70, increasing the capacity of the fuse components.

[0023] Although not shown, the anode blade type fuse includes a pair of blade terminals, each of which is press-fitted into one of the mounting terminals 72. For each fuse, one of the mounting terminals 72 can be connected to a trace extending into a load within the vehicle. The other terminal is electrically connected to a trace extending into a common electrical connection.

[0024] Although not shown, the busbar may also be connected to PCB 70. In one embodiment, the busbar is soldered to a large or widened trace disposed on the surface of PCB 70. The busbar can carry higher current and / or distribute current more efficiently across PCB 70. The busbar also provides an internal heat sink for the power distribution module 10. The busbar may further provide electrical connections for discrete components, such as overvoltage protection components disposed on PCB 70.

[0025] Now go to Figure 2 An example mounting terminal 72 is shown. In this embodiment, the mounting terminal 72 may include a base 80 for connection to a PCB 70 and a first pin 81 separated from the second pin 82 by a gap 83. A central axis 85 extends vertically through the gap 83. The central axis 85 divides the mounting terminal 72 into two symmetrical halves. The first pin 81 and the second pin 82 each include a distal end / free end 87 and a proximal end 86 connected to the base 80.

[0026] Figure 3 The distal ends 87 of the first pin 81 and the second pin 82 are shown in more detail. Each distal end 87 may have a spherical projection 73 extending from the narrow neck 74. Each distal end 87 may further include a circular outer surface 88 and a flat inner surface 90, wherein, when the first pin 81 and the second pin 82 are in a first relaxed configuration, the plane defined by the flat inner surface 90 is oriented at a non-zero angle “θ” relative to the central axis 85 extending through the gap 83. More specifically, the flat inner surface 90 may include a first end 91 and a second end 92, wherein, when the first pin 81 and the second pin 82 are in the illustrated configuration, i.e., when no fuse is connected to the mounting terminal 72, the first end 91 is positioned closer to the central axis 85 than the second end 92.

[0027] like Figure 4As shown, when the terminal 76 of the circuit protection device 78 is present between the first pin 81 and the second pin 82, the distal end 87 of each pin can be slightly deflected outward (i.e., away from the central axis 85). In other words, the plane defined by the flat inner surface 90 is oriented at a zero-degree angle relative to the central axis 85, such that when the terminal 76 of the circuit protection device is present between the first pin 81 and the second pin 82, the first end 91 and the second end 92 are positioned at approximately the same distance from the central axis 85. Because the inner surface 90 is substantially coplanar with the outer surface of the terminal 76 of the circuit protection device, greater friction is generated, making the terminal 76 of the circuit protection device more secure within the mounting terminal 72. In the illustrated embodiment, the inner surfaces 90 of the first pin 81 and the second pin 82 are substantially parallel to each other. Therefore, unlike conventional terminal ends that bend continuously along their inner surfaces, thus causing increased bending of the terminal pins, the mounting terminal 72 of this disclosure has a more uniform friction from the beginning to the end of insertion of the fuse terminal 76.

[0028] Now go to Figure 5 This illustrates a method for increasing terminal electrical contact. At block 201, method 200 may include coupling a circuit protection device to a tuning fork mounting terminal, wherein the tuning fork mounting terminal includes a base and a first pin spaced apart from a second pin. In some embodiments, the tuning fork mounting terminal is coupled to a printed circuit board. In other embodiments, the tuning fork mounting terminal is coupled to a busbar. The embodiments herein are not limited to this context.

[0029] At block 202, method 200 may include receiving a terminal of a circuit protection device between a first pin and a second pin, wherein the first pin and the second pin each include a proximal end connected to a base and a distal end extending toward the circuit protection device, wherein the distal end includes a circular outer surface and a flat inner surface, and wherein, when the first pin and the second pin are in a first configuration, the plane defined by the flat inner surface is oriented at a non-zero angle relative to the central axis extending through the gap.

[0030] At block 203, method 200 may further include holding the terminals of the circuit protection device between the first pin and the second pin, wherein, when the first pin and the second pin are in the second configuration, the plane defined by the flat inner surface is oriented at a zero-degree angle relative to the central axis.

[0031] For convenience and clarity, terms such as “top,” “bottom,” “upper,” “lower,” “vertical,” “horizontal,” “lateral,” and “longitudinal” will be understood as describing the relative position and orientation of the components and their constituent parts appearing in the diagram. Terms will include specifically mentioned words, their derivatives, and words with similar meanings.

[0032] As used herein, elements or operations described in the singular should be understood to include multiple elements or operations unless such exclusion is explicitly stated. Furthermore, references to "one embodiment" in this disclosure are not intended to be limiting. Additional embodiments may also be combined with the described features.

[0033] Furthermore, those skilled in the art will understand that when an element, such as a layer, region, or substrate, is referred to as being formed on, deposited on, or disposed "on," "above," or "on top" of another element, the element may be directly on the other element, or there may be intermediate elements present. Conversely, when an element is referred to as being "directly on," "directly above," or "directly on top of" another element, there are no intermediate elements present.

[0034] While certain embodiments of this disclosure have been described herein, the disclosure is not limited thereto, as it is broad within the scope permitted by the art, and the specification can be read in the same manner. Therefore, the above description should not be construed as limiting. Rather, it is merely an example of specific embodiments. Other modifications will be contemplated by those skilled in the art within the scope and spirit of the appended claims.

Claims

1. A power distribution module, comprising: A circuit protection device connected to a tuning fork mounting terminal, wherein the tuning fork mounting terminal includes: base; and A first pin separated from a second pin by a certain gap, wherein the first pin and the second pin each include a proximal end connected to the base and a distal end extending toward the circuit protection device, wherein the distal end includes a circular outer surface and a flat inner surface, wherein when the first pin and the second pin are in a relaxed configuration, the plane defined by the flat inner surface is oriented at a non-zero angle relative to a central axis extending through the gap, and wherein when the terminal of the circuit protection device is present between the first pin and the second pin, the plane defined by the flat inner surface is oriented at a zero-degree angle relative to the central axis.

2. The power distribution module according to claim 1, wherein, The flat inner surface of the distal end includes a first end and a second end, wherein, when the first pin and the second pin are in the relaxed configuration, the first end is positioned closer to the central axis than the second end.

3. The power distribution module according to claim 2, wherein, When the terminals of the circuit protection device are located between the first pin and the second pin, the first end and the second end are positioned at the same distance from the central axis.

4. The power distribution module according to claim 1, wherein, The circuit protection device is a fuse.

5. The power distribution module according to claim 1, wherein, The circuit protection device is a relay.

6. The power distribution module according to claim 1, wherein, Each distal end includes a spherical projection extending from the narrow neck.

7. The power distribution module according to claim 1, wherein, The tuning fork mounting terminals are connected to the printed circuit board.

8. A tuning fork mounting terminal, comprising: Used to connect to the base of a printed circuit board; and A first pin separated from a second pin by a certain gap, wherein the first pin and the second pin each include a free end and a proximal end connected to the base, wherein the free end includes a circular outer surface and a flat inner surface, wherein when the first pin and the second pin are in a relaxed configuration, the plane defined by the flat inner surface is oriented at a non-zero angle relative to a central axis extending through the gap, and wherein when a terminal of a circuit protection device is present between the first pin and the second pin, the plane defined by the flat inner surface is oriented at a zero-degree angle relative to the central axis.

9. The tuning fork mounting terminal according to claim 8, wherein, The flat inner surface of the free end includes a first end and a second end, wherein, when the first pin and the second pin are in the relaxed configuration, the first end is positioned closer to the central axis than the second end.

10. The tuning fork mounting terminal according to claim 9, wherein, When the terminals of the circuit protection device are located between the first pin and the second pin, the first end and the second end are positioned at the same distance from the central axis.

11. The tuning fork mounting terminal according to claim 9, wherein, Each free end includes a spherical projection extending from the narrow neck.

12. A method for increasing terminal electrical contact, comprising: Connect the circuit protection device to the tuning fork mounting terminal, wherein the tuning fork mounting terminal includes: base; and A first pin separated from a second pin by a certain gap, wherein the first pin and the second pin each include a proximal end connected to a base and a distal end extending toward the circuit protection device, wherein the distal end includes a circular outer surface and a flat inner surface, wherein, when the first pin and the second pin are in a first configuration, the plane defined by the flat inner surface is oriented at a non-zero angle relative to a central axis extending through the gap; and The terminal of the circuit protection device is received between the first pin and the second pin, wherein, when the first pin and the second pin are in a second configuration, the plane defined by the flat inner surface is oriented at a zero-degree angle relative to the central axis.

13. The method according to claim 12, wherein, The flat inner surface of the distal end includes a first end and a second end, wherein, when the first pin and the second pin are in the second configuration, the first end is positioned closer to the central axis than the second end.

14. The method according to claim 13, wherein, When the terminals of the circuit protection device are located between the first pin and the second pin, the first end and the second end are positioned at the same distance from the central axis.

15. The method according to claim 12, wherein, The circuit protection device is connected to the printed circuit board via the tuning fork mounting terminal.

16. The method according to claim 15, wherein, Connecting the circuit protection device to the printed circuit board via the tuning fork mounting terminal includes inserting a relay terminal between the first and second pins.

17. The method of claim 14, wherein, Connecting the circuit protection device to the printed circuit board via the tuning fork mounting terminal includes inserting a fuse terminal between the first and second pins.

Images