ELECTRICAL CONNECTION ARRANGEMENT

Abstract

Electrical connection arrangement (200) comprising: a base (212) comprising a body (220) with a first end (222) and a second end (224), with first and second opposing base beams (260, 262, 264, 266) extending from the first end (222) of the body (220) in a first direction; and a spring clip (214) having a clip base (272, 274) and first and second opposing spring beams (292, 294) extending from the clip base (272, 274) in the first direction and disposed over the first and second base beams (260, 262, 264, 266) to bias the first and second base beams (260, 262, 264, 266) toward each other, wherein the body (220) of the base (212) is configured to allow the spring clip (214) to be mounted on the base (212) in an assembly direction (216) normal to the first direction, wherein the base (212) has an integrally formed locking means (234), which prevents the removal of the spring clip (214) from the base (212) along as well as against the assembly direction (216), characterized in that the locking means (234) is an elongated pawl (236) that encloses portions of the spring clip (214) between the pawl (236) and the second end (224) of the body (220) of the base (212).

Description

BACKGROUND OF THE INVENTION

[0001] This invention relates generally to electrical terminals, such as for use in heavy-duty vehicle electrical connectors. Electrical connectors typically include a body having a non-conductive housing enclosing a conductive plurality of female electrical terminals. The female terminals are each connected to a respective end of a wire connector or fuse element fixed within the housing to complete an electrical circuit. The female terminals are inserted over a plurality of male tab terminals. For example, the male tab terminals may be housed within another connector housing, such as a power distribution box. The female terminals are typically constructed with a spring-like feature to maintain stable electrical contact with the outer surface of the male tab terminals.

[0002] Copper possesses good electrical conductivity and has been a preferred material for terminals, despite its relatively high cost. However, copper is susceptible to relaxation (i.e., the loss of spring force) as the temperature of the copper material increases. Because the temperature of the terminals rises as the current drawn in the electrical circuit increases, copper terminals have a reduced ability to maintain a strong clamping force on the tab terminals. Relaxation of the female terminals potentially reduces the overall contact area with the tab terminals, resulting in reduced electrical conductivity, increased resistance, and a further increase in temperature.

[0003] It is desirable to keep the overall size of an electrical junction box or other connector as small as possible while still providing the necessary current-carrying capacity. In some situations, the spring force cannot be further increased by simply making the terminals thicker or wider. When using copper, the desired spring force may not be achieved due to size limitations.

[0004] Some conventional electrical terminals are designed in two parts, utilizing a copper base to provide electrical communication with a wire connector. The base includes a plurality of fingers or beams that mechanically and electrically engage a plug terminal. A spring clip is disposed over the plurality of beams of the base such that a compressive force biases the beams in an inward direction against the plug terminal. The spring clip is constructed of a suitable material, such as steel, with a high yield strength or spring-like quality. The spring clip material retains its spring-like qualities over a relatively wide temperature range, which is ideal for high-performance applications, such as those found within electric or hybrid vehicles.However, it is desirable to mount the spring clip onto the base so that excessive stress or deformation is applied to the base and / or the spring clip during the assembly process.

[0005] DE 10 2012 006 500 A1 discloses a pole terminal for a socket insert with a pole terminal assembly. The pole terminal assembly comprises a pole terminal component made of a copper-zinc material with at least one conductor entry and a contact tulip for a plug pin, and a spring-loaded contact spring assembly made of a stainless steel material with spring properties. The pole terminal component covers the electrical function of conducting current from the conductor to the plug pin, and the spring-loaded contact spring assembly covers the mechanical function. For this purpose, the spring-loaded contact spring assembly ensures the clamping force for the plug pin clamping in the contact tulip via a first spring-loaded arm and a second spring-loaded arm, and it ensures the clamping force for the conductor clamping and conductor locking via a contact spring with at least one contact spring arm and at least one locking arm.

[0006] EP 0 437 782 A2 discloses an electrical plug which is constructed in two parts, wherein the two cuboidal parts can be pushed against one another and locked together in two stages, wherein one housing part stores insulation displacement contacts formed from stamped sheet metal parts in housing chambers, the insulation displacement contacts of which protrude from the housing and in the other housing part there are individual electrical lines which are contacted with the insulation displacement contacts of the insulation displacement contacts when the housings are locked together in the second stage and wherein the plug has openings for the passage of mating contact elements of a mating plug or similar electrical component for contacting contact spring arms of the insulation displacement contacts.One cuboid part is an inner housing and the second cuboid part is an outer housing, wherein the inner housing has the front plug-in face end wall with plug openings arranged next to one another in a row in the longitudinal direction of the housing and is also formed by the wide side walls, the narrow side end walls and the rear side which is open to the rear, and wherein the contact chambers are located in the inner housing and extend from the open rear side to the plug-in face end wall and are arranged next to one another in the longitudinal direction of the housing, and wherein the outer housing has the plug-in face end wall which is open to the front, the wide side walls, the narrow side end walls and the base wall, via which round plug holes are formed in the wide side wall and plug holes are formed in the wide side wall, each of which is arranged in a row at a distance from one another, wherein the holes are of the same size and are aligned with one another. BRIEF DESCRIPTION OF THE INVENTION

[0007] This invention relates to electrical terminals and, more particularly, to an electrical terminal assembly comprising a base having a body including a first end and a second end. First and second opposed base beams extend from the first end of the body in a first direction. A spring clip comprises a clip base and first and second opposed spring beams extending from the clip base in the first direction and disposed over the first and second base beams, biasing the first and second base beams toward each other. The body of the base is configured to allow the spring clip to be mounted on the base in an assembly direction normal to the first direction. The base includes an integrally formed locking means that prevents removal of the spring clip from the base along as well as opposite the assembly direction.The locking means is an elongated pawl that encloses portions of the spring clip between the pawl and the second end of the body of the base.

[0008] The invention also relates to a method of assembling an electrical terminal assembly, comprising the steps of providing a base having a plurality of opposed base beams extending in a first direction, providing a spring clip having a plurality of opposed spring beams extending in the first direction, deflecting away from each other and spring biasing the opposed spring beams to provide a clearance for positioning the spring clip over the base, and positioning the spring clip over the base by moving the spring clip in an assembly direction perpendicular to the first direction until the spring beams are positioned over the base beams, thereby assembling the electrical terminal assembly.The method according to the invention also comprises deflecting the opposing spring beams by a mandrel tool having a first mandrel and a second mandrel that are movable relative to one another.

[0009] Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments when read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of an advantageous embodiment of an electrical connection arrangement not according to the invention. Fig. 2 is an end elevation view of the electrical terminal arrangement of Fig. 1. Fig. 3 is a bottom view of the electrical connection arrangement of Fig. 1. Fig. 4 is a plan view of the electrical connection arrangement of Fig. 1. Fig. 5 is a perspective view of the base of the electrical terminal assembly of Fig. 1. Fig. 6 is a perspective view of the spring clip of the electrical terminal assembly of Fig. 1. Fig. Figure 7 is a schematic perspective view showing a first advantageous step in assembling the spring clip onto the base of the electrical terminal assembly of Fig. 1 illustrates. Fig. Figure 8 is a schematic perspective view illustrating a second step of the invention in assembling the spring clip onto the base of the electrical terminal assembly of Fig. 1 illustrates. Fig. 9 is a schematic perspective view illustrating a third step of the invention in assembling the spring clip onto the base of the electrical terminal assembly of Fig. 1 illustrates. Fig. 10 is a schematic perspective view illustrating a fourth step of the invention in assembling the spring clip onto the base of the electrical terminal assembly of Fig. 1 illustrates. Fig. 11 is a side view of the electrical connection arrangement in Fig. 10 schematically illustrated fourth step. Fig. 12 is a perspective view of an embodiment of an electrical connection assembly according to the invention. Fig. 13 is a perspective view of the base of the electrical terminal assembly of Fig. 12, which is shown in a pre-assembled position. Fig. 14 is a perspective view of the spring clip of the electrical terminal assembly of Fig. 12. Fig. Figure 15 is a schematic perspective view showing a first advantageous step in assembling the spring clip onto the base of the electrical terminal assembly of Fig. 12 illustrates. Fig. Figure 16 is a schematic perspective view illustrating a second advantageous step in assembling the spring clip onto the base of the electrical terminal assembly of Fig. 12 illustrates. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Now referring to the drawings, in the Fig. 1 to 4 illustrate an advantageous embodiment of an electrical connection assembly, generally designated by reference numeral 10. The electrical connection assembly 10 comprises a base, generally designated by reference numeral 12, and a spring clip, generally designated by reference numeral 14. In an assembled state of the electrical connection assembly 10, the spring clip 14 is inserted over the base 12, as shown in Fig. 1. It should be understood that the base 12 and the spring clip 14 may be shaped differently than shown in the figures. As described below, the spring clip 14 is built or mounted onto the base 12 in a side-loaded manner (from one side of the base) along an assembly direction 16 to form the electrical terminal assembly 10.

[0011] The electrical terminal assembly 10 is used to establish an electrical connection to an electrical connector such as a flat terminal indicated by broken lines 18, as shown in Fig. 1. The tab 18 is inserted into the electrical terminal assembly 10 along an insertion direction 19 that is perpendicular to the assembly direction 16. The electrical terminal assembly 10 may be inserted, molded, or otherwise secured to a plastic body of a connector (not shown). The connector may include multiple electrical terminal assemblies 10 mounted therein. The electrical terminal assembly 10 is well suited for use in power distribution boxes used in motor vehicles.

[0012] The base 12 may be formed from a single metal blank which is stamped and formed into the Fig. 1 to 5. Likewise, the spring clip 14 can also be formed from a single metal blank which is stamped and formed into the configuration shown in the Fig. 1 to 4 and 6. The base 12 is preferably made of an electrically conductive material such as a copper alloy or an aluminum alloy. As explained below, the spring clip 14 is generally provided to assist in urging or pressing electrical contact engagement surfaces of the base 12 against the tab 18. Therefore, the spring clip 14 is preferably made of a material, such as stainless steel, with a relatively high yield strength or spring-like quality. Preferably, the material of the spring clip 14 is capable of retaining its spring-like qualities over a relatively wide temperature range, which may affect the electrical terminal assembly 10 in high-performance applications, such as within electric or hybrid vehicles.

[0013] As in Fig. 5, the base 12 includes a box-shaped body 20 defining a first, front end 22, a second, rear end 24, and a pair of side walls 26 and 28. In the illustrated embodiment, the first end 22 and the second end 24 are open, such that they do not include solid wall portions formed from folded sections of the blank. It should be understood that the first end 22 and the second end 24 may include wall portions (not shown) if desired. The body 20 further defines an upper plate 30 spaced from a lower plate 32. The upper and lower plates, 30 and 32, extend from the first end 22 to the second end 24.

[0014] As best seen in the perspective bottom view of Fig. 1, the body 20 includes an advantageous locking means, which is generally designated 34, which helps to secure the spring clip 14 after assembly onto the base 12 and helps to prevent movement of the spring clip 14 relative to the base 12 in the insertion direction 19, as discussed in detail below. The locking means 34 includes a tab 36 extending outwardly from the lower plate 32 and engaging a portion of the spring clip 14 at an edge 38 of the tab 36. The tab 36 includes an inclined surface 40 which increases in height as it moves along the surface of the lower plate 32 in a direction opposite to the insertion direction 19. Similarly, the upper plate 30, as shown in Fig. 5, include a tab 36a that engages a portion of the spring clip 14 at an edge 38a of the tab 36a. The tab 36a has an inclined surface 40a that increases in height as it moves along the surface of the upper plate 30 in the direction opposite to the insertion direction 19. The tabs 36 and 36a may be created by a cutting and / or punching process. For example, a U-shaped cutout may be sheared into the upper and lower plates 30 and 32. The material within the U-shaped cutout is punched outward, leaving the tabs 36a and 36a attached to the upper and lower plates 30 and 32. During assembly, the tabs 36 and 36a may be elastic so that they are deflected by a relatively small amount when the spring clip 14 is mounted on the base 12.Alternatively, the material of the base 12 may have sufficient strength so that the tabs 36 and 36a are not deflected during the assembly process.

[0015] The locking means 34 may also be defined by indentations or other features formed in the base 12 that interact with the spring clip 14 to prevent movement of the spring clip 14 relative to the base 12 in the assembly direction 16. For example, the second end 24 of the upper plate 30 and the lower plate 32 may be provided with indentations to form ledges or stops 44 therein that act as stops to prevent transverse movement of the spring clip 14 relative to the base 12 in the insertion direction 16. As discussed below, the spring clip 14 is inserted onto the base 12 along the insertion direction 16 until the spring clip 14 contacts the stops 44.If desired, the base 12 and / or the spring clip 14 may be formed with additional features that help prevent the spring clip 14 from moving in the direction opposite to the insertion direction once the spring clip 14 is fully inserted onto the base 12.

[0016] The base 12 further includes a terminal plate 50 extending outwardly from the side wall 28. The terminal plate 50 is used for connecting to one end of a wire conductor (not shown). The end of the wire conductor may be welded, soldered, or otherwise connected to a planar surface of the terminal plate 50 to provide electrical communication between the wire conductor and the base 12. The terminal plate 50 may have any shape or configuration suitable for connecting to the end of the wire conductor. As shown in Fig. As shown in Figure 1, the terminal plate 50 is formed from a pair of relatively thin strip sections of the blank that are folded toward each other. The terminal plate 50 may extend outwardly from the body 20 in any direction.

[0017] Extending from the first end 22 of the body 20 are a plurality of elongated fingers or base beams that engage the tab 18 to establish an electrical connection between the base 12 and the tab 18. In the embodiment shown, the base 12 includes four pairs of opposing base beams, generally designated 60, 62, 64, and 66, extending outwardly from the first end 22 of the body 20 in a direction opposite the insertion direction 19. Each pair of base beams 60, 62, 64, and 66 includes a first base beam extending from the top plate 30 and a second base beam extending from the bottom plate 32. The base beams are resilient such that each of the pair of base beams 60, 62, 64, and 66 moves outwardly away from each other to receive the tab 18 when inserted therebetween. The base bars establish an electrical contact with the flat plug 18.

[0018] With reference to Fig. 6, the spring clip 14 includes a body 70 defining a first U-shaped clip base 72 and a second U-shaped clip base 74. The first and second clip bases, 72 and 74, may be integrally formed together by a bridge 76. The first clip base 72 includes an upper support piece 80, a lower support piece 82, and a U-shaped strut 84 connecting the upper and lower support pieces, 80 and 82. Similarly, the second clip base 74 includes an upper support piece 86 and a lower support piece 88 and a strut 90 connecting the upper and lower support pieces, 86 and 88. The upper support pieces, 80 and 86, are positioned against the top plate 30 of the base 12. The lower supports 82 and 88 are positioned against the lower plate 32 of the base 12. The bridge 76 is attached to the upper supports 80 and 86.The support pieces 80, 82, 86, and 88 may be wider than the struts 84 and 90 to ensure the stability of the spring clamp 14 on the base 12. The struts 84 and 90 may be thinner than the support pieces 80, 82, 86, and 88 to reduce material and weight.

[0019] The spring clip 14 further includes a pair of opposed spring beams, generally designated 92 and 94. The pair of spring beams 92 extend outwardly from the upper and lower support pieces, 80 and 82, of the first clip base 72, opposite the insertion direction 19. The pair of spring beams 94 extend outwardly from the upper and lower support pieces, 86 and 88, of the second clip base 74, opposite the insertion direction 19. The opposed spring beams are resilient, allowing each of the pair of spring beams 92 and 94 to move outwardly away from each other. The pair of spring beams 92 and 94 bias the opposite base beams of the pairs of base beams 60, 62, 64, and 66 toward each other, thereby providing a clamping force. Each of the pair of spring beams 92 and 94 provides a clamping preload force for two pairs of base beams 60, 62, 64 and 66, as shown in the Fig. 1 to 4 shown.

[0020] As in Fig. 6, each of the cantilevers of the pair of cantilevers 92 and 94 includes an end portion 100 with an extension 102 formed between a pair of wing portions 104. Opposing extensions 102 extend inwardly toward each other during final assembly of the electrical connector assembly 10 and are positioned between adjacent base beams of the pairs of base beams 60, 62, 64, and 66. This configuration helps prevent transverse movement of the cantilevers relative to the base beams, so that the biasing force of the cantilevers is uniform.

[0021] The Fig. 7 to 11 illustrate a method according to the invention for assembling the electrical terminal assembly 10. As described below, the spring clip 14 is "side loaded" onto the base 12 in the assembly direction 16. As shown in Fig. 7, the ends of the opposing pairs of base beams 60, 62, 64, and 66 can be initially moved toward each other or held in position against each other by a pair of support arms 110 and 112. The support arms 110 and 112 are in Fig. 7 and may be portions of a tool (not shown) for assisting in the assembly of the electrical terminal assembly 10 by selectively moving the support arms away from and toward each other. It should be understood that this initial operation of positioning the base beams 60, 62, 64, and 66 is optional. However, the use of the support arms 110 and 112 helps protect the base beams from inadvertent deflection during the assembly process and also properly positions any misaligned base beams that may have been deflected out of position.

[0022] As in Fig. 8, a split mandrel tool 114 is used according to the invention to position the opposing pair of spring beams 92 and 94 in a spread-apart manner, as in Fig. 9. It should be noted that Fig. 9 is a perspective bottom view of the spring clip 14 in a different position than in Fig. 8. With further reference to Fig. 8, the split mandrel tool 114 includes an elongated first mandrel 116 and an elongated second mandrel 118. Initially, the first mandrel and the second mandrel, 116 and 118, are positioned adjacent to each other to provide a flat shape, as shown in Fig. 8. The split mandrel tool 114 is then moved in a transverse direction 119 (parallel to the assembly direction 16) until it is positioned between the pairs of opposing spring beams 92 and 94. The first mandrel and the second mandrel, 116 and 118, are then moved away from each other to spread each pair of spring beams 92 and 94 apart, as shown in Fig. 9. Consequently, the movement of the split mandrel tool 114 overcomes the biasing spring force holding the opposing spring beams 92 and 94 toward each other. The spread-apart spring clip 14 is then "side loaded" or moved over the base 12, as shown in FIGS. Fig. 10 and Fig. 11. The spring clip 14 is moved in the assembly direction 16 until the spring clip 14 engages the stops 44. The first mandrel and the second mandrel, 116 and 118, can then be retracted to allow the opposing spring arms 92 and 94 to be positioned on respective pairs of base beams 60, 62, 64 and 66, as shown in Fig. 1. If desired, the first and second mandrels 116 and 118 can be moved closer together before retraction, preferably in a manner that does not damage the base beams 60, 62, 64, and 66. The retaining arms 110 and 112 can be removed before or after retraction of the first and second mandrels 116 and 118.

[0023] It is understood that the tips of the opposite base beams can touch each other in the relaxed state, as best shown in Fig. 2, or may be configured to have a gap therebetween. If a gap is present, the support arms 110 and 112 may be used to move the tips of the base beams together during the assembly process to assist in providing clearance for the first mandrel and the second mandrel, as shown in Fig. 11 shown.

[0024] The dimensions of the spring clip 14 and the base 12 may be set such that when the spring clip 14 is inserted into position on the base 12, the pad 88 slides along the edge 38 of the tab 36 and the pad 86 slides along the edge 38a of the tab 36a to provide a tight, yet slight, interference fit to assist in securing the spring clip 14 to the base 12.

[0025] Due to the side-loaded terminal assembly as described above, the base 12 can have a relatively short depth compared to conventional electrical terminal assemblies, such as those disclosed in U.S. Patent No. 8,366,497, which is incorporated herein by reference. U.S. Patent No. 8,366,497 discloses a front-loaded assembled electrical terminal assembly in which the spring clip is inserted onto the base in the direction opposite to the assembly direction 16. Although the dimension of the spring clip 14 can be the same compared to conventional spring clips such as those disclosed in U.S. Patent No. 8,366,497, the depth of the base 12 can be significantly reduced, thereby providing an electrical terminal assembly 10 requiring a smaller package depth.

[0026] In Fig. 12 illustrates an embodiment of an electrical terminal assembly according to the invention, generally designated by reference numeral 200. The electrical terminal assembly 200 is similar in structure and function to the electrical terminal assembly 10. Accordingly, features of the electrical terminal assembly 200 that are similar to features of the electrical terminal assembly 10 are designated by reference numerals incremented by 200. The electrical terminal assembly 200 includes a base, generally designated by reference numeral 212, and a spring clip, generally designated by reference numeral 214. In an assembled state of the electrical terminal assembly 200, the spring clip 214 is slid over the base 212, as shown in Fig. 12. As described below, the spring clip 214 is built or mounted onto the base 212 in a side-loaded manner (from one side of the base 212) along an assembly direction 216 to form the electrical terminal assembly 200.

[0027] The base 212 may be formed from a single metal blank that is stamped and formed into the Fig. 13. Likewise, the spring clip 214 may be formed from a single metal blank that is stamped and formed into the configuration shown in Fig. 14. The base 212 is preferably made of an electrically conductive material such as a copper alloy or an aluminum alloy. As explained below, the spring clip 214 is generally provided to assist in urging or pressing electrical contact engagement surfaces of the base 212 against a connector or a tab (not shown). Therefore, the spring clip 214 is preferably made of a material, such as stainless steel, with a relatively high yield strength or spring-like quality. Preferably, the material of the spring clip 214 can retain its spring-like qualities over a relatively wide temperature range, which may affect the electrical terminal assembly 200 in high-performance applications, such as within electric or hybrid vehicles.

[0028] As shown in the bottom view of Fig. 13, the base 212 includes a box-shaped body 220 defining a first, front end 222, a second, rear end 224, and a pair of side walls 226 and 228. In the illustrated embodiment, the first end 222 and the second end 224 are open, such that they do not include solid wall portions formed from folded sections of the blank. It should be understood that the first end 222 and the second end 224 may include wall portions (not shown) if desired. The body 220 further defines an upper plate 230 spaced from a lower plate 232. The upper and lower plates, 230 and 232, extend from the first end 222 to the second end 224.

[0029] The body 220 includes an integrally formed locking means, generally designated 234, which helps ensure removal of the spring clip 214 after assembly onto the base 212 and helps prevent movement of the spring clip 214 relative to the base 212 in a direction transverse to the assembly direction 216. The locking means 234 is configured, according to the invention, as an elongated strap or pawl 236. The pawl 236 has a first end 237 that is hingedly connected to the side wall 226 by simply bending or deflecting the first end 237 of the pawl 236 adjacent the side wall 228. The pawl 236 has a curved second end 238 that includes a tab 240 extending from the second end 238. The second end 238 of the pawl 236 also has a pair of lugs 242 extending therefrom in a direction parallel to the tab 240.During assembly, as discussed below, the tab 240 is inserted into a recess or slot 244 formed in the sidewall 226 of the body 220. The body 220 may further include integrally formed stop members 246 extending from the top and bottom plates, 230 and 232, at the second end 224.

[0030] The top and bottom plates 230 and 232 may include optional dome-shaped protrusions 248 formed therein. The protrusions 248 extend outwardly from the top and bottom plates 230 and 232. The protrusions 248 assist in frictionally holding the spring clip 214 to the base 212 when configured with a slight interference fit. The protrusions 248 may act as contact points that reduce rattling of the spring clip 214 relative to the base 212. The protrusions 248 may also help reduce scratching of the contacting surfaces of the base 212 when the spring clip 214 is slid into position during assembly of the electrical terminal assembly 200. Excessive scratching or etching of the base 212 is undesirable.

[0031] The base 212 further includes a terminal plate 250 extending outwardly from the side wall 228. The terminal plate 250 is used to connect to one end of a wire conductor (not shown). Extending from the first end 222 of the body 220 are a plurality of elongated fingers or base bars that engage the connector or blade to establish an electrical connection between the base 212 and the tab 18. In the embodiment shown, the base 212 includes four pairs of opposing base bars, generally designated 260, 262, 264, and 266, extending outwardly from the first end 222 of the body 220. Each pair of base bars 260, 262, 264, and 266 includes a base bar extending from the top plate 230 and a base bar extending from the bottom plate 232.The base beams are resilient so that each base beam moves outwardly away from the pair of base beams 260, 262, 264 and 266 to receive the connector or tab when inserted therebetween.

[0032] With further reference to Fig. 14, the spring clip 214 includes a body 270 defining a first U-shaped clip base 272 and a second U-shaped clip base 274. The first and second clip bases, 272 and 274, may be integrally formed together by a bridge 276. The first clip base 272 includes an upper support piece 280, a lower support piece 282, and a U-shaped strut 284 connecting the upper and lower support pieces, 280 and 282. Likewise, the second clip base 274 includes an upper support piece 286 and a lower support piece 288 and a strut 290 connecting the upper and lower support pieces, 286 and 288. The upper support pieces, 280 and 286, are positioned against the top plate 230 of the base 212. The lower supports, 282 and 288, are positioned against the lower plate 232 of the base 212. The bridge 276 is attached to the upper supports 280 and 286.The support pieces 280, 282, 286, and 288 may be wider than the struts 284 and 290 to ensure the stability of the spring clamp 214 on the base 212. The struts 284 and 290 may be thinner than the support pieces 280, 282, 286, and 288 to reduce material and weight.

[0033] The spring clip 14 further includes a pair of opposed spring beams, generally designated 292 and 294. The pair of spring beams 292 extend outwardly from the upper and lower support pieces, 280 and 282, of the first clip base 272. The pair of spring beams 294 extend outwardly from the upper and lower support pieces, 286 and 288, of the second clip base 274. The opposed spring beams 292 and 294 are resilient, allowing each of the spring beams to move outwardly away from the pair of spring beams 292 and 294. The pair of spring beams 292 and 294 bias the opposite base beams of the pairs of base beams 260, 262, 264, and 266 toward each other, thereby providing a clamping force. Each of the pair of spring beams 292 and 294 provides a clamping preload force for two pairs of base beams 260, 262, 264 and 266, as shown in Fig. 12. However, unlike the spring clip 14 described above, the spring clip 214 does not have any extensions to help prevent transverse movements of the spring beams relative to the base beams.

[0034] The Fig. 15 and Fig. 16 illustrate an advantageous method for assembling the electrical connector assembly 200. As described below, the spring clip 214 can be "side loaded" onto the base 212 in the assembly direction 216. As shown in Fig. 15, the ends of the opposing pairs of base beams 260, 262, 264 and 266 can be moved towards each other by a pair of support arms 310 and 312. The support arms 310 and 312 are in the Fig. 15 and Fig. 16 and may be portions of a tool for assisting in the assembly of the electrical terminal assembly 200 by selectively moving the support arms 310 and 312 away from and toward each other. It should be noted that the use of the support arms 310 and 312 compresses the tips of the base beams, thereby closing any gap 313 between them, as shown in Fig. 12. It should be understood that this initial process of positioning the base beams 260, 262, 264, and 266 is optional. However, the use of the support arms 310 and 312 helps protect the base beams from inadvertent deflection during the assembly process and also properly positions any misaligned base beams that may have been deflected out of position.

[0035] The spring clip 214 is then slid laterally in the assembly direction 216 over and onto the base 212 until the spring clip 214 contacts the stops 246. It should be noted that the absence of extensions on the end portions of the spring beams 292 and 294 provides a relatively smooth surface that can slide over the base beams 260, 262, 264, and 266. Consequently, a mandrel tool may not be necessary to spread the spring beams 292 and 294 apart. The retaining arms 310 and 312 can then be removed, allowing the opposing spring beams to spread apart, forming gaps 313 until the base beams engage the spring beams 292 and 294.

[0036] To secure the spring clip 214 relative to the base 212, the latch 236 at the first end 237 can be bent and pivoted so that the second end 238 is positioned adjacent the second, rearward end 224 of the body 220. The tab 240 can then be inserted into the slot 244 and secured there. The tab 240 and the slot 244 can be configured with a dovetail shape to prevent the tab 240 from being pulled out of the slot 244. The now-locked latch 236 helps prevent the spring clip 214 from moving relative to the base 212. The presence of the latch 236 encloses the spring clip 214 and prevents the spring clip from moving in a forward or rearward direction (normal to the assembly direction 216).In addition, the struts 284 and 290, which are enclosed between the stops 246 and the lugs 242 formed on the pawl 236, prevent the spring clip 214 from moving in transverse directions parallel to the assembly direction 216.

[0037] The principle and method of operation of this invention have been explained and illustrated in its preferred embodiments. However, it should be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.

Claims

[1] Electrical connection arrangement (200) comprising: a base (212) comprising a body (220) with a first end (222) and a second end (224), with first and second opposing base beams (260, 262, 264, 266) extending from the first end (222) of the body (220) in a first direction; and a spring clip (214) having a clip base (272, 274) and first and second opposing spring beams (292, 294) extending from the clip base (272, 274) in the first direction and disposed over the first and second base beams (260, 262, 264, 266) to bias the first and second base beams (260, 262, 264, 266) toward each other, wherein the body (220) of the base (212) is configured to allow the spring clip (214) to be mounted on the base (212) in an assembly direction (216) normal to the first direction, wherein the base (212) has an integrally formed locking means (234), which prevents the removal of the spring clip (214) from the base (212) along as well as against the assembly direction (216), characterized by , that the locking means (234) is an elongated pawl (236) that encloses portions of the spring clip (214) between the pawl (236) and the second end (224) of the body (220) of the base (212). [2] Electrical connection arrangement (200) according to claim 1, characterized by in that the spring clip (214) is configured to be elastic so that the first and second spring beams (292, 294) can be deflected away from each other, thereby allowing the spring clip (214) to be movable along the assembly direction (216) over the body (220) of the base (212) during an assembly process of the electrical connection arrangement (200). [3] Electrical connection arrangement (200) according to claim 1, characterized by that the locking means (234) prevents further movements of the spring clip (214) relative to the base (212) in a rearward direction perpendicular to the assembly direction (216). [4] Electrical connection arrangement (200) according to claim 1, characterized by that the pawl (236) has a tab (240) extending from one end (238) of the pawl (236), and wherein the tab (240) is disposed in a slot (244) formed in the second end (224) of the body (220) of the base (212), whereby the end (238) of the pawl (236) is secured to the second end (224) of the body (220). [5] Electrical connection arrangement (200) according to claim 4, characterized by that the pawl (236) has a lug (242) formed therein and positioned adjacent to the spring clip (214) to prevent movement of the spring clip (214) in the assembly direction (216). [6] Electrical connection arrangement (200) according to claim 1, characterized bythat the base (212) has one or more dome-shaped projections (248) which engage surfaces of the spring clip (214). [7] Electrical connection arrangement (200) according to claim 1, characterized by that the spring clip (214) is made of a material with a higher yield strength than a material from which the base (212) is made. [8] Electrical connection arrangement (200) according to claim 1, characterized by that the spring clip (214) is made of steel. [9] Electrical connection arrangement (200) according to claim 1, characterized by that the base (212) is made of a highly conductive alloy. [10] A method for assembling an electrical connection arrangement (10; 200), comprising the following steps: (a) providing a base (12, 212) having a plurality of opposed base beams (60, 62, 64, 66; 260, 262, 264, 266) extending in a first direction; (b) providing a spring clip (14; 214) having a plurality of opposed spring beams (92, 94; 292, 294) extending in the first direction; (c) deflecting away from each other and spring-biasing the opposing spring beams (92, 94; 292, 294) to provide a clearance for positioning the spring clip (14; 214) over the base (12; 212); and (d) positioning the spring clip (14; 214) over the base (12; 212) by moving the spring clip (14; 214) in an assembly direction (16; 216) perpendicular to the first direction until the spring beams (92, 94; 292, 294) are positioned over the base beams (60, 62, 64, 66; 260, 262, 264, 266), thereby assembling the electrical connection assembly (10; 200), characterized bythat the opposing spring beams (92, 94; 292, 294) are deflected by a mandrel tool (114) with a first mandrel (116) and a second mandrel (118) which are movable relative to one another. [11] Method according to claim 10, characterized by that before step (d) tips of opposite base beams (60, 62, 64, 66; 260, 262, 264, 266) are moved towards each other. [12] Method according to claim 11, characterized by that the tips of the opposite base beams (60, 62, 64, 66; 260, 262, 264, 266) are moved towards each other by using a holding tool with a pair of arms (110, 112; 310, 312) which are movable relative to each other.

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