Electrical connection arrangement with split sheath

Abstract

Electrical connection arrangement (10), comprising: a contact member (12) having a contact base (18) and a plurality of contact arms (22) extending in an arm direction (24) from the contact base (18) and arranged on opposite sides of a terminal plane (26); a spring member (14) supported on the contact member (12) and having a spring base (28), a plurality of spring arms (36) extending from the spring base (28) on opposite sides of the terminal plane (26) in the arm direction (24), engaging the plurality of contact arms (22) and biasing the contact arms (22) toward the terminal plane (26), and a shell (38) extending around and beyond the contact arms (22) in the arm direction (24), the shell (38) having a terminal passage (64) in which the terminal plane (26) is located, wherein the sheath (38) comprises a first side protection part and a second side protection part positioned on opposite sides of the contact arms (22), wherein the first side protection part comprises a first section (40a) and a second section (42a) positioned on opposite sides of the connection plane (26), and the second side protection part comprises two sections (40b, 42b) positioned on opposite sides of the connection plane (26), wherein the electrical connection arrangement (10) has a first side gap (44a) between the first section (40a) of the first side protection part and the second section (42a) of the first side protection part, the height of the first side gap (44a) being greatest at a joining end (46) of the sheath (38) remote from the spring base (28) and being lower at a base end (48) of the sheath (38) closest to the spring base (28).

Description

BACKGROUND OF THE INVENTIONThe present invention relates generally to an electrical terminal assembly. More particularly, the present invention relates to an electrical terminal assembly including a spring member positioned on a contact member.Electrical terminals commonly include a receptacle and corresponding plug which can be mated together to establish an electrical connection. Electrical connectors are made in various shapes, including pins and knives, and electrical connectors are made in complementary shapes that can engage the appropriate connector. Terminal sockets often contain a contact section with a plurality of contact arms pressing on the side of the terminal plug. It is known to provide a connector with a spring member to increase the pressing force between the connector and the connector. An example of such a spring is shown in U.S. Patent 7,892,050. The spring member is typically made of a material that has poorer electrical conductivity compared to the material of the contact portion, but is less susceptible to relaxation. The spring maintains the desired compressive force without the need to increase the dimensions of the contact portion and allows the receptacle to maintain a desired contact area with the plug even as the temperature of the receptacle increases. An electrical connection arrangement with a spring element is also known from DE 10 2010 024 155 A1.It is also known to provide a connection socket with front end protection. An example of such front end protection is shown in U.S. Patent 9,548,553. The terminal shown in the '553 patent includes a spring member with an integral front end guard. The spring engages contact arms to maintain a compressive force between the jack and a corresponding plug, similar to the spring member described in the '050 patent. In addition, the spring member includes a cage that extends around and beyond the contact arms. The cage protects the contact arms from damage during shipping, handling, installation, and use. Since the cage is part of the spring member, no additional parts need to be added to the connector socket. It would be desirable to provide a spring member that provides both good compressive force on the contact member and protection for the contact arms and can be used in combination with additional types of connector plugs.Connection sockets with an additional spring member, which has a housing arranged around the contact arms of the contact member for protecting the contact arms, are also known from DE 196 50 253 A1, DE 10 2014 009 207 A1 and DE 196 02 822 A1. In this case, DE 196 50 253 A1 discloses continuous side surfaces. In DE 10 2014 009 207 A1 and DE 196 02 822 A1, the side surfaces have further spring arms.Furthermore, DE 10 2018 209 457 A1 discloses an electrical connection with symmetrical front end protection. The terminal includes a contact member having a contact base and a plurality of contact arms extending from the contact base and disposed on opposite sides of a terminal plane, and a spring member having a spring base and a plurality of spring arms extending from the spring base. Each of the spring arms engages one or more of the contact arms. In addition, the spring member includes a shroud that extends around and beyond the contact arms. The sheathing has two sheathing sections each with two side shields which are separated from one another by uniform sheathing gaps.SUMMARY OF THE INVENTIONThe invention relates to an electrical connection arrangement. The electrical terminal assembly includes a contact member having a contact base. A plurality of contact arms extend in an arm direction from the contact base. The contact arms are disposed on opposite sides of a terminal plane. The electrical terminal assembly includes a spring member supported on the contact member. The spring member includes a spring base. A plurality of spring arms extend from the spring base on opposite sides of the terminal plane in the arm direction. The spring arms engage the plurality of contact arms and bias the contact arms toward the terminal plane. Furthermore, the spring element has a casing. The shroud extends around and beyond the contact arms in the arm direction. The casing has a connection passage in which the connection plane is located. The shroud includes a first side guard portion and a second side guard portion positioned on opposite sides of the contact arms. The first side protection part has a first portion and a second portion positioned on opposite sides of the terminal plane. The second side protection part also has two portions positioned on opposite sides of the connection plane. According to the invention, a first side gap is provided between the first and the second section of the first side protection part, wherein the height of the side gap is the greatest at a joining end of the sheathing located remote from the spring base and is lower at a base end of the sheathing located closest to the spring base.Various aspects of the present invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments when read with reference to the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is a perspective view of an electrical terminal assembly according to the present invention. FIG. 2 is an exploded view of the electrical terminal assembly illustrated in FIG. 1, showing a contact member separated from a spring member. FIG. 3 is a perspective view similar to FIG. 1, but additionally showing the electrical connector assembly mated with a corresponding electrical connector. FIG. 4 is a cross-sectional view taken along line 4- 4 of FIG. 1. FIG. 5 is a cross-sectional view taken along line 5- 5 of FIG. 3.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTReferring now to the drawings, there is illustrated in FIG. 1 a perspective view of an electrical terminal assembly, generally designated 10, in accordance with the present invention. The electrical terminal assembly 10 includes a contact member, generally designated 12, and a spring member, generally designated 14. FIG. 2 is an exploded perspective view of the electrical terminal assembly 10 showing the contact member 12 separated from the spring member 14. FIG. 4 is a cross-sectional view of the electrical terminal assembly 10 taken along line 4- 4 of FIG. 1 ; details of the electrical terminal assembly 10 will be described with reference to these figures.The illustrated contact member 12 is made from a single sheet of material that has been stamped and folded into the illustrated configuration. However, the contact member 12 may be manufactured by any desired process. The illustrated contact member 12 is made of copper, but may be made of any desired material. Preferably, the contact member 12 is made of a material having a good electrical conductivity, such as aluminum.The contact member 12 includes a connection portion 16 configured to connect to an electrical conductor such as a wire (not shown). The connection portion 16 may be configured for any desired type of connection. The contact member 12 includes a contact base 18 connected to the connecting portion 16. The illustrated contact base 18 is a box having a substantially rectangular cross-sectional shape defining an interior space 20. However, the contact base 18 may have any desired shape.The contact member 12 includes a plurality of contact arms, generally designated 22, that extend from the contact base 18 in an arm direction 24. In the illustrated embodiment, the connection portion 16 and the contact arms 22 are on opposite sides of the contact base 18, but the components may have any desired relative orientations. The contact arms 22 are arranged on mutually opposite sides of a connection plane 26. In the illustrated embodiment, the contact member 12 includes a total of eight contact arms 22 arranged in four opposing pairs, but the contact member 12 may have any desired number and arrangement of contact arms 22.The illustrated spring member 14 is made from a single sheet of material that is stamped and folded into the illustrated configuration. However, the spring member 14 may be manufactured by any desired process. The illustrated spring member 14 is made of stainless steel, but may be made of any desired material. Preferably, the spring member 14 is made of a material having a good spring characteristic even at relatively high temperatures.The spring member 14 includes a spring base 28. The illustrated spring base 28 includes a first bridge 30 and a second bridge 32, each connected to two U-shaped struts 34. However, the spring base 28 may have any desired shape. The illustrated first bridge 30 and second bridge 32 are located on opposite sides of the terminal plane 26 and are symmetrical across the terminal plane 26. The illustrated struts 34 cross the terminal plane 26 and in the illustrated embodiment are the only part of the spring member 14 through which the terminal plane 26 passes. Further, the spring member 14 includes a plurality of spring arms, generally designated 36, extending in the arm direction 24 from the spring base 28. In the illustrated embodiment, spring member 14 includes two spring arms 36 extending from first bridge 30 and two spring arms 36 extending from second bridge 32. The spring arms 36 are disposed on opposite sides of the terminal plane 26 in opposing pairs with two on each side of the terminal plane 26. The spring member 14 may include any desired number and arrangement of spring arms 36.The spring member 14 includes a shroud, generally designated 38. The illustrated shroud 38 includes a first shroud portion 40 and a second portion 42 located on opposite sides of the terminal plane 26. The illustrated first shroud portion 40 is attached to the first bridge 30 of the spring base 28, while the second shroud portion 42 is attached to the second bridge 32 of the spring base 28. The illustrated first shroud portion 40 and second shroud portion 42 are mirror images of each other across the terminal plane 26, but may have any desired shapes. Moreover, the jacket 38 may be made of any desired number and arrangement of sections.The first shroud portion 40 includes a first portion first side guard portion 40 aconnected to the spring base 28 and extending further than the spring arms 36 in the arm direction 24. The first shroud portion 40 also includes a first portion second side guard portion 40 bconnected to the spring base 28 and extending further in the arm direction 24 than the spring arms 36. The first portion first side guard 40 aand the first portion second side guard 40 bare located on opposite sides of the spring arms 36 and are each connected to a first end guard 40 cpositioned past the spring arms 36 in the arm direction 24.Similarly, the second shroud portion 42 includes a second portion first side guard portion 42 aconnected to the spring base 28 and extending further than the spring arms 36 in the arm direction 24. The second shroud portion 42 also includes a second portion second side guard portion 42 bconnected to the spring base 28 and extending further in the arm direction 24 than the spring arms 36. The second portion second side guard 42 aand the second portion second side guard 42 bare located on opposite sides of the spring arms 36 and are each connected to a second end guard 42 cpositioned past the spring arms 36 in the arm direction 24.When the electrical terminal assembly 10 is assembled, as shown in FIG. 1, the shell 38 extends around the contact arms 22 of the contact member 12 and further to provide side and end protection for the contact arms 22 during handling, installation, and use. The side protection portions 40 a, 40 b, 42 aand 42 bprevent the contact arms 22 from being accidentally touched by the sides, and the end protection portions 40 cand 42 cprevent the contact arms 22 from being touched by the electric terminal assembly 10 by mistake from the front.The first side protection part 40 aof the first section is situated opposite the first side protection part 42 aof the second section with respect to the connection plane 26. The first side guard part 40a of the first section and the first side guard part 42a of the second section are separated by a first side gap 44a. The first side gap 44 aextends from a mating end 46 of the shroud 38 that is the end of the shroud 38 remote from the spring base 28 to a base end 48 of the shroud 38 that is the end of the shroud 38 closest to the spring base 28. The connection plane 26 runs through the first side gap 44 a.The first side gap 44a has a height that varies between the mating end 46 and the base end 48 of the shroud 38. The height of the first side gap 44a varies with the distance between the first portion first side guard 40a and the second portion first side guard 42a. In the illustrated embodiment, the height of the first side gap 44 ais greatest at the mating end 46 and gradually decreases from the mating end 46 to a first gap transition 50 a. Thereafter, the height of the first side gap 44 aconceases further from the first gap transition 50 ato the base end 48 of the casing 38, but at a lower rate compared to the portion between the joining end 46 and the first gap transition 50 a.Similarly, the second side guard 40b of the first portion is opposite the second side guard 42b of the second portion with respect to the terminal plane 26. The second first section side guard 40 band the second second section side guard 42 bare separated by a second side gap 44 b. The second side gap 44 aextends from the joining end 46 of the sheathing 38 to the base end 48 of the sheathing 38, and the connection plane 26 runs through the second side gap 44 b.Similar to the first side gap 44 a, the second side gap 44 bhas a height that changes between the joining end 46 and the base end 48 of the casing 38. The height of the second side gap 44b varies with the distance between the first section second side guard 40b and the second section second side guard 42b. The illustrated second side gap 44 bis largest at the mating end 46, and its height decreases from the mating end 46 to a second gap transition. Thereafter, the height of the second side gap 44 bconceases further from the second gap transition 50 bto the base end 48 of the shroud 38, but at a lesser rate compared to the portion between the mating end 46 and the second gap transition.Further, the illustrated spring member 14 includes a plurality of spring tabs 54 that serve to properly position the spring member 14 relative to the contact member 12. The spring tabs 54 extend from the spring base 28 to the terminal plane 26 In the illustrated embodiment, the spring member 14 includes four spring tabs 54, two on the first bridge 30 and two on the second bridge 32 When the electrical terminal assembly 10 is mounted, the spring tabs 54 are located between the shell 38 and the contact base 18. Between each spring tab 54 and the shell 38 is a spring cutout 56. Each spring cutout 56 is an open space located between one of the spring tabs 54 and the shell 38.Referring now to FIG. 3, a perspective view similar to FIG. 1 is illustrated with a corresponding terminal 58 shown mated with the electrical terminal assembly 10. FIG. 5 is a cross-sectional view taken along line 5- 5 of FIG. 3 ; the corresponding terminal 58 is a blade terminal plug, but may be any desired type of electrical terminal. The illustrated corresponding terminal 58 is an oversized terminal and has a terminal width 60 that is greater than the inner width 62 of the electrical terminal assembly 10. The inner width 62 is the distance between the side guard portions 40a, 42a, 40b, and 42b of the shroud 38 along the terminal axis 26.As best seen in FIG. 4, the first side gap 44 aand the second side gap 44 btogether provide the shroud 38 with a port passage generally designated 64. The terminal passage 64 passes through the terminal plane 26 and allows mating of the corresponding terminal 58 with the electrical terminal assembly 10 by allowing the oversized corresponding terminal 58 to engage the contact arms 22 without engaging the spring member 14. The terminal passage 64 has portions of the first side gap 44 aand the second side gap 44 bat the mating end 46 of the shell 38 that are greater than a terminal thickness 66 of the corresponding terminal 58. This allows the corresponding terminal 58 to move past the mating end 46 of the shroud 38 and engage the contact arms 22 without engaging the shroud 38.When the corresponding terminal 58 engages the contact arms 22 of the electrical terminal assembly 10, the contact arms 22 are spread apart in opposite directions away from the terminal plane 26. The contact arms 22 flex with respect to the contact base 18, and the contact arms 22 on either side of the terminal plane 26 are moved a distance substantially equal to half a terminal thickness 66 of the corresponding terminal 58. In addition, the spring arms 36 are also spread apart in opposite directions away from the connection plane 26.As previously described, the illustrated spring member 14 is symmetrical about the terminal plane 26. As a result, spring member 14 normally experiences a similar deflection on each side of terminal plane 26. Because the bridge 30 and the bridge 32 are not fixed to the contact base 18, the spring arms 36 and the bridges 30 and 32 flex relative to the struts 34 when the spring arms 36 are spread apart away from the terminal plane 26. As described above, the first cover portion 40 is fixed to the first bridge 30, and the second cover portion 42 is fixed to the second bridge 32. Thus, as the spring arms 36 are spread apart away from the terminal plane 26, the first shroud portion 40 and the second shroud portion 42 move with the first bridge 30 and the second bridge 32 and rotate away from the terminal plane 26. As a result, the height of the first side gap 44 aand the second side gap 44 bincreases as the spring arms 36 spread apart. This can be seen by comparing the second side gap 44 bin FIGS. 4 and 5.Referring to FIG. 4, it should be appreciated that the height of the first side gap 44 abetween the first gap transition 50 aand the base end 48 of the shroud 38 may be less than the terminal thickness 66 of the corresponding terminal 58 when the electrical terminal assembly 10 is assembled, if desired. As shown in FIG. 5, when the corresponding terminal 58 engages the contact arms 22, the corresponding terminal 58 spreads the shell portions 40 and 42 apart, thereby increasing the height of the first side gap 44 ato accommodate the corresponding terminal 58. This prevents the spring member 14 from engaging the corresponding terminal 58, which may be advantageous in preventing the spring member 14 from damaging the corresponding terminal 58.Referring again to FIG. 4, the spring member 14 has a tapered profile between the mating end 46 of the shroud 38 and the spring base 28 perpendicular to the terminal plane 26. From the joining end 46, the spring member 14 is positioned further from the connection plane 26 toward a spring bend 70. In the illustrated embodiment, the spring flexure 70 is located on the shroud 38 between the spring base 28 and the mating end 46 proximate the spring base 28. From the spring bend 70, the spring member 14 is positioned closer to the connection plane 26 back to the struts 34. In the illustrated embodiment, both the first shroud portion 40 and the second shroud portion 42 include similar symmetric spring bends 70.As described above, when the electrical connection arrangement 10 is joined to the corresponding connection 58, the first bridge 30 and the second bridge 32 are spread away from the connection plane 26 by the spring arms 36. This also moves the first shroud portion 40 and the second shroud portion 42 causing these shroud portions 40 and 42 to rotate away from the terminal plane 26. As a result, the mating ends 46 of the shroud 38 are at a mated distance 72 bfrom the terminal plane 26 when the electrical terminal assembly 10 is mated with the corresponding terminal 58. Because the first shroud portion 40 and the second shroud portion 42 rotate about lines located near the spring base 28, the mating ends 46 are the portion of the shroud 38 that experience the greatest amount of linear motion when the electrical terminal assembly 10 is mated with the corresponding terminal 58. The spring flexure 70 positions the mating ends 46 of the shroud 38 closer to the terminal plane 26 than they would be if the spring member 14 did not include the spring flexure 70.It should be appreciated that the terminal housing (not shown) that receives the electrical terminal assembly 10 is large enough to receive the electrical terminal assembly 10 when mated with the corresponding terminal 58 and is at its largest size. The spring flexure 70 does not reduce the height of the assembled electrical terminal assembly 10 that is located at the spring flexure 70 in the illustrated embodiment. However, the spring flexure 70 reduces the height of the electrical terminal assembly 10 at the mating ends 46 when the electrical terminal assembly 10 is mated with the corresponding connector 58. Thus, the required size of the terminal housing can be reduced without the need to reduce the size of the entire electrical terminal assembly 10.In the illustrated embodiment, the spring flexure 70 is a flexure in the material of the spring member 14, however, the spring flexure 70 may be configured as any other feature or characteristic that provides the spring member 14 with a reduced height at the mating end 46. For example, a portion of the shroud 38 may be cut away at the mating end 46, or the material of the shroud 38 may be thinner at the mating end 46.The principle and mode of operation of the present invention have been illustrated and illustrated with respect to preferred embodiments thereof. It is to be understood, however, that the present invention may be practiced otherwise than as specifically illustrated and illustrated without departing from its spirit or scope.

Claims

An electrical terminal assembly (10) comprising: a contact member (12) having a contact base (18) and a plurality of contact arms (22) extending in an arm direction (24) from the contact base (18) and disposed on opposite sides of a terminal plane (26); a spring member (14) supported on the contact member (12) having a spring base (28), a plurality of spring arms (36) extending on opposite sides of the terminal plane (26) in the arm direction (24) from the spring base (28), engaging the plurality of contact arms (22) and biasing the contact arms (22) toward the terminal plane (26), and a shroud (38) extending in the arm direction (24) about and beyond the contact arms (22), the shroud (38) having a terminal passage (64), in which the terminal plane (26) is located, wherein the casing (38) has a first side protection part and a second side protection part which are positioned on opposite sides of the contact arms (22), wherein the first side protection part has a first section (40a) and a second section (42a) which are positioned on opposite sides of the terminal plane (26), and the second side protection part has two sections (40b, 42b) which are positioned on opposite sides of the terminal plane (26), wherein the electrical terminal arrangement (10) has a first side gap (44a) between the first section (40a) of the first side protection part and the second section (42a) of the first side protection part, wherein the height of the first side gap (44a) is greatest at a joining end (46) of the sheathing (38) located remote from the spring base (28) and is lower at a base end (48) of the sheathing (38) located closest to the spring base (28).The electrical connection assembly (10) of claim 1, wherein the spring member (14) is symmetrical across the connection plane (26).The electrical terminal assembly (10) of claim 1, wherein the spring member (14) includes a spring flexure (70) between the spring base (28) and a mating end (46) of the shroud (38) remote from the spring base (28) such that the mating end (46) of the shroud (38) tapers toward the terminal plane (26).The electrical terminal assembly (10) of claim 3, wherein the enclosure (38) includes a first enclosure portion (40) secured to the spring base (28) on a first side of the terminal plane (26) and a second enclosure portion (42) secured to the spring base (28) on an opposite, second side of the terminal plane (26).The electrical terminal assembly (10) of claim 4, wherein the spring base (28) includes a first bridge (30) located on the first side of the terminal plane (26) and a second bridge (32) located on the second side of the terminal plane (26), the spring base (28) further including a strut (34) connected to the first bridge (30) and the second bridge (32).The electrical connection arrangement (10) according to claim 5, wherein the spring member (14) is symmetrical across the connection plane (26).The electrical terminal assembly (10) of claim 6, wherein the spring member (14) includes spring tabs (54) located between the shroud (38) and the contact base (18).The electrical terminal assembly (10) of claim 7, wherein the spring member (14) defines spring cut-outs (56) between the spring tabs (54) and the shroud (38).

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