Female terminal and manufacturing method of such a terminal
The female terminal design with a reinforced tulip-shaped socket and connection support addresses issues of high-current conduction, heating, and vibration resistance, ensuring efficient and cost-effective performance in power connection systems.
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- APTIV TECHNOLOGIES AG
- Filing Date
- 2024-12-12
- Publication Date
- 2026-06-17
AI Technical Summary
Existing female terminals in power connection systems for motor vehicles face challenges in conducting high currents without excessive heating, maintaining mechanical strength, and withstanding vibrations, particularly during welding and resonance frequencies.
A female terminal design comprising a tulip-shaped socket with contact blades and a connection support, where the socket is rolled from a sheet metal portion and reinforced with radial reinforcement means to enhance electrical and thermal conduction, prevent dislodgment, and optimize material selection for mechanical robustness.
The design ensures efficient high-current conduction, minimizes heating, withstands vibrations, and eliminates the need for additional bonding methods, while allowing cost-effective material choices.
Smart Images
Figure IMGAF001_ABST
Abstract
Description
[0001] The disclosure relates to the field of power connection systems for motor vehicles. For example, the disclosure can find an application in power connectors, such as those used to charge a rechargeable electric or hybrid vehicle battery or as those used in interconnect power circuits for connecting batteries, converters, electrical motors, and any other power device of a vehicle.
[0002] In the field of power connection systems for motor vehicles, the female terminals can be machined by bar turning from a bar of conductive material, for example a copper alloy. The female terminals can also be made by cutting, stamping, embossing, a blank in an electrically conductive material in sheet, and rolling up a cut-out region of the blank. The present disclosure concerns a female terminal of the latter type.
[0003] Such a female terminal 1 is intended to be mated to a male terminal at one side and to be connected, at another side, to a connecting element (e.g. a cable, a busbar, or any other conductive element). Thus, the female terminal 1 comprises a tulip shape socket 2 and a connection support 4 (see Figures 1 to 3 for example).
[0004] The socket 2 is formed of a sheet metal portion rolled up around a central axis CA, to form an inner region 3 intended to receive at least part of a contact portion of the male terminal. The socket 2 has contact blades 5. It is advantageous to choose the material of the socket 2 so as to obtain an appropriate resilience of the contact blades 5, for example, in addition to its ability to conduct a high current. Indeed, to conduct high current intensities between male and female terminals without excessive heating, the resistance must be minimized at the contact points between the male and female terminals. For this purpose, a sufficient contact force must be applied at each contact point. The contact blades of the female terminal must therefore exert sufficient force on the pin of the male terminal. However, this force must be controlled so as to limit the force of insertion of the pin of the male terminal in the socket.
[0005] The connection support 4 has a connection portion 6 and a support portion 7. The connection portion 6 is configured to electrically and mechanically connect the terminal 1 to another conductive element. The support portion 7 is configured to support the socket 2. The material of the connection support 4 is also advantageously chosen for its ability to conduct a high current, but also for its mechanical properties. For example, if the connection portion is used to be crimped on a cable, it is advantageous to choose a material that is deformable, that does not produce cracks when deformed, etc. The material of the connection portion may also be chosen for its ability (e.g., with respect to its electro-chemical potential, mechanical strength, etc.) to be connected and / or welded to said conductive element.
[0006] There is therefore a need to design and manufacture a female terminal made of at least two pieces, for example, so as to chose for each one of these pieces the most appropriate material.
[0007] As the female contact is to be made from the assembly of two parts, the conduction of electricity and heat between these two parts, as well as the mechanical strength of this assembly, must be sufficient for their uses in the intended application and / or location in a power electrical circuit.
[0008] More particularly, the mechanical connection and assembly between the connection support and the socket must be robust and able to withstand vibrations, in particular those generated during welding between the connection portion of the connection support and a conductive element.
[0009] This disclosure is intended to at least partially meet one or several of these needs.
[0010] To this aim it is disclosed below an electrical female power terminal for electrical power connections of a vehicle, with a terminal body comprising a tulip shape socket and a connection support, wherein the socket is formed of a sheet metal portion rolled up around a central axis, to form an inner region intended and configured to receive at least part of a contact portion of a male terminal, the socket has contact blades, the number of which is greater than or equal to two, being cut out of the sheet metal portion, each contact blade extending between a ring-shape base and a free end, the ring-shape base having a cylindrical wall symmetrical around an axis of revolution parallel to the central axis, and the ring-shape base extending longitudinally, parallel to the central axis, from an edge towards the contact blades, the connection support has a connection portion and a support portion, the connection portion being configured to electrically and mechanically connect the terminal to another conductive element, and the support portion having a thickness defined between a first main face and a second main face, at least one opening being formed through the thickness between the first and second main faces, the socket being inserted in said opening so that a portion of the socket comprising the contact blades extend on a side of the support portion corresponding to the first main face.
[0011] Further, the ring-shape base comprises reinforcement means configured to prevent the socket from moving out of the opening in the direction from the second main face to the first main face.
[0012] The reinforcement means have a number of advantages, such as: they can increase the surface area for electrical and thermal conduction between the socket and the connection support, which may make it unnecessary to add a layer of silver between these two parts while maintaining good electrical and thermal conduction, and / or they can prevent the base from being pulled out of the connection support if the socket is pulled or if vibrations occur in the female contact when a cable or busbar is ultrasonically welded to the connection portion, for example if such vibrations occur between 10 and 50 kHz and more particularly at approximately 20kHz (and in particular if a resonance occurs at a frequency comprised in the range of 10-40kHz and more particularly close to 20kHz), and / or they avoid the need for costly solutions (e.g., welding, etc.) to hold the socket and the connection support together, etc. they enable the socket and connection support materials to be chosen in a way that is optimised in terms of their electrical and mechanical properties, of their respective costs, etc.
[0013] This female terminal optionally further comprises any of the following features, considered independently of one another or in combination with one or more others: the reinforcement means extend radially outwardly from the ring-shape base and are configured to mechanically engage the second main face of the connection support; when the socket is forced into the connection support, it is not necessarily needed to have a structure that holds the socket in place on each of the first and second main faces; the reinforcement means consists in a continuous rim circularly and continuously extending, all around the ring-shape base, symmetrically with respect to the central axis; the symmetry eliminates the need to orientate the socket in relation to the support (around the central axis); the rim is formed by deforming said edge of the ring-shape base, radially outwards from the socket; this is one of the simplest ways of forming the rim; the ring-shape base is press-fitted in the opening with an interference comprised between 0.5 and 1mm; the presence of the rim may limit the interference and therefore require less force to insert the socket into the connection support, which may also prevent damage to the socket and / or support; the socket is made of a copper alloy with good relaxation behaviour in the event of overheating and good elastic behaviour to provide a contact force suited to the application; the connection support is made of 100% IACS ("IACS" stands for International Annealed Copper Standard), i.e., pure copper, for a good electrical conductivity;
[0014] According to another aspect, it is disclosed below a method of manufacturing an electrical female power terminal, this method comprising, for example, the steps of providing a first sheet of conductive material, forming (e.g., by stamping, drawing, etc.) in the first sheet of conductive material, a socket comprising a ring-shape base and contact blades, the number of contact blades being greater than or equal to two, each contact blade extending between the ring-shape base and a free end, the ring-shape base having a cylindrical wall symmetrical around an axis of revolution parallel to the central axis, the ring-shape base extending longitudinally, parallel to the central axis, from an edge towards the contact blades, and ring-shape base comprising reinforcement means, providing a second sheet of conductive material, forming (e.g., by stamping, drawing, etc.) in the second sheet of conductive material, a connection support having a connection portion and a support portion, the connection portion being configured to electrically and mechanically connect the terminal to another conductive element, and the support portion having a thickness defined between a first main face and a second main face, at least one opening being formed through the thickness between the first and second main faces, inserting the socket in said opening so that a portion of the socket comprising the contact blades extend on a side of the support portion corresponding to the first main face, and so that the reinforcement means prevent the socket from moving out of the opening in the direction from the second main face to the first main face.
[0015] Other features and advantages of the invention will become apparent on reading the following detailed description and from the attached drawings. In these drawings: Figures 1 to 3 represent, schematically and in perspective, prior art examples of female terminals, Figure 4 shows, schematically and in perspective, a prior-art socket such as that fitted to the female terminals in Figures 1 to 3; Figure 5 shows, schematically and in perspective, an example of socket for a female terminal; Figure 6 represents, schematically, in perspective and in cross-section, an example of socket such as that of figure 5, this socket being press-fitted in a connection support; Figure 7 represents, schematically, in perspective and in cross-section, a detail of Figure 6; Figure 8 represent schematically in cross-section an example of reinforcement means; Figure 9 represent schematically in cross-section another example of reinforcement means; and Figure 10 represent schematically steps of an example of a method of manufacturing an electrical female power terminal.
[0016] A first example of a female terminal 1 is represented in Figure 1. This female terminal 1 comprises a socket 2 and a connection support or carrier 4. An example of socket 2 is shown in Figure 4. The socket 2 is cut out of a sheet metal portion (for example from C18070 copper alloy, or a copper alloy CuNi3SiMg, etc.). The socket 2 is rolled up around a central axis CA, to form an inner region 3 intended to receive at least part of a contact portion of a male terminal (not shown). For example, this female terminal 1 is configured to mate with an 8 mm diameter male terminal. The socket 2 has contact blades 5, each contact blade 5 extending between a ring-shape base 8 and a free end 9. The ring-shape base 8 and the contact blades 5 are symmetrically arranged around an axis of revolution (corresponding to the central axis CA). The ring-shape base 8 has a cylindrical wall 10. The ring-shape base 8 extends longitudinally, parallel to the central axis CA from an edge 11 towards the contact blades 5. The connection support 4 is cut out of a sheet metal portion (for example from a Cu-ETP tape). The connection support 4 is of example 2mm thick. The connection support 4 has a connection portion 6 and a support portion 8. The connection portion 6 is configured to electrically and mechanically connect the terminal 1 to another conductive element. More particularly, in the example illustrated in Figure 1, the connection portion 6 is configured to be crimped over a stripped portion of electrical cable (not shown). In other words, the connection portion 6 comprises two crimping wings 12 configured to be folded over the stripped portion of an electrical cable. The support portion 8 has a thickness defined between a first main face 13 and a second main face 14. An opening 15 being is formed through its thickness between the first 13 and second 14 main faces. In the example illustrated in Figure 1, the opening 15 is surrounded by a collar 16. The socket 2 has a ring-shape base 8 that is inserted in the opening 15 and press-fitted in the opening 15 and the collar 16, so that a portion of the socket 2 comprising the contact blades 5 extend on the side of the first main face 13.
[0017] A second example of a female terminal 1 is represented in Figure 2. This female terminal 1 comprises a socket 2 and a connection support 4. For example, this female terminal 1 is configured to mate with a 12 mm diameter male terminal (not shown). The socket 2 is similar to the one shown in Figure 1, except for its dimensions and possibly its number of contact blades 5 and the thickness of sheet metal portion from which it is cut. The connection support 4 has a connection portion 6 and a support portion 8. The connection support 4 is cut out of a sheet metal portion (for example from a Cu-ETP tape). The connection support 4 is of example 2mm thick. The connection portion 6 is configured to electrically and mechanically connect the terminal 1 to another conductive element. In the example illustrated in Figure 2, the connection portion 6 is configured to be welded to a busbar (not shown). An opening 15 is made in the support portion 8 through its thickness, between the first 13 and second 14 main faces. The ring-shape base 8 of the socket 2 is inserted and press-fitted in the opening 15 so that a portion of the socket 2 comprising the contact blades 5 extend on the side of the first main face 13.
[0018] A third example of a female terminal 1 is represented in Figure 3. This female terminal 1 comprises a socket 2 and a connection support 4. For example, this female terminal 1 is configured to mate with a 11 mm diameter male terminal (not shown). The socket 2 is similar to the one shown in Figure 1 or 2, except for its dimensions, and possibly its number of contact blades 5 and the thickness of sheet metal portion from which it is cut. The connection support 4 has a connection portion 6 and a support portion 8. The connection support 4 is cut out of a sheet metal portion (for example from a Cu-ETP tape). The connection support 4 is of example 2mm thick. The connection portion 6 is configured to electrically and mechanically connect the terminal 1 to another conductive element. In the example illustrated in Figure 3, the connection portion 6 is configured to be crimped over a stripped portion of electrical cable (not shown). An opening 15 is made in the support portion 8 through its thickness, between the first 13 and second 14 main faces. The ring-shape base of the socket 2 is inserted and press-fitted in the opening 15 so that a portion of the socket 2 comprising the contact blades 5 extend on the side of the first main face 13.
[0019] Advantageously, the socket 2 illustrated in Figure 4 and disclosed in relation with Figures 1 to 3 is replaced by the example of socket 20 shown in Figures 5, 6 and 7. As the socket 2 of Figures 1 to 3, the socket 20 is cut out of a sheet metal and rolled up around a central axis CA, to form an inner region 3 intended to receive at least part of a contact portion of a male terminal. The socket 20 has contact blades 5, each contact blade 5 extending between a ring-shape base 8 and a free end 9. The ring-shape base 8 and the contact blades 5 are symmetrically arranged around the central axis CA. The ring-shape base 8 has a cylindrical wall 10. The ring-shape base 8 extends longitudinally, parallel to the central axis CA, from an edge 11 towards the contact blades 5.
[0020] Further, the ring-shape base 8 comprises reinforcement means 17 extending radially outwardly from the ring-shape base 8 and configured to mechanically engage the second main face 14 of the connection support 4. These reinforcement means 17 may be a continuous or segmented rim or flange, a continuous or segmented conical shape or wedge(s) or chock(s), etc.
[0021] For example, the socket 20 comprises a rim 18 or flange that is continuous, i.e., that symmetrically extends all around the ring-shape base 8 (see Figure 5). This rim 18 extends radially outwardly from the ring-shape base 8 (in a direction essentially perpendicular to the central axis CA). The rim 18 is formed by deforming the edge 11 of the ring-shape base 8, radially outwards from the socket 20. Therefore, when inserted and press-fitted into the opening 15 of the support portion 8, from its second main face 14, the rim 18 blocks the socket 20 to the second main face 14 and prevents it from moving out of the opening 15 in the direction from the second main face 14 to the first main face 13 (see Figure 6).
[0022] For example, the edge surrounding the opening 15 on the second main face 14 is machined to form an oblique surface 19 which forms an angle a with the central axis CA of between 15 and 40 degrees (see figures 8 and 9). Then, for example, when the socket 20 is press-fitted in the opening, the reinforcement means 17 is pressed against the oblique surface 19.
[0023] However, the reinforcement means 17 may have another shape.
[0024] For example, the rim may not extend continuously all around the ring-shape base 8. One or several rim segments (not shown) may extend outwardly from the ring-shape base 8, at the edge 11 of the ring-shape base 8.
[0025] According to another example, the reinforcement means 17 may be formed as a continuous circular bead (not shown), or one or several bead segments (not shown), outwardly extending around the ring-shape base 8. The bead(s) may be located at said edge 11 of the ring-shape base 8 or between said edge 11 and the blades 5.
[0026] According to another example, the reinforcement means 17 may be formed as a continuous circular conical shape (not shown), or one or several bevelled segments (not shown) formed at the edge 11 of the ring-shape base 8. This conical shape or bevelled segment(s) have a surface inclined towards the outside of the socket 20 and complementary to a surface formed in the thickness of the support portion 8, at the location of the opening 15.
[0027] According to another example, the reinforcement means 17 may be formed as wedge(s) or chock(s) (not shown) having a shape that is adapted to engage the support portion 8, at the location of the opening 15, so as to prevent the socket 20 from moving out of the opening 15 in the direction from the second main face 14 to the first main face 13.
[0028] The female terminal 1 for electrical power connectors of a vehicle, is made with a manufacturing method comprising, for example, the steps of providing a first sheet of conductive material, forming (e.g., by stamping, drawing, etc.) in the first sheet of conductive material, a socket 20 comprising a ring-shape base 8 and contact blades 5, the number of contact blades 5 being greater than or equal to two, each contact blade 5 extending between the ring-shape base 8 and a free end 9, the ring-shape base 8 having a cylindrical wall symmetrical around an axis of revolution parallel to the central axis CA, the ring-shape base 8 extending longitudinally, parallel to the central axis CA, from an edge 11 towards the contact blades 5, and ring-shape base 8 comprising reinforcement means 17, providing a second sheet of conductive material, forming (e.g., by stamping, drawing, etc.) in the second sheet of conductive material, a connection support 4 having a connection portion 6 and a support portion 8, the connection portion 6 being configured to electrically and mechanically connect the terminal 1 to another conductive element, and the support portion 8 having a thickness defined between a first main face 13 and a second main face 14, at least one opening 15 being formed through the thickness between the first 13 and second 14 main faces, inserting the socket 20 in said opening 15 so that a portion of the socket 20 comprising the contact blades 5 extend from the first main face 13 (or at least on the side of the support portion corresponding to the first main face 13), and so that the reinforcement means 17 prevent the socket 20 from moving out of the opening 15 in the direction from the second main face 14 to the first main face 13.
Claims
1. An electrical female power terminal (1) for electrical power connections of a vehicle, with a terminal body comprising a tulip shape socket (20) and a connection support (4), wherein - the socket (20) is formed of a sheet metal portion rolled up around a central axis (CA), to form an inner region (3) intended and configured to receive at least part of a contact portion of a male terminal, - the socket (20) has contact blades (5), the number of which is greater than or equal to two, being cut out of the sheet metal portion, each contact blade (5) extending between a ring-shape base (8) and a free end (9), the ring-shape base (8) having a cylindrical wall (10) symmetrical around an axis of revolution parallel to the central axis (CA), and the ring-shape base (8) extending longitudinally, parallel to the central axis (CA), from an edge (11) towards the contact blades (5), - the connection support (4) has a connection portion (6) and a support portion (7), the connection portion (6) being configured to electrically and mechanically connect the terminal (1) to another conductive element, and the support portion (7) having a thickness defined between a first main face (13) and a second main face (14), at least one opening (15) being formed through the thickness between the first (13) and second (14) main faces, the socket (20) being inserted in said opening (15) so that a portion of the socket (20) comprising the contact blades (5) extend on a side of the support portion (7) corresponding to the first main face (13), characterized in that the ring-shape base (8) comprises reinforcement means (17) configured to prevent the socket (20) from moving out of the opening (15) in the direction from the second (14) main face to the first main face (13).
2. The electrical female power terminal (1) according to claim 1, wherein the reinforcement means (17) extend radially outwardly from the ring-shape base (8) and are configured to mechanically engage the second main face (14) of the connection support (4).
3. The electrical female power terminal (1) according to claim 2, wherein the reinforcement means (17) consists in a continuous rim (18) circularly and continuously extending, all around the ring-shape base (8), symmetrically with respect to the central axis (CA).
4. The electrical female power terminal (1) according to claim 3, wherein the rim (18) is formed by deforming said edge (11) of the ring-shape base (8), radially outwards from the socket (20).
5. The electrical female power terminal (1) according to any of claims 1 to 4, the ring-shape base (8) is press-fitted in the opening (15) with an interference comprised between 0.5 mm and 1 mm.
6. The electrical female power terminal (1) according to any of claims 1 to 5, wherein the socket (20) is made of a copper alloy.
7. The electrical female power terminal (1) according to any of claims 1 to 6, wherein the connection support (4) is made of pure copper.
8. A method of manufacturing an electrical female power terminal (1), this method comprising, for example, the steps of - providing a first sheet of conductive material, - forming in the first sheet of conductive material, a socket (20) comprising a ring-shape base (8) and contact blades (5), the number of contact blades (5) being greater than or equal to two, each contact blade (5) extending between the ring-shape base (8) and a free end (9), the ring-shape base (8) having a cylindrical wall (10) symmetrical around an axis of revolution parallel to the central axis (CA), the ring-shape base (8) extending longitudinally, parallel to the central axis (CA), from an edge (11) towards the contact blades (5), and ring-shape base (8) comprising reinforcement means (17), - providing a second sheet of conductive material, - forming in the second sheet of conductive material, a connection support (4) having a connection portion (6) and a support portion (7), the connection portion (6) being configured to electrically and mechanically connect the terminal (1) to another conductive element, and the support portion (7) having a thickness defined between a first main face (13) and a second main face (14), at least one opening (15) being formed through the thickness between the first (13) and second (14) main faces, - inserting the socket (20) in said opening (15) so that a portion of the socket (20) comprising the contact blades (5) extend on a side of the support portion (7) corresponding to the first main face (13), and so that the reinforcement means (17) prevent the socket (20) from moving out of the opening (15) in the direction from the second main face (14) to the first main face (13).