Tubular high current female terminal

Abstract

A tubular high current female terminal for mating with a male terminal, the female terminal having an external terminal and at least one core terminal. The external terminal includes at least a mating portion and a termination portion. The core terminal includes a plurality of spring contacts and preferably a latch for mounting them on an elongated opening of the external terminal. The external terminal is a preformed seamless tube extending from the mating portion which extends integrally to the termination portion as a single piece. The termination portion is connectable to at least an electrical conductor or to an electrical cable by welding, crimping, or mechanical fastening such that the external terminal and the electrical cable extend either parallel or perpendicular. The plurality of tubular high current female terminals may be joined to each other at their termination portions by welding or mechanical fastening. Furthermore, the tubular high current female terminals may have their mating portions at both ends thereof such that the male terminals respectively connected thereto extend at approximately 90°, approximately 180°, or at any desired angle. Furthermore, the mating portion may be a cylindrical tube for mating with the tubular male terminal while the termination portion is attachable to an electrical cable.

Description

[Technical field]

[0001] In the field of high current electrical terminals, round terminals are usually made available by machining. However, machining the round terminals by removing material in various parts thereof makes the machining process inefficient, low productivity and expensive. Moreover, blade-type female terminals, especially in ultra-high current applications, are very few due to the complexity of the existing design or structural arrangement of blade-type female terminals and due to their current carrying capacity.

[0002] With the rapid development of new energy technologies, more efficient, reliable and cheaper high current electrical connection technologies are being developed in the automotive industry, especially for battery electric vehicles (BEVs).

[0003] The present invention thus generally relates to a tubular high current female terminal. The tubular high current female terminal of the present invention is of a low profile, simple, single piece and integral tubular construction or structural arrangement, which is applicable for connection with, for example, blade-type or round pin-type male terminals. The design or structural arrangement of one end of the tubular high current female terminal of the present invention is provided to allow multiple termination options and multiple orientation options when the tubular high current female terminal of the present invention is connected to a high voltage cable. The tubular high current female terminal of the present invention may be formed of a preformed copper tube or the like. It can be easily, highly precisely and highly productively manufactured with a rigid and strong structural arrangement or design to guide, support and protect the generally flexible spring element of the core terminal inserted and housed therein, so that flexible and multiple contact points can be maintained by the core terminal for a reliable connection. [Background technology]

[0004] For high current connectors, multiple but separate spring contacts between male and female terminals are necessary to minimize contact resistance. Usually, there are two types of terminals used in the industry depending on the shape of the male terminal (i.e., blade male terminal or cylindrical male terminal). For conventional high current connectors to mate with cylindrical male terminals, the cylindrical outer terminal of the female terminal is mainly made by machining, which is wasteful and has high manufacturing costs due to the large amount of material scrap removed during machining. There are some cylindrical female terminals that are formed of stamped and formed from metal sheets. However, such cylindrical female terminals are not robust enough, and they are easily deformed and cannot transport very high currents. As an example, the box-type female terminals formed by stamping and shaping to mate with the blade-type male terminals exhibit the above-mentioned weaknesses or shortcomings derived from conventional devices. Summary of the Invention

[0005] The tubular high current female terminal of the present invention generally comprises an outer terminal and a core terminal housed therein, the core terminal having a plurality of spring elements. The outer terminal is preferably formed of seamless copper tubing and may be mated or connected to, for example, a blade-type male terminal or a round male terminal. Furthermore, the female terminal may be mated or connected to the male terminal in any orientation or direction. The end of the outer terminal may be connected to another electrical conductor (e.g., a bus bar terminal, a high voltage cable, etc.) by welding, crimping, mechanical fastening, etc. [Brief description of the drawings]

[0006] [Figure 1]FIG. 1 is a perspective view of a first embodiment of a tubular high-current female terminal of the present invention having a seamless tubular outer terminal and a core terminal, the outer terminal having an elongated coupling portion for receiving at least a first type of core terminal therein, and further having a termination portion for connecting to a high voltage cable or conductor (e.g., a bus bar terminal, etc.). [Diagram 2] FIG. 1 is a perspective view of a first embodiment of a tubular high-current female terminal of the present invention having an outer terminal and a core terminal, the outer terminal having an elongated coupling portion for receiving at least a second type of core terminal therein, and further having a termination portion for connecting to a high voltage cable or an electronic component. [Diagram 3] 1 is an exploded view of a first embodiment of a tubular high current female terminal of the present invention, showing a second type of core terminal and an elongated blade-type male terminal for insertion therein. [Figure 4] 1 is an exploded view of a first embodiment of the tubular high current female terminal of the present invention, in which a second type of core terminal is inserted into an elongated coupling portion and an elongated blade-type male terminal is inserted into the core terminal. FIG. [Diagram 5] 1 is a perspective view of a first type of core terminal having an elongated opening and a plurality of spring contacts for receiving and mating with a blade-type male terminal; FIG. [Figure 6] FIG. 1 is a perspective view of a second type of core terminal having an elongated opening and a plurality of spring contacts for receiving and mating with a blade-type male terminal, and further having a latch member attached to the elongated opening of the tubular outer terminal. [Figure 7] FIG. 1 is a perspective view of a third type of core terminal having an elongated opening and multiple spring contacts for receiving and mating with a blade-type male terminal, the perspective view showing a latch member along the elongated opening and showing the core terminal bent at its tip in the insertion direction. [Figure 8] FIG. 2 is an exploded view of a first embodiment of a tubular high current female terminal of the present invention, showing the tip of a third type of core terminal for insertion into an elongated coupling portion, where an elongated blade-type male terminal is to be inserted into the core terminal. [Figure 9A] 1 shows a structural arrangement in which the end of the external terminal of a first embodiment of the tubular high current female terminal of the present invention is connected to an electrical cable such that the longitudinal directions along which the tubular high current female terminal and the electrical cable extend are perpendicular to each other. [Figure 9B] 1 shows a structural arrangement in which the end of the external terminal of a first embodiment of the tubular high-current female terminal of the present invention is connected to an electrical cable such that the longitudinal directions along which the tubular high-current female terminal and the electrical cable extend are parallel. [Figure 10] FIG. 1 shows a structural arrangement in which the ends of the outer terminals of two tubular high current female terminals of the present invention are fastened to one another such that the longitudinal or insertion directions of the two male terminals along which the tubular high current female terminal extends are perpendicular to one another. [Figure 11] FIG. 1 is an exploded view of a second embodiment of the tubular high current female terminal of the present invention, showing the elongated coupling portions at both ends thereof, in which a plurality of elongated blade-type male terminals are to be inserted into the elongated coupling portions of the external terminal in a 180° coupling orientation, respectively. [Figure 12A] FIG. 13 is an exploded view of a third embodiment of the tubular high current female terminal of the present invention, showing the elongated coupling portions at both ends thereof, in which a plurality of elongated blade-type male terminals are to be inserted into the elongated coupling portions of the external terminal, respectively, at coupling directions of any preset angle. [Figure 12B] FIG. 11 is an exploded view of a fourth embodiment of the tubular high current female terminal of the present invention, showing the elongated coupling portions at both ends thereof, in which a plurality of elongated blade-type male terminals are to be inserted into the elongated coupling portions of the external terminal, respectively, in a coupling orientation at an angle of approximately 90°. [Figure 13]FIG. 11 is a perspective view of a fifth embodiment of a tubular high current female terminal of the present invention, showing the terminating portion of the external terminal in the form of a cylindrical tube, the cylindrical portion of which can be attached to a high voltage cable by crimping. [Figure 14] FIG. 11 is a perspective view of a fifth embodiment of a tubular high current female terminal of the present invention, showing a tubular coupling portion in the form of a tubular tube for receiving a cylindrical male terminal therein, and further showing a termination portion for an external terminal attachable to a high voltage cable or electrical conductor (e.g., a bus bar terminal, etc.). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] FIG. 1 illustrates a first embodiment of a tubular high current female terminal of the present invention, generally designated as 1, having an outer terminal 3 and a core terminal 5. The outer terminal 3 includes an elongated coupling portion 7, and a terminating portion 9. The elongated coupling portion 7 and the terminating portion 9 are integrally connected therebetween via a transition portion 6. The elongated coupling portion 7 has a seamless elongated opening 12 therein for allowing the core terminal 5 to pass therethrough and ultimately be received within the elongated coupling portion 7, as described below. The terminating portion 9 is attachable to an electrical cable or conductor, as also described below. Illustrated in FIG. 1 is a first type of core terminal 5. The term "elongated" is defined herein as a member having a dimension whose width is greater than that of its thickness.

[0008] The high current female terminal 1 is of a tubular design with an overall profile that can be easily and precisely preformed and preformed to receive an elongated male terminal therein (e.g., an elongated blade-type male terminal or an elongated cylindrical male terminal, as described below).

[0009] The material cut-out 8 at the transition portion 6 facilitates the process of forming the coupling portion 7 and the termination portion 9 with different profiles in the manufacture of the external terminal 3 .

[0010] The outer terminal 3 is preferably single piece, low profile and robust in construction or configuration to guide, support and protect the core terminal 5 as it is inserted into the outer terminal 3. The outer terminal 3 is further preferably formed of a pre-formed seamless tube without the need for machining, which as previously mentioned is inefficient and unproductive.

[0011] The core terminal 5 includes a plurality of spring contacts 24, 26, as will be described in more detail below. The core terminal 5 has an elongated opening 13, 14 at each of its ends that mates to fit within the elongated opening 12 of the elongated mating portion 7 of the outer terminal 3. Each elongated opening 13, 14 of the core terminal 5 has two longitudinal sides 18, 20 for mating with an elongated blade-type male terminal, also as will be described below.

[0012] Shown in Figure 2 is a first embodiment of the tubular high current female terminal 1 of the present invention having similar members or parts as described above with respect to Figure 1, except for a second type core terminal 30. Shown in Figure 2 is the second type core terminal 30, which, like the first type core terminal 5, has a plurality of spring contacts 34, 36 and elongated openings 39, 40 that align to fit within the elongated opening 12 of the elongated coupling portion 7 of the outer terminal 3. Each of the elongated openings 39, 40 has two longitudinal sides 42, 44 for mating with an elongated blade-type male terminal, also as described below (see Figures 3 and 4).

[0013] Attached to longitudinal sides 42, 44, respectively, of the elongated opening 40 of the second type core terminal 30 are latches 48, 50. The latches 48, 50 are coupled to longitudinal sides 49, 51, respectively, of the elongated opening 12 of the elongated mating portion 7 of the external terminal 3 when the second type core terminal 30 is fully inserted into the elongated mating portion 7, as will be described below.

[0014] The tubular high current female terminal 1 of the present invention is shown in Figure 3, which shows a second type core terminal 30 and an elongated blade-type male terminal 52 for insertion into the core terminal 30. As shown in Figure 4, the latches 48, 50 of the second type core terminal 30 are attached to the longitudinal sides 49, 51, respectively, of the elongated opening 12 of the elongated coupling portion 7 of the external terminal 3. The spring contacts 36 of the second type core terminal 30 are visible through the elongated opening 12 of the elongated coupling portion 7. Also shown in Figures 3 and 4 are the elongated coupling portions 7 and the termination portion 9, which are integrally connected therebetween via a transition portion 6.

[0015] 5 shows a first type of core terminal 5 having a plurality of spring contacts 24, 26. The core terminal 5 has an elongated opening 13, 14 at each of its ends that aligns to fit within an elongated opening 12 of the elongated coupling portion 7 of the external terminal 3 (see FIG. 1). Each elongated opening 13, 14 of the core terminal 5 has two longitudinal sides 18, 20 for mating with an elongated blade-type male terminal 52. The longitudinal sides 18, 20 of the elongated openings 13, 14 of the core terminal 5 also act as end supports for the plurality of spring contacts 24, 26. Approximately in the middle of the longitudinal sides 18, 20 and the plurality of spring contacts 24, 26 is a spring beam 60 that acts as a contact between the core terminal 5 and the elongated blade-type male terminal 52. Maximizing the number of spring contacts 24, 26 ensures that the electrical contact resistance mating with the elongated blade-type male terminal 52 is lowest.

[0016] As further shown in Figure 5, the core terminal 5 has a non-cylindrical geometry for matching or corresponding to the elongated opening 12 of the elongated mating portion 7 of the outer terminal 3 and mating with the elongated blade-type male terminal 52. Furthermore, as the core terminal 5 is manufactured, it is initially in one piece and then shaped or folded into the configuration shown in Figure 5 with a seam 65 extending between the longitudinal sides 18, 20 of the elongated openings 13, 14.

[0017] As discussed above with respect to the core terminal 5 in Fig. 5, the core terminal 30 in Fig. 6 similarly illustrates a second type of core terminal 30 having a plurality of spring contacts 34, 36. The core terminal 30 has an elongated opening 39, 40 at each of its ends that aligns to fit within the elongated opening 12 of the elongated coupling portion 7 of the outer terminal 3 (see Fig. 2). Each elongated opening 39, 40 of the core terminal 30 has two longitudinal sides 42, 44 for mating with an elongated blade-type male terminal 52 (see Fig. 4). Attached to the longitudinal sides 42, 44 of the elongated opening 40 of the second type of core terminal 30 are latches 48, 50, respectively. Each latch 48, 50 is generally C-shaped in a configuration or arrangement that can be attached to a respective longitudinal side 49, 51 of the elongated opening 12 of the elongated coupling portion 7 of the external terminal 3 when the second type core terminal 30 is fully inserted into the elongated coupling portion 7 (see FIG. 4). The longitudinal sides 42, 44 of the elongated openings 39, 40 of the core terminal 30 also act as end supports for the plurality of spring contacts 34, 36. Approximately central to the longitudinal sides 42, 44 and the plurality of spring contacts 34, 36 is a spring beam 70 that acts as a contact point between the core terminal 30 and the elongated blade-type male terminal 52. Maximizing the number of spring contacts 34, 36 ensures that the electrical contact resistance mating with the elongated blade-type male terminal 52 is lowest.

[0018] As further shown in Figure 6, the core terminal 30 has a non-cylindrical geometry for matching or corresponding with the elongated opening 12 of the elongated mating portion 7 of the outer terminal 3 and mating with the elongated blade-type male terminal 52. Furthermore, as the core terminal 30 is manufactured, it is initially in one piece and then shaped or folded into the configuration shown in Figure 6 with a seam 75 extending between the longitudinal sides 42, 44 of the elongated openings 39, 40.

[0019] FIG. 7 shows a third type of core terminal 80 having multiple spring contact beams 83, 85. The core terminal 80 is non-cylindrical. The core terminal 80 is stamped and folded along the insertion direction, i.e., toward the elongated opening 12 of the elongated coupling portion 7 of the external terminal 3. Extending beyond the center of the multiple spring contacts 83, 85 are spring beams 87, 89, respectively, which act as multiple contact points between the core terminal 80 and the elongated blade-type male terminal 52. When the stamped core terminal 80 is folded as shown in FIG. 7, the upper and lower parts of the folded core terminal 80 are generally symmetrical. At the ends of the core terminal 80 are elongated members 100, 102, and attached to the elongated members 100, 102 are latches 103, 105, respectively. As in the second type core terminal 30, each of the latches 103, 105 of the third type core terminal 80 is generally C-shaped in a form or configuration that can be attached to each of the longitudinal sides 49, 51 of the elongated opening 12 of the elongated coupling portion 7 of the external terminal 3 when the third type core terminal 80 is fully inserted into the elongated coupling portion 7 (see FIG. 4 ).

[0020] As further shown in FIG. 7, the latches 103, 105 have a generally symmetrical configuration. Moreover, the latches 103, 105 have a retracting and guiding configuration when the elongated blade-type male terminal 52 is inserted into the core terminal 80. The latches 103, 105 also support the insertion force exerted by the elongated blade-type male terminal 52 when it is inserted into the core terminal 80. Moreover, when the latches 103, 105 are attached to the longitudinal sides 49, 51, respectively, of the elongated opening 12 of the elongated coupling portion 7 of the external terminal 3, the latches 103, 105 position and latch the core terminal 80 within the elongated coupling portion 7. The end of the core terminal 80 opposite the latches 103, 105 is a tip 108 that faces the elongated opening 12 of the elongated coupling portion 7 of the external terminal 3 when the core terminal 80 is inserted, as shown in FIG. 8.

[0021] The tip 108 of the core terminal 80 is a folded portion of the originally stamped core terminal 80, as can be seen in Figs. 7 and 8, which is folded at the tip 108 along the insertion direction toward the elongated opening 12 of the elongated coupling portion 7 of the external terminal 3. In Fig. 8, the tip 108 of the third type of core terminal 80 enters the elongated opening 12 of the elongated coupling portion 7 of the external terminal 3. The core terminal 108 enters and is housed in the elongated coupling portion 7 of the external terminal 3 in its entirety. The latches 103, 105 then effectively position and latch the core terminal 80 inside the elongated coupling portion 7 when the latches 103, 105 are attached to the longitudinal sides 49, 51, respectively, of the elongated opening 12 of the elongated coupling portion 7 of the external terminal 3. When the core terminal 108 is inserted within the elongated coupling portion 7, the core terminal 80 is positioned therein to receive the elongated blade-type male terminal 52. During insertion of the elongated blade-type male terminal 52, it is drawn in and guided by latches 103, 105 attached to the longitudinal sides 49, 61 of the elongated opening 12 of the elongated portion 7 of the outer terminal 3. The insertion force exerted by the elongated blade-type male terminal 52 is also supported by the latches 103, 105. When the elongated blade-type male terminal 52 is fully inserted into the core terminal 80, the spring beams 87, 89 extending across and between the spring contacts 83, 85 act as contacts between the core terminal 80 and the elongated blade-type male terminal 52. The contact areas 110 of the elongated blade-type male terminals 52 are preferably elongated in shape to maximize contact of the elongated blade-type male terminals 52 with the spring beams 87 , 89 of the core terminals 80 .

[0022] As mentioned above, the first embodiment of the tubular high current female terminal 1 of the present invention is composed of an external terminal 3 and a core terminal 5, 30, 80. The external terminal 3 includes an elongated coupling portion 7 and a terminal end portion 9. The terminal end portion 9 is connected to an electric cable or electronic component 115 as shown in Figures 9A and 9B. In Figure 9A, the terminal end portion 9 of the external terminal 3 is connected by welding, crimping or mechanical fastening to the electric cable 115 such that the longitudinal directions along which the tubular high current female terminal 1 and the electric cable 115 extend are perpendicular to each other.

[0023] In FIG. 9B, the end portion 9 of the external terminal 3 is connected, by welding, crimping or mechanical fastening, to the electrical cable 115 such that the longitudinal directions along which the tubular high current female terminal 1 and the electrical cable 115 extend are parallel.

[0024] For example, as described above with respect to FIG. 4, the tubular high-current female terminal 1 is composed of an outer terminal 3 and a core terminal 5, 30, 80. The outer terminal 3 includes an elongated joint portion 7 and an end portion 9, and the elongated joint portion 7 accommodates the core terminal 5, 30, 80 therein. In FIG. 10, the end portions 9 of the outer terminals 3 of the two tubular high-current female terminals 1 of the first embodiment of the present invention are fastened to each other by welding or mechanical fastening (such as bolting) such that their longitudinal directions along which the tubular high-current female terminal 1 extends are perpendicular. In the above-mentioned structural arrangement, as shown in FIG. 10, the elongated blade-type male terminals 52, which are respectively coupled to the core terminals 30, 80 and respectively fastened inside the core terminals 5, 30, 80, allow the tubular high-current female terminals 52 to be coupled to the core terminals 30, 80 at approximately 90°, respectively.

[0025] A second embodiment of the tubular high current female terminal 200 of the present invention is a single uniform external terminal 210 having substantially symmetrical ends, each end having an elongated opening 212, 214 for 180° mating with two opposing elongated blade-type male terminals 52, as shown in Fig. 11. Housed within the tubular current female terminal 200 are two core terminals 5, 30, 80 (shown in Fig. 11 are second type 30 or third type 80 core terminals) that are attached to the elongated openings 212, 214, respectively, by latches 48, 50 or latches 103, 105 (see Figs. 6 and 7). The tubular high current female terminal 200 is shown in Fig. 11 in a 180° mating state with two elongated blade-type male terminals 52 that enter the opposing elongated openings 212, 214, respectively, of the single uniform external terminal 210. Although the core terminals 5, 30, 80 are depicted as two core terminals 5, 30, 80 in the second embodiment of the tubular high current female terminal 200 of the present invention, each core terminal 5, 30, 80 may also be a single core terminal 5, 30, 80 contacting both elongated blade-type male terminals 52 from both coupling portions having opposing elongated openings 212, 214, respectively.

[0026] The third embodiment of the tubular high current female terminal 300 of the present invention is also a single-piece external terminal 310 having two opposing elongated blade-type male terminals 52 and substantially symmetrical ends with elongated openings 312, 314 at each end for coupling at any preset angle, as shown in Fig. 12A. The two symmetrical coupling parts with elongated openings 312, 314, respectively, are integrally connected between each other through a transition part. Housed within the tubular high current female terminal 300 are two core terminals 5, 30, 80 (shown in Fig. 11 are the second type core terminal 30 or the third type core terminal 80) that are attached to the elongated openings 312, 314, respectively, by latches 48, 50 or latches 103, 105. A tubular high current female terminal 300 is shown in FIG. 12A in a pre-set arbitrary angle mating state with two elongated blade-type male terminals 52 which fit into opposing elongated openings 312, 314, respectively, of a single-piece external terminal 310.

[0027] The fourth embodiment of the tubular high current female terminal 400 of the present invention is yet another single-piece external terminal 410 having two opposing elongated blade-type male terminals 52 and substantially symmetrical ends with elongated openings 412, 414 at each end for coupling at a substantially 90° angle, as shown in Fig. 12B. The two symmetrical coupling parts with elongated openings 412, 414, respectively, are integrally connected between each other through a transition part. Housed within the tubular high current female terminal 400 are two core terminals 5, 30, 80 (shown in Fig. 12B are the second type core terminal 30 or the third type core terminal 80) that are attached to the elongated openings 412, 414, respectively, by latches 48, 50 or latches 103, 105 (see Figs. 6 and 7). The tubular high current female terminal 400 is shown in a preset, approximately 90° angled mating state with two elongated blade-type male terminals 52 which fit into opposing elongated openings 412, 414, respectively, of a single-piece external terminal 410.

[0028] As described above in the second embodiment of the tubular high-current female terminal 200, in the third embodiment 300 (FIG. 12A) and the fourth embodiment 400 (FIG. 12B) of the high-current female terminal of the present invention, each core terminal 5, 30, 80 may similarly be a single core terminal 5, 30, 80 contacting both elongated blade-type male terminals 52 from both coupling portions having opposing elongated openings 312, 314, or opposing elongated openings 412, 414, respectively.

[0029] A fifth embodiment of a tubular high-current female terminal, generally designated by reference number 500 and shown in FIG. 13, includes an outer terminal 503 and a core terminal 5. A first type of core terminal 5 is shown in FIG. 13, but the second and third types of core terminals 30, 80 are equally applicable. The outer terminal 503 includes an elongated coupling portion 507 that is structured substantially similarly to the elongated coupling portion 7 of the first embodiment of the tubular high-current female terminal 1. The terminal portion 509 of this fifth embodiment of the tubular high-current female terminal 500, however, has the form of a cylindrical tube that is attached to an electric cable, for example by crimping. The elongated coupling portion 507 and the terminal portion 509 are integrally connected therebetween via a transition portion 506. A material cutout 508 at the transition portion 506 facilitates the forming process of the coupling portion 507 and the terminal portion 509 with different profiles in the manufacture of the outer terminal 503.

[0030] A sixth embodiment of a tubular high current female terminal, generally designated by reference numeral 600 and shown in FIG. 14, includes an outer terminal 603 and a fourth type core terminal 611. The outer terminal 603 includes an extended tubular coupling portion 607 and a terminal end portion 609. The extended tubular coupling portion 607 and the terminal end portion 609 are preferably integrally connected therebetween via a transition portion 606. The extended tubular coupling portion 607 has a substantially circular opening 612 therein for allowing the fourth type core terminal 611 to pass therethrough and ultimately be accommodated within the extended tubular coupling portion 607. As in the core terminals 5, 30, 80, the core terminal 603 is preferably bent into a circular shape to pass through and be stamped and accommodated within the circular opening 612 of the extended tubular coupling portion 607. The extended cylindrical male terminal 620 is inserted into the circular opening 612 of the extended tubular coupling portion 607 and mates with the core terminal 611 mounted therein. The termination portion 609 is attached to an electrical cable or dielectric (e.g., a bus bar terminal, etc.) by welding, crimping, or mechanical fastening.

[0031] The high current female terminal 600 is of a tubular design with an overall profile that can be easily and precisely preformed and preformed to fit the extended cylindrical male terminal 620 therein. The outer terminal 603 is preferably of a single piece, low profile, and robust structure or construction to support and protect the core terminal 611. The outer terminal 603 is also preferably formed of a preformed tube without the need for inefficient and low productivity machining as previously described. The core terminal 611 includes a plurality of spring contacts 624 and is preferably configured to align with and fit within the circular opening 612 of the extended cylindrical coupling portion 607 of the outer terminal 603.

[0032] The present invention is not limited to the above-described embodiments, and various modifications in design, structural arrangement, etc. may be used without departing from the scope or equivalent of the present invention.

Claims

1. A tubular high current female terminal for mating with an elongated male terminal, comprising: an external terminal formed from a preformed, substantially seamless tube, the external terminal having an elongated opening at one end thereof with longitudinal sides; at least one core terminal for mating with the elongated male terminal, the core terminal having a plurality of spring contacts and extending between the longitudinal sides of the elongated opening of the external terminal; Equipped with The at least one core terminal is a tubular high current female terminal for mating with an elongated male terminal having a first side with a first elongated opening having a first pair of longitudinal sides and a second side with a second elongated opening having a second pair of longitudinal sides.

2. the external terminal includes a seamless elongated joining portion and a termination portion extending integrally therebetween; the elongated coupling portion includes therein the at least one core terminal for coupling with the elongated male terminal; 2. A tubular high current female terminal for mating with an elongated male terminal as claimed in claim 1.

3. the external terminal extends from the coupling portion and integrally extends to the termination portion as a single piece; 3. A tubular high current female terminal for mating with an elongated male terminal as claimed in claim 2.

4. The core terminal includes a plurality of spring contacts and a latch for attaching them to the elongated opening of the outer terminal.

2. A tubular high current female terminal for mating with an elongated male terminal as claimed in claim 1.

5. The core terminal comes into contact with the elongated portion of the elongated terminal which is the male terminal.

2. A tubular high current female terminal for mating with an elongated male terminal as claimed in claim 1.

6. the termination portion connects to at least the conductor by one of welding, crimping, and mechanical fastening; 3. A tubular high current female terminal for mating with an elongated male terminal as claimed in claim 2.

7. a plurality of tubular high current female terminals, each for mating with a corresponding one of the elongated male terminals; a first external terminal formed of a preformed substantially seamless tube, the first external terminal having an elongated first opening and at least one first core terminal for mating with a first elongated male terminal having a plurality of spring contacts and extending between longitudinal sides of the elongated first opening of the first external terminal; a second external terminal formed of a preformed substantially seamless tube, the second external terminal having an elongated second opening and at least one second core terminal having a plurality of spring contacts and for mating with a second elongated male terminal extending between longitudinal sides of the second elongated second opening of the second external terminal; At least A plurality of tubular high current female terminals, wherein the at least one first core terminal has a first side with a first elongated opening having a first pair of longitudinal sides and a second side with a second elongated opening having a second pair of longitudinal sides.

8. the first external terminal includes a first elongated joining portion and a first terminating portion extending integrally therebetween; the first elongated coupling portion includes therein the at least one first core terminal for coupling with the first elongated male terminal; the second external terminal includes a second elongated joining portion and a second terminating portion extending integrally therebetween; the second elongated mating portion includes therein the at least one second core terminal for mating with the second elongated male terminal; the first end portion and the second end portion are joined to one another; A plurality of tubular high current female terminals according to claim 7.

9. the first end portion and the second end portion are joined to one another by one of welding and mechanical fastening; A plurality of tubular high current female terminals according to claim 8.

10. A tubular high current female terminal for mating with at least two elongated male terminals, an external terminal formed from a preformed, substantially seamless tube, the external terminal having at both ends a first elongated opening at one end thereof with longitudinal sides and a second elongated opening at another end thereof with longitudinal sides; a first core terminal having a plurality of spring contacts and extending between the longitudinal sides of the first elongated opening of the outer terminal for mating with a first elongated male terminal; a second core terminal having a plurality of spring contacts and extending between the longitudinal sides of the second elongated opening of the outer terminal for mating with a second elongated male terminal; Equipped with the first elongated opening and the second elongated opening are connected at opposite ends of the external terminal in a linear connection with the first elongated male terminal and the second elongated male terminal extending from opposite ends of the external terminal; The first core terminal has a first side with a first elongated opening having a first pair of longitudinal sides, and a second side with a second elongated opening having a second pair of longitudinal sides. A tubular high current female terminal for mating with at least two elongated male terminals.

11. the external terminal is a preformed seamless tube extending as a single piece from the first elongated opening to the second elongated opening; 11. The tubular high current female terminal for mating with at least two elongated male terminals according to claim 10.

12. each of the first core terminal and the second core terminal includes a plurality of spring contacts and a latch for attaching them to the first elongated opening and the second elongated opening of the external terminal, respectively; 11. The tubular high current female terminal for mating with at least two elongated male terminals according to claim 10.

13. A tubular high current female terminal for mating with at least two elongated male terminals, an external terminal formed of a preformed, substantially seamless tube having at both ends thereof a first elongated opening with longitudinal sides at one end thereof and a second elongated opening with longitudinal sides at another end thereof; a first core terminal having a plurality of spring contacts and extending between the longitudinal sides of the first elongated opening of the outer terminal for mating with a first elongated male terminal; a second core terminal having a plurality of spring contacts and extending between the longitudinal sides of the second elongated opening of the outer terminal for mating with a second elongated male terminal; Equipped with the first and second elongated openings are connected at opposite ends of the external terminal in a non-linear connection with the first and second elongated male terminals extending from opposite ends of the external terminal; The first core terminal has a first side with a first elongated opening having a first pair of longitudinal sides, and a second side with a second elongated opening having a second pair of longitudinal sides. A tubular high current female terminal for mating with at least two elongated male terminals.

14. the first and second elongated openings are connected at opposite ends of the external terminal in a generally perpendicular connection with the first and second elongated male terminals extending from opposite ends of the external terminal; 14. The tubular high current female terminal for mating with at least two elongated male terminals according to claim 13.

15. the external terminal is a preformed seamless tube extending as a single piece from the first elongated opening to the second elongated opening; 14. The tubular high current female terminal for mating with at least two elongated male terminals according to claim 13.

16. A tubular high current female terminal for mating with an elongated male terminal, comprising: an external terminal having an elongated opening; at least one core terminal having a plurality of spring contacts and extending between longitudinal sides of the elongated opening of the outer terminal for mating with the elongated male terminal; Equipped with the external terminal comprises an elongated joining portion and a terminating portion extending integrally therebetween, the elongated joining portion including therein the at least one core terminal for mating with the elongated male terminal; the termination is a cylindrical tube that can be attached by crimping at least one electrical cable; The at least one core terminal has a first side with a first elongated opening having a first pair of longitudinal sides and a second side with a second elongated opening having a second pair of longitudinal sides. Tubular high current female terminal for mating with elongated male terminal.

17. the external terminal being a single piece, preformed seamless tube extending integrally from the coupling portion to the termination portion; 17. A tubular high current female terminal for mating with an elongated male terminal as claimed in claim 16.

18. A tubular high current female terminal for mating with at least two elongated male terminals, an external terminal formed from a preformed substantially seamless tube having at opposite ends thereof a first elongated opening with longitudinal sides and a second elongated opening with longitudinal sides; at least one core terminal having a plurality of spring contacts extending (a) between the longitudinal sides of the first elongated opening of the external terminal for mating with a first elongated male terminal, and (b) between the longitudinal sides of the second elongated opening of the external terminal for mating with a second elongated male terminal; Equipped with The at least one core terminal has a first side with a first elongated opening having a first pair of longitudinal sides and a second side with a second elongated opening having a second pair of longitudinal sides. A tubular high current female terminal for mating with at least two elongated male terminals.

19. the first elongated opening and the second elongated opening are connected at opposite ends of the external terminal in a linear connection with the first elongated male terminal and the second elongated male terminal extending from opposite ends of the external terminal; 20. The tubular high current female terminal for mating with at least two elongated male terminals according to claim 18.

20. the first and second elongated openings are connected at opposite ends of the external terminal in a non-linear connection with the first and second elongated male terminals extending from opposite ends of the external terminal; 20. The tubular high current female terminal for mating with at least two elongated male terminals according to claim 18.

21. the first and second elongated openings are connected at opposite ends of the external terminal in a generally perpendicular connection with the first and second elongated male terminals extending from opposite ends of the external terminal; 20. The tubular high current female terminal for mating with at least two elongated male terminals according to claim 18.

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