Arc Resistant Power Terminals

Abstract

An electrical terminal for coupling to a conductive structure includes a body having a wire-receiving portion for receiving a conductor. A cup portion is electrically coupled to the wire-receiving portion, and a protrusion extends from the cup portion. An overmolded structure of insulating material is formed in the cup portion and covers a side surface of the cup portion. An opening is formed in the body and extends through the cup portion and the protrusion for receiving a post of the conductive structure to secure the terminal to the conductive structure. A fastener is configured to engage the post and secure the protrusion to the conductive structure. The protrusion is configured to surround the opening to provide an electrically conductive surface free of insulating material for mating with the conductive structure. The fastener and post are included in the cup portion, and an insulating cap is configured to engage the overmolded structure and seal the cup structure around the fastener and post of the conductive structure.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Patent Application No. 62 / 932,284, filed November 7, 2019 (pending), the disclosure of which is incorporated herein by reference.

[0002] The present invention relates generally to electrical connectors or terminals, and more particularly to improving the performance of such terminals in preventing electrical arcing and failure. [Background technology]

[0003] Electrical connectors or terminals for terminating power cable connections are often connected side-by-side, such as to a ground stud, to a power strip, or on top of one another, such as on a terminal block or power strip. The electrical connectors or terminals provide power to the circuits and electronics of a system, vehicle, or device, and as such are often coupled in tight configurations to address space constraints, such as in an aircraft. The terms lug, terminal lug, and terminal are used interchangeably in this application to refer to such terminal connectors.

[0004] While wires and cables terminated to such terminals are insulated along their length, the terminals themselves are exposed for making electrical contact with other terminals, terminal blocks, or equipment connections. As a result, arcing can occur between adjacent terminals. Such exposure can also result in electrocution.

[0005] Problems with short circuits or arcing are particularly problematic in the aerospace industry. Most new airframes are designed to eliminate hydraulic systems and replace them with electromechanical actuators. Recent advances have also resulted in the use of higher voltages and higher frequencies in aircraft. The increased use of electrical systems, higher voltages, and higher frequencies directly impacts the likelihood of accidental short circuits and arc tracking at terminal connection points. Accidental short circuits or arcing between different voltage phases used in such systems can result in damage and potentially even cut power to the system. Additionally, space constraints exacerbate the problem as terminals are often positioned near each other at terminal blocks or equipment connection points. Still further, passenger comfort results in greater humidity in the electrical system environment.

[0006] Contaminants between the terminals can also cause arcing problems. Various dry, liquid, or vapor contaminants have the potential to create an electrical path between the terminals under dry, humid, or wet conditions. When various contaminants can create a path of sufficiently low resistance for electrical current between the terminals, arc tracking can begin and progress to significant levels of damage.

[0007] There are various existing methods that attempt to insulate terminals from one another to prevent arcing. However, such methods often involve mechanical partitions or require increased separation distances, which may not always be feasible. However, such existing methods have been optimized, and even with current precautions, existing elements and methods may still allow the conductive surfaces of the terminals to get close enough to one another to allow arc tracking. Various physical partitions are not sufficient to prevent arc tracking.

[0008] Furthermore, the problem of changing or reconfiguring a connection is often complicated by the insulating or containment environment. The material, such as molten insulating material, that is applied to the connections and terminals once they are secured is usually permanent in nature. To disconnect a terminal or to install an additional terminal, the material must first be removed. Then, once the new connection configuration is complete, the material must be reapplied. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] US Patent Application Publication No. 14 / 010,073 [Patent Document 2] U.S. Patent Application Publication No. 12 / 371,765 [Patent Document 3] U.S. Pat. No. 8,519,267 [Patent Document 4] U.S. Pat. No. 9,385,449 Summary of the Invention [Problem to be solved by the invention]

[0010] It is therefore an object of the present invention to address the concerns of arcing between adjacent electrical terminals. It is a further object to prevent arcing without compromising the functionality of the terminals. It is a further object to improve the construction and construction capabilities of such terminal connections. The present invention addresses these objects, as well as the shortcomings of the prior art. [Means for solving the problem]

[0011] An electrical terminal for coupling to a conductive structure includes a body having a wire-receiving portion for receiving a conductor. A cup portion is electrically coupled to the wire-receiving portion and a protrusion extends from the cup portion. The protrusion includes an exposed flat surface for mating with the conductive structure. An overmolded structure of insulating material is formed in the cup portion and covers a side of the cup portion. An opening is formed in the body and extends through the cup portion and the protrusion for receiving a post of the conductive structure to secure the terminal to the conductive structure. A fastener is configured to engage the post and secure the protrusion relative to the conductive structure. The protrusion is configured to surround the opening to provide an electrically conductive surface free of insulating material for mating with the conductive structure. The fastener and the post are included in the cup portion and an insulating cap is configured to engage the overmolded structure and seal the cup structure around the fastener and the post of the conductive structure.

[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description of the invention provided below, serve to explain the principles of the invention. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 illustrates an embodiment of the present invention in which the terminals incorporate conductors. [Diagram 2] 2 is a cross-sectional view of an embodiment of a terminal as shown in FIG. 1. [Figure 2A] 2 is a diagram of an alternative embodiment of a terminal as shown in FIG. 1; [Figure 2B] FIG. 2 is a diagram of another alternative embodiment of a terminal as shown in FIG. [Figure 2C] FIG. 13 is a view of another alternative embodiment of a terminal. [Figure 2D] FIG. 13 is a view of another alternative embodiment of a terminal. [Diagram 3] 2 is a cross-sectional view of an embodiment of a terminal as shown in FIG. 1 coupled to a terminal block or other attachment point such as a motor. [Figure 4]FIG. 2 is a view of a wire slid into an embodiment of the cross-section of the terminal of FIG. 1 for illustrative purposes. [Diagram 5] FIG. 5 is a view of the assembled and crimped embodiment of FIG. 4. [Figure 6] FIG. 6 is a cross-sectional view of the embodiment as indicated in FIG. 5. [Figure 7] FIG. 13 is a perspective view of another alternative embodiment of the terminal of the present invention. [Figure 8] FIG. 8 is a cross-sectional view of the embodiment of FIG. [Figure 8A] FIG. 8 is a cross-sectional view of the embodiment as shown in FIG. 7 coupled with a terminal block. [Figure 8B] 1 is a cross-sectional view of an alternating mounting arrangement of multiple terminals as coupled to a terminal block. FIG. [Figure 9] FIG. 13 is a perspective view of another alternative embodiment of the terminal of the present invention. [Figure 10] FIG. 10 is a cross-sectional view of the embodiment of FIG. [Figure 11] FIG. 13 is a perspective view of another alternative embodiment of the terminal of the present invention. [Figure 12] FIG. 12 is a cross-sectional view of the embodiment of FIG. [Figure 13] 1 is a cross-sectional view of an embodiment of a terminal of the present invention. [Figure 13A] FIG. 14 is a detailed view of the embodiment as shown in FIG. 13. [Figure 13B] FIG. 14 is a detailed view of the embodiment as shown in FIG. 13. [Figure 14] FIG. 2 is a perspective view of multiple overlapping and connected terminals according to the present invention. [Figure 15] FIG. 2 is a perspective view of a terminal and cable of a connection point according to the present invention showing a test arrangement. [Figure 16] 11 is an exploded perspective view of a terminal system according to another embodiment of the present invention. FIG. [Figure 17] FIG. 16 is a perspective view of the terminal according to the embodiment of the present invention in FIG. [Figure 17A] 16 is a perspective view of the terminal according to the embodiment of the present invention in FIG. 15 without an overmolded structure. [Figure 18] 16 is a cross-sectional view of the terminal system according to the embodiment of the present invention in FIG. 15. [Figure 18A] 16 is a cross-sectional view of an alternative conductive post for the terminal system according to the embodiment of the present invention in FIG. 15. [Figure 19] FIG. 16 is a side view of the terminal according to the embodiment of the present invention in FIG. [Figure 20] 16 is a top view of the terminal according to the embodiment of the present invention in FIG. 15. [Figure 21A] 16 is a partial cross-sectional view of a terminal according to another embodiment of the present invention shown in FIG. 15. [Figure 21B] 16 is a partial cross-sectional view of a terminal according to another embodiment of the present invention shown in FIG. 15. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] It should be understood that the accompanying drawings are not necessarily to scale, and present somewhat simplified depictions of various features illustrating the underlying principles of the invention. For example, the specific design features of the sequences of operations as disclosed herein, including the specific dimensions, operations, locations, and shapes of the various illustrated components, will be determined in part by the specific intended application and environment of use. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to facilitate visualization and clear understanding. In particular, thin features may be thickened, for example, for clarity or illustration purposes.

[0015] Referring to FIG. 1, in one embodiment of the present invention, an arc resistant electrical terminal 100 according to features of the present invention is incorporated into a cable or wire assembly 101. The arc resistant terminal 100 comprises a body made of a suitable electrically conductive material, such as a metal, such as copper or aluminum. In one embodiment, the terminal 100 is a solid piece of 1100 aluminum per ASTM B221. The terminal has a body with a solid or unitary construction and includes a wire receiving portion 102 and a unitary mounting portion 104. The terminal 100 is incorporated into a cable assembly 101 with a suitable wire or conductor 20, as shown in FIG. 1. The conductor 20 may be, for example, a solid or stranded copper or aluminum wire having a center conductor 22 and an insulating sheath 24. In one embodiment, the conductor 20 connected with the terminal may also include a wear sheath 26.

[0016] 1 and 3, an embodiment of an arc resistant terminal according to the present invention is shown. The terminal 100 comprises a body defining a wire receiving portion 102 having a front surface 106 including an opening 108, a rear surface or wall 110, and an outer wall 112 between the front surface 106 and the rear surface 110. The receiving portion 102 thus has an open end and a sealed end and is configured to receive an end of a conductor 20. As shown, the receiving portion 102 is shown as a cylinder, which corresponds to the typical cylindrical shape of an electrical wire, but may be of various other shapes. Between the rear surface 110 of the receiving portion 102 and the integral mounting portion 104 is a transition area or transition zone 114 that transitions into the mounting portion 104.

[0017] To connect the terminal 100 to an appropriate structure at an electrical connection point, such as a terminal block (see FIG. 3), the mounting portion has legs or tongues 116, which may be formed from a solid conductive metal. In the illustrated embodiment, the tongues are referred to as RT, ring tongue, or sealed tongue configurations. The tongues 116 define opposing face surfaces, including an upper face surface 120 and a lower face surface 122, which in one embodiment are oriented approximately parallel to an axis 124 of the receiving portion 102 of the terminal 100. The tongues 116 in the illustrated embodiment are offset and oriented in a plane below the axis 124. In the embodiment of FIGS. 1-3, 5, an opening or hole 126 is formed between the face surfaces 120, 122 for connecting the terminal to a connector, either individually or with other terminals stacked as shown in FIG. 8B. The opening 126 passes through the legs 116 of the mounting portion 104 and extends from the upper face surface or face 120 to the lower face surface or face 122. The receiver 102 also has an upper portion 130 and a lower portion 132 as determined by the orientation of the upper surface 120 and the lower surface 122 of the legs 116. The receiver 102 is configured to be crimped to the wire or conductor 20.

[0018] In accordance with one aspect of the present invention, the arc resistant terminal 100 incorporates a foot or tongue 116 having raised or elevated projections 220a, 220b surrounding the opening 126. A raised base is formed to surround the opening on the opposite face surface. In a specific embodiment, projections are positioned on both the upper and lower face surfaces 120, 122 of the tongue 116 as shown in FIG. 2. The projections 220a, 220b are preferably integrally formed with the tongue 116 to extend above the respective face surfaces 120, 122 surrounding the opening 126. However, as shown in FIG. 2D, one or more of the projections 223a, 223b may be configured as separate elements to which the tongue 116 is attached, to be used in conjunction with the tongue 116 to provide the present invention and its advantages.

[0019] 2, the height H of the projections 220a, 220b can range from 0.001 inches to 0.125 inches above the respective face surfaces 120, 122. The projections surround the aperture, and in the illustrated embodiment, the projections are generally circular around the aperture 126 to surround the aperture. The projections may have other shapes to surround the aperture 126. In the illustrated embodiment, the outer diameter D of the circular projections can be in the range of 0.050 inches in diameter greater than the aperture 126, up to the full width of the tongue 116. Optionally, the diameter D is equal to or greater than the size of the washer 229 below the nut 228. The size of the projections depends on the overall size of the aperture 126 and the nominal dimensions of the stud or bolt 222 that extends through the aperture 126 as shown in FIG. 3. Generally, the projections provide a suitable electrically conductive surface 221 for forming an electrical connection with a terminal bar or terminal block 224 or other connection point to which the cable assembly 101 and terminal 100 are coupled. The projections 220a, 220b are configured and sized to provide a sufficient connection to a metal area at the terminal block, other terminal, or connection point to which the terminal 100 is secured. For example, the projections may be configured and sized based on the size of the post 222 and the respective nut 228 and washer 229 combination (see FIG. 3 or FIG. 8A, FIG. 8B). FIG. 3 shows a nut and washer combination for securing the tongue. A lock washer (not shown) or a specially designed lock nut may be implemented in a fixed configuration to further secure the tongue in place. The size of the washer 229 and projections 220a, 220b are selected to ensure good electrical contact. The outer extent of the diameter of the projection is generally less than the width of the tongue 116 to allow for greater insulation between the projection and the edge of the tongue 116 .

[0020] In accordance with another feature of the present invention, tongue 116 and at least a portion of receiving portion 102 of the terminal are covered with a layer of insulating material in the form of a coating to increase the arc resistance of the terminal (see, e.g., FIG. 9). The layer of insulating material or coating is configured to cover a substantial portion of exposed terminal 100, leaving each prong 220a, 220b exposed or free of the layer of insulating material for proper electrical connection through the terminal.

[0021] In one embodiment of the invention, the tongue 116 and a portion of the wire-receiving portion 102 are covered with a layer or coating 230 made of a dielectric insulating material. In other embodiments, a larger portion of the terminal has a layer of insulating material coating formed thereon, and in some, the entire terminal has a coating layer thereon. The coating of dielectric insulating material extends over the tongue, leaving only the respective projections 220a, 220b free of layer 230.

[0022] The layer or coating 230 of dielectric insulating material may include a material selected from one or more of the following: a fluorocarbon material (e.g., PTFE, PFA, FEP, ETFE, etc.), a polymeric material, PVC, polyurethane, a thermoplastic material, a phenolic material, a silicone, a rubber, a ceramic, or some other material that has desirable dielectric properties and provides dielectric and / or sealing protection from leakage of fluids or vapors, and provides arc tracking protection along the insulating material surface or between conductive surfaces at and near the terminals. A combination of such materials may be used to form the layer 230. Referring to FIG. 2A, the layer 250 may be formed by a chemical conversion process to form a conversion coating, as discussed herein.

[0023] The layer 230 is suitably applied to at least a portion of the tongue 116, specifically the entire tongue 116, and also a portion of the wire-receiving portion 102, thereby leaving only the protrusions 220a, 220b exposed. In one embodiment of the present invention, a coating of dielectric material is applied and formed on the terminal 100 by a suitable application process. The application process may include any suitable process, and may include a spraying process, a dipping process, or a molding process. The applied coating of dielectric insulating material 230 as shown in FIG. 2 may have a thickness T of approximately 0.001 inches to 0.250 inches.

[0024] In one embodiment of the invention, the dielectric insulating coating 230 may have a thickness T similar to the overall height H of the protrusions. The coating in combination with each protrusion would then provide or define the upper and lower surfaces 120, 122 of the tongue 116.

[0025] In other embodiments of the present invention, the dielectric insulating coating 230 may have a thickness T that is less than the overall height H of the protrusions.

[0026] In a more specific embodiment, as shown in the figures, the coating 230 is dimensioned with a thickness T that is greater than the height H of the projections 220a, 220b. Then, as shown in Figures 3, 8A, 8B and discussed below, when the terminal 100 is secured to a terminal block or other connection point and clamped down to contact the projections, the coating 230 presses slightly down onto the projections and seals the junction at the projections. By implementing the insulating material layer 230, an environmental seal is created at the junction of the tongue and the terminal block or other connection point. Additionally, the seal reduces or eliminates galvanic reaction of dissimilar metals on the terminal and any other surfaces.

[0027] One possible material for the dielectric insulating material coating 230 is RTV silicone rubber available from Nusil Technology LLC of Carpinteria, Calif. The coating 230 may be sprayed onto the tongue 116 with the protrusions 220 and openings 126 appropriately masked or covered to maintain a free electrically conductive surface. Alternatively, the coating 230 may be formed by dipping the tongue with the protrusions and openings also covered. In yet another alternative embodiment, a mold may be formed from the material that is placed over or slid onto the tongue 116 to form the coating 230.

[0028] In one embodiment, as stated, the height H of the projections 220a, 220b is dimensioned to be less than or equal to the thickness T of the dielectric insulating coating 230. When the terminal 100 is positioned such that the post 222 of the terminal base 224 is positioned to extend through the opening 126 and the tongue 116 is secured at the post 222 by a suitable nut 228 and washer 229 (possibly with a lock nut or lock washer, not shown), as shown in FIG. 3, the underside of the washer 229 and the surface 232 of the terminal base 224 seal the interface between the tongue 116 and the nut 228 and the interface between the tongue 116 and the conductive surface 232 of the terminal base 224 while compressing the insulating coating adjacent the periphery or edge of each projection, respectively, to create good electrical contact with the projection and the terminal tongue 116. The structure of each projection is then sealed. In accordance with one aspect of the invention, this prevents the metal of tongue 116, protrusions 220a, and protrusions 220b from becoming a point of arcing, such as arcing between adjacent terminals in a terminal block, or arcing with other metal structures adjacent to tongue 116.

[0029] The terminals of the present invention have been found to provide a significant improvement in arc resistance when tested against conventional terminals. More specifically, for the terminal and cable assemblies of the present invention, a 3% saline solution 225 is dropped into a test configuration 227, as shown in FIG. 15, in which multiple cable assemblies 101 and terminals 100 are placed next to each other in a terminal block 224. When utilizing conventional terminals, arcing occurs as early as 15 seconds into the application of the test, with significant damage to the terminals and cable assemblies, and continues for 8 minutes. Instead, when implementing the arc resistant design of the present invention, arcing is prevented or delayed for as long as 8 hours, with only minor damage to the tongues 116 of the terminals 100. Thus, the present invention provides a significant improvement over existing terminal arrangements, and specifically, over terminal arrangements incorporating conventional cable assemblies and terminals connected together in close proximity in a common terminal block.

[0030] 2A, an alternative embodiment of the present invention is shown in which terminal 100a incorporates a non-conductive conversion coating layer formed on tongue 116 by a chemical conversion process. Specifically, as shown in FIG. 2A, through a chemical conversion process, a substantial depth D of the metal of the terminal is converted to a generally non-electrically conductive conversion coating layer 250. The conversion coating layer 250 is formed on at least a portion of the electrically conductive material of the tongue to reduce the conductivity of the tongue portion. For example, anodization may be used to form layer 250. Alternatively, another chemical conversion process may be used to form layer 250. Specifically, in one embodiment, layer 250, such as an oxide layer, is formed on aluminum terminal 100 through a suitable chemical conversion, such as by exposing terminal 100 to a cathodic or chemical conversion process. In such a process, protrusions 220a, protrusions 220b, and openings 126 are appropriately masked to prevent conversion coating 250 from forming in the areas of the protrusions and openings such that the protrusions and openings remain conductive for proper electrical connection with the terminal bar, threaded post, and nut, as shown in Figure 3. Generally, the conversion coating may be formed to a depth D of about 2-3 mils, although other depths may be suitable.

[0031] As shown in Fig. 2B, in accordance with yet another embodiment of the present invention, an insulating material layer or coating 230 may be utilized in combination with a conversion coating layer 250 for purposes of providing arc resistance in the terminal 100. Referring now to Fig. 2B, a terminal 100b is shown incorporating a combination of both a conversion coating layer 250 formed on the terminal 100b and an insulating material layer 230 applied to the terminal and layer 250. The combination of the two layers 230, 250 provides additional arc resistance to the terminal 100b. The insulating material layer 230 is formed to overlie at least a portion of the conversion coating layer 250.

[0032] FIG. 2C shows another embodiment of the invention in which a protrusion is located on only one side of the terminal tongue 116. Clearly, it may only be necessary to secure the tongue to a conductive surface on one side, so that only one protrusion, such as protrusion 220b as shown in FIG. 2C, may be used. Protrusion 220b is located on the underside of the terminal 100g or tongue 116 to provide a conductive surface to a conductive element or attachment point, such as terminal block 224 as shown in FIG. 3. In the embodiment of FIG. 2C, the upper surface of the tongue 116 is generally flat. In general, it is desirable to utilize a protrusion on which the tongue is attached to a surface to provide a desired consistent electrical connection at a point. As shown in FIG. 8B and FIG. 14, it may be desirable to attach multiple terminals together when fastening the terminals to an attachment point, so that protrusions 220a, 220b on both the top and bottom of the terminal 100 may be used as shown in FIG. 2.

[0033] 2D illustrates further embodiments of the present invention. In some of the illustrated embodiments, protrusions 220a, 220b are shown as integral with or formed with the tongue structure. In an alternative embodiment of terminal 100h, protrusions 223a, 223b may be formed separately and positioned about tongue opening 126 and used in conjunction with the tongue to achieve the benefits of the present invention. Protrusions 223a, 223b are similarly sized, positioned, and used as shown herein in conjunction with layer 230 or conversion coating layer 250 to achieve the features and benefits of the present invention.

[0034] 5 and 6, the wire-receiving portion 102 of the terminal 100 is configured to be crimped to form the cable assembly 101 and has a continuous annular inner wall 133 forming a crimp portion 134 (FIG. 6). In one embodiment of the invention, the crimp portion seals the terminal in addition to making contact with the conductor 22 and thus includes a seal or sealing portion 136 and a wire contact portion 138. The sealing portion 136 is adjacent to and spaced from the contact portion 138 towards the opening 108. In one embodiment, the sealing surface 142 is divided into four regions 144a, 144b, 144c, 144d as defined by three integral sealing rings 146a, 146b, 146c that project radially inwardly from the surface 142 as shown in FIG. In this embodiment, all four regions 144a, 144b, 144c, 144d are substantially the same diameter, but in other embodiments, the diameters may be different. Similarly, sealing rings 146a, 146b, 146c have a diameter smaller than the diameter of the four regions 144a, 144b, 144c, 144d. Although the sealing rings are illustrated with substantially the same diameter, in other embodiments, the diameters may be different. It is also contemplated that there may be more or less sealing rings than the three illustrated. A transition area 154 is positioned between the seal or sealing portion 136 and the contact portion 138. The transition area 154 guides the conductor 22 of the wire 20 from the larger sealing portion 136 to the contact portion 138 when the wire 20 is inserted into the terminal 100. Suitable wire terminal crimp configurations for use with the present invention are disclosed in U.S. patent application Ser. No. 14 / 010,073, entitled "TERMINAL / CONNECTOR HAVING INTEGRAL OXIDE BREAKER ELEMENT," filed Aug. 26, 2013, which is a continuation-in-part of U.S. patent application Ser. No. 12 / 371,765, entitled "TERMINAL / CONNECTOR HAVING INTEGRAL OXIDE BREAKER," filed Feb. 16, 2009, which now issued as U.S. Patent No. 8,519,267 on Aug. 27, 2013, which applications and patents are incorporated by reference herein in their entireties.

[0035] The terminal 100 of the present invention can be used to form a wire or cable assembly 101 (FIG. 1) in which an electrical wire 20 is inserted into the terminal 100 such that the conductor 22 is guided by the area 154 to the contact portion 138. The three sealing rings 146a, 146b, 146c surround the insulation 24 and the contact portion 138 surrounds the conductor 22 of the electrical wire. The conductor 101 is placed in a suitable crimping die, such as a modified hexagonal crimping die, and crimped to create a cable 184 with a crimp portion 186 (FIG. 5). The crimp portion 186 includes two opposing concave facets 188 and four straight facets 190. There are six corners 192 between the facets. One of the concave facets 188 includes an index button 194. The index button 194 will be properly formed if the electrical wire 20 is properly inserted and crimped.

[0036] 6, the conductor 20 is tightly clamped together at 195 in the sealing portion 136 and the contact portion 138 as compared to a portion 196 on the outside of the terminal 100. The sealing rings 146a, 146b, 146c are clamped onto the insulating jacket 24 to create a hydrostatic seal 198. The contact portion 138 is clamped onto the conductor 22 to provide the assembly 101 with a conductive electrical path 202 between the receiving portion 102 and the wire 20.

[0037] According to one embodiment, sealing may be enhanced by implementing flexible sealing rings in conjunction with the sealing rings 146a-c. Specifically, as shown in FIG. 2, one or more flexible sealing rings 147a, 147b may be implemented in one or more of the regions 144a-d between the sealing rings 146 of the sealing portion 136.

[0038] For example, as shown in FIG. 2, flexible sealing ring 147a is positioned between and adjacent rings 146a and 146b, and flexible sealing ring 147b is positioned between and adjacent rings 146b and 146c. Flexible sealing ring 147b is formed of a suitably flexible material and is positioned in suitable space 144, generally occupying less than the space or volume between sealing rings 146. Each of flexible sealing rings 147 is preferably formed continuously 360° around the surface of seal portion 136. Flexible sealing rings 147 are bent when the wire receiving portion is crimped to form a complete wire assembly or cable 101 with a suitable wire, as described herein.

[0039] Once terminal 100 is crimped to the wire, a suitable insulating sleeve may be placed over crimp portion 134 and suitably shrunk or secured over portion 134 and a portion of wire 20, as shown in FIG. 15, to further insulate the crimped metal of the terminal on wire 20.

[0040] 7-12 show additional alternative embodiments of the present invention incorporating the arc resistant features of the present invention. Specifically, the figures show different terminal alternatives with a tongue with multiple openings, a tongue with multiple projections similar to those shown in Figures 1-3, or a tongue with a single elongated projection for multiple openings. Additionally, the embodiments show various configurations with insulating material layers. For each of the embodiments as shown in Figures 7-12, it should be readily understood that different combinations of applied dielectric insulating material layers or coatings, conversion coating layers, and combinations thereof may be utilized similar to the embodiments as shown and described in connection with Figures 1-3. As such, Figures 7 and 12 only show the use of an applied dielectric insulating material layer 230, and the embodiments may utilize only the conversion coating layer 250 as described, or may be implemented with a combination of both the conversion coating layer 250 and the insulating material layer coating 230 applied over the conversion coating layer. Thus, the present invention is not limited to only those specific combinations shown in the figures, and other combinations of terminals and layers / coatings are covered.

[0041] 7, a terminal 100c is shown having a tongue 116 with a plurality of openings 126. Each of the openings has a corresponding projection 220a, 220b, as shown in FIG. 8, surrounding the respective opening in the face surface of the tongue. The embodiment of FIGS. 7 and 8 shows a material layer insulation 230 applied over the tongue 116 and the transition region 114 that transitions to the contact portion 138 of the wire-receiving portion 102 of the terminal 100c. As discussed herein, the projections 220a, 220b have a specific height H relative to the face surfaces 120 and 122, which height H is slightly less than the overall thickness T of the dielectric insulation material layer 230 to provide the desired sealing characteristics, as noted herein.

[0042] To that end, Figure 8A shows terminal 100c as assembled with terminal block 224 having appropriate posts 222, nuts 228, and washers 229 to physically and electrically couple the terminal to the terminal block. As discussed herein, a locking washer (not shown), or nut 228 with locking features, may be utilized in conjunction with nut 228 and washer 229 to provide a robust electrical and mechanical coupling of the terminal with a mounting, connection point, or structure. The multiple apertures 126 provide multiple points of contact with terminal block 224 or some other connection point.

[0043] According to one specific use of the invention, the raised projections 220a, 220b provide a robust electrical connection on both sides of the terminal 100 when the terminal is connected to a connection point or to another terminal. Referring again to FIG. 8B and FIG. 14, the invention provides the ability to stack multiple terminals integrally on top of one another for the purpose of securing the terminals to a connection point. The raised projections 220a, 220b abut one another as shown in FIG. 8B to provide a robust electrical connection. For example, the projection 220a on the top of a terminal abuts the projection 220b on the bottom of another terminal that is positioned above the first terminal as shown. Both terminals can then be secured with a suitable nut 228, washer 229 (and any suitable locking mechanism, if desired), or the like. Three or more terminals may be stacked as shown in FIG. 8B, FIG. 14, depending on the shape and orientation of the terminals.

[0044] FIG. 9 illustrates an alternative embodiment of the invention in which terminal 100d is almost completely covered with a layer of dielectric insulating material. Notably, terminal 100d has a plurality of openings 126 similar to the embodiment of FIG. 7, and is thereby constructed and operates similarly to that embodiment, as illustrated in FIGS. 7-8A. A dielectric insulating coating 230 is applied along the length of terminal 100d. Thus, layer 230 extends over transition 114 from tongue 116 to wire-receiving portion 102, and extends the length of wire-receiving portion 102 from rear surface 110 to opening or opening 108, as detailed with respect to FIG. 1. Thus, a larger portion of the exposed metal surface of terminal 100d is covered with dielectric insulating coating 230. The raised or raised protrusions 220a, 220b are left uncovered and are appropriately masked when the material for forming layer 230 is applied. FIG. 10 illustrates a cross-sectional view of terminal 100d of FIG. 9.

[0045] According to another embodiment of the present invention, Figs. 11 and 12 show an embodiment of the present invention as terminal 100e, in which an elongated protrusion extends between the multiple openings 126. That is, instead of a separate single protrusion for the multiple openings 126, a single protrusion extends between the openings 126 and surrounds both openings. Specifically, an elongated upper protrusion 220d and an elongated lower protrusion 220e extend between the openings 126, respectively. Protrusions 220d, 220e are free of dielectric insulating material for the purpose of making electrical contact with elements such as conductive surfaces of the terminal block. Therefore, protrusions 220d, 220e are appropriately masked during application of dielectric insulating material to form layer 230. For electrical contact with terminal 100e, a surface or connector shaped similarly to protrusions 220d, 220e may be used in the terminal block for a robust electrical connection. Figs. 11 and 12 show dielectric insulating material layer 230 extending the length of wire receiving portion 102 in addition to the length of tongue 116. Alternatively, layer 230 may be implemented as shown in Figures 7-8, substantially covering only tongue 116, such that in an alternative embodiment, in combination with the conductive protrusion, layer 230 may not extend beyond reference line 241 as shown in Figure 11.

[0046] As discussed herein, embodiments such as those shown in Figures 7-12 may incorporate various combinations of conversion coating layers and / or insulating material layers. Similar to the insulating material layer 230 as shown in Figures 7-12, the conversion coating layer may extend over only the tongue, over the entire terminal including the tongue 116 and wire receiving portion 102, or over the tongue 116 and a portion of the wire receiving portion 102 of the terminal. Such a conversion coating layer may be utilized in combination with the insulating material layer 230 used primarily over the tongue 116, over the entire terminal, or over the tongue and a portion of the terminal, as shown in Figures 9-11. Thus, the present invention is not limited to the particular embodiments as shown in the figures, but may utilize various different combinations of the individual projections 220a, 220b, extended projections 220d, 220e described, and / or the disclosed combinations of insulating material layers 230 and conversion coating layers 250.

[0047] Referring to FIG. 15, the unique combination of the insulated coating and exposed protrusions provides adequate metallic contact surfaces on the top and bottom of the tongue for electrical connection purposes while reducing and / or preventing arc tracking, as well as reducing and / or preventing accidental electrocution due to exposed terminals.

[0048] 13, 13A, and 13B illustrate other possible features that may be utilized in various terminals of the present invention. Specifically, the terminals of the present invention may utilize structure in the wire-receiving portion 102 of the terminal, specifically at the contact portion 138. To do so, the terminals may utilize an integral oxide breaking element to penetrate and break through non-conductive oxides that may form on the surfaces of conductors, such as aluminum conductors.

[0049] The contact portion 138 has a continuous cylindrical wall 155 with a threaded outer diameter 156 and an integral oxide breakdown portion or oxide breakdown element 158, the term integral oxide breakdown portion or oxide breakdown element being used in this application to refer to a macroscopic object that penetrates and breaks through the oxide layer in the conductor 22 when the wire-receiving portion is crimped.

[0050] The integral oxide breaking element 158 ​​includes a plurality of protrusions, such as tapered protrusions 162, extending radially inward from the outer thread diameter 156 of the contact portion 138. The protrusions are configured to engage the conductor of an electrical wire positioned in the contact portion and to protrude into the electrical wire when the wire receiving portion is crimped. The tapered protrusions 162 can be separate from one another, but in other embodiments, for ease of manufacturing, the tapered protrusions 162 are in the form of helical threads 164 (FIGS. 13A, 13B) that are conveniently manufactured on metal cutting or forming equipment. In one embodiment, the threads 164 have a thread angle 166 of 60 degrees, a pitch 167 of 80, and a depth of 0.008 / 0.010 inches. A pitch 167 of 60 has also worked well. It is contemplated that other thread angle 166 and pitch 167 combinations and depths will also work. A thread root diameter 168 equal to 0.481±0.002 inches was used for a 2 / 0 wire gauge. The oxide breaker 158 further comprises a coating 170 on the protrusion 162. In various embodiments, the oxide breaker and the structure forming it may be coated with a layer of material or may be left uncoated. In one specific embodiment, the coating 170 is electroless nickel plate of 0.0005±0.002 per ASTM B733 Type III. This may be conveniently placed into a blind hole (blind referring to a hole with only one opening 108) using an appropriate coating process. In addition to nickel, other coatings may be utilized and may be electrolytic nickel, gold, silver, tin, tin lead, and alkali bismuth tin.

[0051] The oxide breaking element configuration not only provides the ability to penetrate and break through the oxide layers in the conductor strands, but also enhances the electrical and mechanical characteristics of the present invention. For example, electrically, the oxide breaking element configuration increases the surface area of ​​the crimp and contact with the conductor, improving the overall electrical properties of the connection at the wire-to-terminal transition. Additionally, the oxide breaking element 158 ​​increases the gripping capability at the contact portion 138, increasing the pulling force required to remove the wire 20 from the terminal 100.

[0052] It is also contemplated that other forms of structure or elements may be used for the oxide breaking element 158, for example, individual annular projections may be used. The creation of one or more helical threads is a highly accomplished and efficient process. Other possible features and oxide breaker elements for use with the terminals of the present invention are disclosed in U.S. patent application Ser. No. 14 / 010,073, entitled "TERMINAL / CONNECTOR HAVING INTEGRAL OXIDE BREAKER ELEMENT," filed Aug. 26, 2013, now issued as U.S. Patent No. 9,385,449 on July 5, 2016, which is a continuation-in-part of U.S. patent application Ser. No. 12 / 371,765, entitled "TERMINAL / CONNECTOR HAVING INTEGRAL OXIDE BREAKER," filed Feb. 16, 2009, now issued as U.S. Patent No. 8,519,267 on August 27, 2013, which are incorporated by reference herein in their entireties.

[0053] 16-20 disclose alternative embodiments of the arc-resistant electrical terminal and grounding system of the present invention. An attachable, easily removable terminal is used with the grounding structure as described herein to provide a good electrical ground or power signal to the cable and to provide greater flexibility when fastening and reconfiguring the cable. Specifically, as shown in FIG. 16, the terminal 300 comprises a body made of a suitable electrically conductive material such as copper or aluminum. As disclosed herein, the body of the terminal 300 has a suitable wire receiving portion 302 that can be suitably crimped to the conductor of the wire or cable. The wire receiving portion 302 may resemble the structure as described herein in connection with FIGS. 1-15. The body also comprises a cup portion 304 as shown in FIGS. 17A and 18, which is electrically and physically coupled to the wire receiving portion 302 by a suitable connection portion 306 (see FIG. 18). The cup portion 304 interfaces with a post 314 and a conductive structure 312 to secure the terminal end of the cable and ensure a proper ground or power signal reference.

[0054] The cup portion 304 further includes a protrusion 310 extending downwardly from the bottom of the cup portion 304 as shown in FIG. 18. In one embodiment, the protrusion is integrally formed with the cup portion 304. The protrusion 310 makes electrical contact with a flat mounting surface 313 of a conductive structure 312. The conductive structure 312 can be in the form of a bus bar, mounting plate, or block, as appropriate, to provide a ground reference or power signal and to provide an electrical ground or power reference and structure for anchoring the end of a cable through the terminal 300. To that end, the protrusion 310 has a complementary flat or planar surface 311 that mates with surface 313.

[0055] In one embodiment of the invention as shown in Figures 16, 18, and 18A, a conductive stud or post 314 extends upwardly from the conductive structure 312 and is coupled to secure the cup portion 304 of the terminal. In the embodiment of Figure 18, the post 314 is in the form of a bolt structure that fits through an aperture 315 in the conductive structure 312 as shown. The bolt has a head 317 that limits the passage of the bolt through the aperture 315. The post 314 includes threads 319 on an exterior surface for securing the cup portion 304 of the terminal as described herein. The post 314 can be of stainless steel construction and can have an outer coating or cladding of a more highly conductive metal such as copper. The post can be secured with the conductive structure 312, such as by soldering or otherwise securing the post to the structure. In other embodiments as shown in Figure 18A, the post 314a can be press-fit or screwed into a suitable feature 315a in the conductive structure 312.

[0056] 16, 18 and 20, the body of the terminal 300 includes an aperture 320 formed therein that extends through the cup portion 304 and the protrusion 310. The aperture can be appropriately sized to receive the post 314 and allow passage of the post 314 through the protrusion and cup portion of the terminal when the terminal 300 is mounted on the conductive structure 312 and the post 314. That is, as shown in FIG. 18, the post 314 extends through the protrusion 310 and cup portion 304, through the aperture 320, and upwardly into the interior region 305 of the cup portion.

[0057] A fastener 330 engages the post and secures the cup and prong surface 311 to the surface 313 to secure the terminal 300, specifically the prong 310 and cup portion 304 to the conductive structure 312. In one embodiment, the post 314 may include external threads 319. Thus, as shown in FIGS. 16 and 18, a fastener 330, such as a threaded nut or other hardware fastener, may be secured to the post 314 and tightened down to secure the cup portion 304 of the terminal 300 to the conductive structure 312. Specifically, the exposed surface 311 of the prong is secured to the surface 313 of the conductive structure 312. The fastener is configured to fit within the area 305 contained within the cup portion. Although a single fastener 330 is shown in FIG. 16, it is understood that other hardware, such as washers, lock washers, and other structures may be utilized to secure the terminal 300 to the post 314 and mounting plate 312. Fastener 330 is fully contained within area 305 to be covered as described herein.

[0058] According to one aspect of the invention, an overmolded structure 308 of insulating material is formed on the cup portion. The overmolded structure 308 covers the sides of the cup portion and the sides of the protrusions as seen in FIG. 18. FIG. 17A shows the terminal 300 without the overmolded structure, showing the cup portion and the protrusions, as well as the connection portion. The overmolded structure is made of a suitable insulating material that is formed on the terminal 300 such that the sides 303 of the cup portion and the sides 309 of the protrusions are appropriately covered with a layer of insulating material. The insulating material may include a suitable silicone material or one or more of the following: fluorocarbon material, PTFE, PFA, FEP, ETFE, polymeric material, PVC, polyurethane, thermoplastic material, phenolic material, rubber, ceramic. In one embodiment, the insulating material may be injection molded as the overmolded structure 308 to cover the various portions 302, 304, 306 of the terminal 300 to prevent arcing. The overmolded structure may extend over a portion of the wire-receiving portion 302. To that end, the terminal 300 as shown in FIG. 17A may include features such as a recess 301 that indicates the extension of the overmolded structure 308 in the terminal. The overmolded structure of insulating material 308 encapsulates the electrical terminal 300 in the conductive structure 312, electrically insulating the terminal 300. The overmolded structure 308 covers the sides 303 and 309 and extends down the height H of the cup and protrusion, but does not cover the bottom surface 311 of the protrusion 310. The bottom surface 311 of the protrusion is exposed. In this manner, insulation is provided between the cup portion 304 and the connection portion 306 to the conductive structure, but a clear interface and conductive path is provided at the mating surfaces 311, 313. 18, the cup portion 304 is attached to the post 314 such that the exposed bottom surface 311 of the protrusion 310 rests flush against the top surface 313 of the conductive structure 312, and the overmolded structure surrounds the sides of the cup portion and the sides of the protrusion. Thus, electrical current flows through the conductive structure 312, through the protrusion 310 and the cup portion 304, through the connection portion 306, to the wire-receiving portion 302, and thereby to a wire, cable, or other conductor that is crimped to the wire-receiving portion 302.

[0059] According to one aspect of the invention, the cup portion 304 and protrusions may have a combined height H that is dimensioned to create an area 305 to accommodate most of the exposed posts 314 and fasteners 330 inside the cup portion 304 of the terminal. In this manner, all of the conductive hardware is covered with insulating material to prevent arcing. As shown in FIG. 16, the top edge 323 and inner surface 325 of the cup portion 304 that form the area 305 are exposed through the overmolded structure 308 and insulating material. The area 305 created by the surface 325 in the insulated cup portion 304 completely surrounds and encapsulates the mounting posts 314 and fasteners 330.

[0060] According to one embodiment of the invention, an insulating material cap 332 is secured over the cup portion to further enclose the posts 314 and the conductive surfaces 323, 325 of the cup portion 304. The insulating cap 332 is configured to engage the overmolded structure 308 and seal the cup structure around the posts 314 of the conductive structure 312. The insulating cap 332 is dimensioned to fit across the open portion and area 305 of the cup portion 304 and rest or overlap the overmolded structure 308 adjacent the edge 323. In this manner, the exposed area of ​​the posts 314 and the entire inner surface 325 of the cup portion 304 that forms the area 305 that accommodates the fasteners 330 and any other mounting hardware are also completely surrounded with insulating material. The cap may have a portion 331 that engages the inner surface 325 of the cup portion and may be made of a suitable material such as PTFE, some other polymer, or other material similar to the insulating material of the overmolded structure. The insulating cap 332 may be secured in the cup portion 304 and overmolded structure 308 by any suitable fastening method. For example, a friction fit of the section 331 with the inner surface 325 of the cup portion may be used. In other embodiments, as shown in FIG. 18, the portion 331 may include internal threads for threading onto the post 314 in the cup portion. Still other clip or stop structures may be used to secure the insulating cap 332 with the overmolded structure to surround the terminal 300.

[0061] For example, Figures 21A and 21B show possible embodiments in which cap 332 and cup portion 304 are configured with complementary structures for snap-on and locking engagement such that the cap engages overmolded structure 308. For example, referring to Figure 21A, cup portion 304 may include an annular recess 340 around the top edge 323 of cup portion 304 that receives a similarly shaped or complementary shaped ridge feature 342 formed around cap 332 to snap the cap into place on terminal 300. Similarly, in Figure 21B, an annular recess 344 around cap 332 receives a similarly shaped or complementary shaped ridge feature 346 formed around the top edge 323 of cup portion 304 of cap 332 to snap the cap into place on terminal 300 to engage overmolded structure 308 and seal the terminal.

[0062] In accordance with another feature of the present invention, the terminal 300 can be easily removed by removing the insulating cap 332 to expose the post 314, fastener 330, or other hardware. The fastener can be removed so that the terminal 300 can be easily slid off the post 314. Similarly, the terminal 300 can be reapplied or installed as disclosed herein. In this manner, the terminal can be installed and encapsulated in the insulating material without the need to apply the insulating material in a separate step, such as a coating step with tape or epoxy. Furthermore, the hardware can be easily removed without the need to remove the insulating material from the exposed surface. Still further, worker safety is improved and arcing events are reduced since the hardware mounting elements are completely covered, including the post 314 and fastener 330. As stated, the well or area 305 created in the insulated cup portion 304 completely surrounds and encapsulates the mounting post 314 and fastener 330.

[0063] To further insulate the terminal 300, as shown in Figures 17, 19 and 20, the overmold structure 308 includes a reduced diameter section 350 configured to receive a tubular portion of insulating material 352, such as heat shrink insulating material. The insulating material 352 fits over section 350 and the wire receiving portion 302. The insulating material may extend over a portion of the outer insulation of a wire or cable (not shown) that is attached to the terminal 300. Through the application of heat, the insulating material 352 shrinks to cover the wire receiving portion 302, the reduced diameter section 350, and any cable insulation that it overlies to further seal the terminal against fluids and prevent electrical arcing.

[0064] The present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of this application to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will be readily apparent to those skilled in the art. Thus, the present invention in its broader aspects is not limited to the apparatus and method depicted in specific details, and to the illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the broad inventive concept of the present application. [Explanation of symbols]

[0065] 20 Electric wires and conductors 22 Center conductor 24 Insulating clothing 26 Wear Coating 100, 100a, 100b, 100c, 100d, 100e, 100g, 100h Arc Resistant Electrical Terminals 101 Cable assemblies, electric wire assemblies 102 Wire receiving section 104 Mounting part 106 Front 108 Aperture 110 Rear, wall 112 Exterior Wall 114 Transition range, transition area, transition region, transition part 116 Legs, tongues 120 Top surface 122 Bottom surface 124 Axis 126 opening, hole 130 Top 132 Lower 133 Interior wall 134 Crimping section 136 Seal part, sealing part 138 Wire contact part 142 Sealing surface 144 Space 144a, 144b, 144c, 144d areas 146, 146a, 146b, 146c integral sealing ring 147, 147a, 147b Flexible sealing ring 154 Transition Zone 155 Wall 156 Thread outer diameter 158 Integrated oxide destruction part, oxide destruction element 162 Tapered protrusion 164 Helical Thread 166 Thread angle 167 pitch 170 Coating 184 Cable 186 Crimping section 188 Concave facet 190 Straight Face 192 corner 194 Index Button 195 Fastening part 196 A part of the outside of the terminal 100 198 Hydrostatic Seal 202 Electrical Path 220a, 220b protrusion 220d Long, thin upper protrusion 220e Long, thin protrusion on the lower side 221 Electrically Conductive Surface 222 Studs, bolts, columns 223a, 223b protrusions 224 Terminal bar, terminal block 225 Salt Water 227 Test Configuration 228 Nut 229 Washer 230 Dielectric insulating coating, dielectric insulating material layer 232 Surface 241 Reference line 250 conversion coating layers 300 Terminals 301 Depression 302 Wire receiving section 303 Side of the cup 304 Cup section 305 Inner area 306 Connection 308 Overmolded structure 309 Side of protrusion 310 Protrusion 311 Bottom surface, joint surface 312 Conductive structure, mounting plate 313 Mounting surface, joining surface, upper surface 314, 314a pillar 315 Aperture 315a Features 317 Head 319 Male thread 320 aperture 323 Conductive surface, upper edge 325 Conductive Surface, Inner Surface 330 Fasteners 331 A portion that engages with the inner surface 325 332 Insulating material cap 340 Depression 342 Ridged Features 344 Depression 346 Ridged Features 350 Small diameter area 352 Insulating materials D: Outer diameter and depth of protrusion H Height of protrusion T Coating thickness

Claims

1. 1. An electrical terminal for coupling to a conductive structure, comprising: a body having a wire receiving portion for receiving a conductor; a cup portion electrically connected to the wire receiving portion, the cup portion having an inner region defined therearound; a protrusion extending downward from a bottom of the cup portion and having a flat surface for mating with the conductive structure; an opening formed in the body and extending through the cup portion and the protrusion, the opening opening into an interior region of the cup portion for receiving a pillar of the conductive structure and configured to position a portion of the pillar within the interior region of the cup portion; an overmolded structure of insulating material formed on the cup portion, covering a side surface of the cup portion, the protrusion being configured to surround the opening at the bottom of the cup portion to provide an electrically conductive surface free of insulating material for mating with the conductive structure; a fastener configured to fit within an interior region of the cup portion to engage a post and secure the cup portion and the protrusion to the conductive structure; an insulating cap configured to engage an upper end of the cup portion and the overmolded structure and seal the cup portion and an interior region to seal the fastener and posts of a conductive structure; An electrical terminal comprising:

2. 10. The electrical terminal of claim 1, further comprising a connection portion for connecting the wire-receiving portion and the cup portion of the body of the electrical terminal, the overmolded structure of insulating material being formed over the connection portion.

3. The electrical terminal of claim 1 , wherein the overmolded structure is injection molded onto the cup portion.

4. 2. The electrical terminal of claim 1, wherein the post of the conductive structure has threads that the fastener engages to secure the protrusion to the conductive structure.

5. The electrical terminal of claim 1 , wherein the overmolded structure of insulating material is formed over at least a portion of the wire-receiving portion.

6. 10. The electrical terminal of claim 1, wherein the cup portion and the insulating cap include complementary structure for engagement to secure the insulating cap with the cup portion and the overmolded structure.

7. The electrical terminal of claim 1 , wherein the protrusion is integrally formed with the cup portion.

8. 10. The electrical terminal of claim 1, wherein the overmolded structure is formed from an insulating material comprising a material selected from one or more of the following: fluorocarbon material, PTFE, PFA, FEP, ETFE, polymeric material, PVC, polyurethane, thermoplastic material, phenolic material, silicone, rubber, ceramic.

9. a conductive structure having pillars extending therefrom; an electrical terminal for electrically connecting to the conductive structure, a body having a wire receiving portion for receiving a conductor; a cup portion electrically coupled to the wire receiving portion, the cup portion having an inner region defined therearound; a protrusion extending downward from a bottom of the cup portion and having a flat surface for mating with the conductive structure; an opening formed in the body and extending through the cup portion and the protrusion, the opening opening into an interior region of the cup portion for receiving the pillar of the conductive structure and configured to position a portion of the pillar within the interior region of the cup portion; an overmolded structure of insulating material formed on the cup portion, covering a side surface of the cup portion, the protrusion being configured to surround the opening at the bottom of the cup portion to provide an electrically conductive surface free of insulating material for mating with the conductive structure; a fastener configured to fit within an interior region of the cup portion to engage a post and secure the cup portion and the protrusion to the conductive structure; an insulating cap configured to engage an upper end of the cup portion and the overmolded structure and seal the cup portion and an interior region to seal the fastener and a post of a conductive structure; An electrical terminal comprising: An electrical grounding or power system comprising:

10. 10. The electrical grounding or power system of claim 9, further comprising a connection portion for connecting the wire-receiving portion and the cup portion of the body of the electrical terminal, the overmolded structure of insulating material being formed over the connection portion.

11. 10. The electrical grounding or power system of claim 9, wherein the overmolded structure is injection molded onto the cup portion.

12. 10. The electrical grounding or power system of claim 9, wherein the post of the conductive structure has threads that the fastener engages to secure the protrusion to the conductive structure.

13. 10. The electrical grounding or power system of claim 9, wherein the overmolded structure of insulating material is formed over at least a portion of the wire-receiving portion.

14. 10. The electrical grounding or power system of claim 9, wherein the cup portion and the insulating cap include complementary structure for engagement to secure the insulating cap with the cup portion and the overmolded structure.

15. 10. The electrical grounding or power system of claim 9, wherein the protrusion is integrally formed with the cup portion.

16. 10. The electrical grounding or power system of claim 9, wherein the overmolded structure is formed from an insulating material including a material selected from one or more of the following: fluorocarbon materials, PTFE, PFA, FEP, ETFE, polymeric materials, PVC, polyurethane, thermoplastic materials, phenolic materials, silicone, rubber, ceramic.

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