Male electrical terminal and its connection method

Abstract

The male electrical terminal of the present invention includes a clamp or crimp area, a body, and a blade. A tongue member with a lever member locks with the connector assembly. The protruding member and support member of the body act as overstress protection. The body includes a tapered portion, a protruding guide member, and a panel shield member to guide the male electrical terminal, and the panel shield member protects the protruding guide member. The male electrical terminal is polarized such that the upper portion of the body in the upper section of the connector assembly is narrower than the lower portion of the body in the lower section of the connector assembly. The present invention also includes a method of securing a male electrical terminal to a wire or cable using a pair of wire insulation clamp tabs or insulation crimp wing portions and a pair of wire clamp tabs or core crimp wing portions.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This patent application claims priority to U.S. Provisional Patent Application No. 62 / 893,679, filed August 29, 2019, which is incorporated herein by reference in its entirety. [Background technology]

[0002] It is desirable to provide the male electrical terminal with an overstress protection and guiding aid structural arrangement or feature to effectively protect and guide the male electrical terminal, thereby preventing undesired deformation of the male electrical terminal during mating with a connector assembly.

[0003] It is further desirable to ensure that the orientation or polarity of the male electrical terminal of the present invention and the corresponding connector assembly is maintained in order for them to mate properly.

[0004] It is also desirable to provide a method for ensuring effective gripping of an electrical wire or cable by the male electrical terminal of the present invention and preventing slippage of the electrical wire or cable within or away from the male electrical terminal by including a pair of wire clamping tabs or core crimping wing portions thereof that are clamped or folded and crimped against the inserting wire core portion of the electrical wire or cable.

[0005] It is also desirable to provide a method for ensuring effective gripping of an electrical wire or cable by the male electrical terminal of the present invention and preventing slippage of the electrical wire or cable within or away from the male electrical terminal by including a pair of wire insulation clamping tabs or insulation crimping wing portions thereof that deform, clamp, or bend and crimp against the inserting insulation of the electrical wire or cable. Summary of the Invention

[0006] The present invention provides a male electrical terminal for mating with a connector assembly, generally including a clamp or crimp area, a body, and a blade.

[0007] The clamp or crimping area includes a pair of wire insulation clamping tabs or insulation wing portions and a pair of wire clamping tabs or core crimping wing portions. To ensure secure contact and gripping with the electrical wire or cable, the pair of wire clamping tabs or core crimping wing portions include a plurality of substantially elongated notches and protruding members on their electrical wire or cable contact surfaces. The pair of wire clamping tabs or core crimping wing portions are deformed, clamped, or folded over and crimped against the core portion of the electrical wire or cable. Furthermore, the pair of wire insulation clamping tabs or insulation crimping wing portions are also deformed, clamped, or folded over and crimped against the insulation portion of the electrical wire or cable, respectively. A forward portion of the clamp or crimping area has a neck member that transitions to the body of the male terminal.

[0008] The body is substantially box-shaped and generally includes a tongue member that includes a lever member that locks the male electrical terminal with the connector assembly. The lever member has a protruding member that contacts another protruding member extending from the body when the lever member is deflected. Both protruding members act as overstress protection for the lever member, i.e., prevent or protect the lever member from deformation when the male terminal is mated with the connector assembly.

[0009] A protruding guide member protrudes from and is attached to the tongue member. The front end portion of the body also includes a tapered portion. The front end portion of the body further includes a panel shield member that protects the protruding guide member. The tapered portion, together with the protruding guide member of the body and the panel guide member, helps guide the male terminal of the present invention when mated with a connector assembly. The front end portion of the body transitions into a blade having a tip end that is also tapered. The body further includes a support member at either end thereof.

[0010] The male electrical terminals of the present invention also have an orientation or polarity to properly mate within a corresponding connector assembly, and the corresponding connector assembly has an orientation or polarity that is similarly maintained to properly mate with the male electrical terminal. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1A is a top perspective view of the front of a male electrical terminal of the present invention, and FIG. 1B is a top perspective view of the rear of a male electrical terminal of the present invention. [Figure 2] FIG. 2A is a right side view of the male electrical terminal of the present invention, and FIG. 2B is a left side view of the male electrical terminal of the present invention. [Figure 3] FIG. 3A is a top view of the male electrical terminal of the present invention, and FIG. 3B is a bottom view of the male electrical terminal of the present invention. [Figure 4A] FIG. 4A shows a top view of a clamping or crimping area having a pair of bendable wire insulation clamping tabs or insulation crimp wing portions and a pair of wire clamping tabs or core crimping wing portions each having a plurality of substantially elongated cutouts extending substantially to near the ends of the wire clamping tabs or core crimping wing portions. [Figure 4B]FIG. 4B shows a top view of a clamping or crimping area having a pair of bendable wire insulation clamping tabs or insulation crimp wing portions and a pair of wire clamping tabs or core crimping wing portions each having a plurality of substantially elongated cutouts extending to the ends of the wire clamping tabs or core crimping wing portions. [Figure 4CD] FIG. 4C shows a cross-sectional view of the floor of the wire clamp tab or core crimp wing portion as being substantially flat in shape, while FIG. 4D shows a cross-sectional view of the floor of the wire clamp tab or core crimp wing portion as being substantially concave or rounded in shape. [Figure 5A] FIG. 5A shows the body of the male terminal with the tongue member, further illustrating the structural arrangement or mechanism for guiding and protecting the male terminal against overstress. [Figure 5B] FIG. 5B shows the first and second support members positioned at the front and rear end portions of the body, respectively. [Figure 6] 6A and 6B show the tapered portion of the body having a protruding guide member and a panel shield member that protects the protruding guide member. [Figure 7] FIG. 7 shows the male blade extending from the tapered front end portion of the body. [Figure 8] FIG. 8A is a front view of the male terminal of the present invention, while FIG. 8B is a rear view of the male electrical terminal of the present invention. [Figure 9] FIG. 9 shows a conventional electrical wire or cable inserted into the male terminal of the present invention, the conventional electrical wire or cable having an insulation portion and a wire core portion at its front portion. [Figure 10] FIG. 10 shows a cross-sectional view of how the wire clamp tab or core crimp wing portion is folded over and deformed into the wire core portion of an electrical wire or cable. [Figure 11]FIG. 11 is a side view showing how a pair of bendable wire insulation clamping tabs or insulation crimping wing portions are clamped or bent and crimped onto an insulation portion of an electrical wire or cable. [Figure 12] FIG. 12A is a perspective view of another embodiment of a pair of bendable wire insulation clamp tabs or insulation crimp wing portions, and FIG. 12B is a top view of another embodiment of a pair of bendable wire insulation clamp tabs or insulation crimp wing portions, wherein the pair of bendable wire insulation clamp tabs or insulation crimp wing portions are substantially directly opposite each other or substantially symmetrical to each other. [Figure 13] FIG. 13 is a cross-sectional view of a pair of substantially opposed or substantially symmetrical bendable wire insulation clamping tabs or insulation crimp wing portions, the ends of which are bent into the insulation of an electrical wire or cable. [Figure 14A] FIG. 14A shows a front view of a male electrical terminal of the present invention in a pre-locked position within a connector assembly, and FIG. 14A further illustrates the polarity or orientation of the male electrical terminal of the present invention and the corresponding connector assembly for effective mating thereof. [Figure 14B] FIG. 14B shows a front view of the male electrical terminal of the present invention in a fully resting and fully locked position within a connector assembly, and further illustrates the polarity or orientation of the male electrical terminal of the present invention and the corresponding connector assembly for effective mating thereof. DETAILED DESCRIPTION OF THE INVENTION

[0012] FIG. 1 is a front, top perspective view of a male electrical terminal, generally referred to as 1. Male electrical terminal 1 includes a clamping or crimping area 3, a body 5, and a blade 7 integrally formed along its length. As will be described more fully below, clamping or crimping area 3 includes a pair of wire clamping tabs or core crimping wing portions 10, 11 and a pair of wire insulation clamping tabs or insulation crimping wing portions 13, 14. Body 5 includes a tongue member 15 and a tapered portion 17 at its front end portion 20. Tapered portion 17 narrows toward blade 7. Also shown in the rear, top perspective view of male terminal 1 in FIG. 1B is clamping or crimping area 3, including a pair of wire clamping tabs or core crimping wing portions 10, 11 and a pair of wire insulation clamping tabs or insulation crimping wing portions 13, 14. 1B, a rear top perspective view of male electrical terminal 1, also shown as in FIG. 1A, is tongue member 15 and tapered portion 17 at forward end portion 20 of body 5. Preferably, body 5 has an outline or shape that is substantially box-shaped or the like, but is not limited to such.

[0013] As shown in FIGS. 2A and 2B , the pair of wire insulation clamp tab or insulation crimp wing portions 13, 14 are misaligned when viewed in side view (i.e., one 13 of the pair of wire insulation clamp tab or insulation crimp wing portions 13, 14 is positioned closer to the wire clamp tab or core crimp wing portion 10, 11 compared to the position of one of the pair of wire insulation clamp tab or insulation crimp wing portions 14). As also shown in FIGS. 2A and 2B , the clamping or crimping area 3 integrally transitions to the body 5 by a neck member 52, while the front end portion 20 of the body 5 integrally transitions to the blade 7. As shown in FIG. 2A , the tongue member 15 includes a lever member 25 having an unattached end portion 28 and an attached end portion 30. As can be further seen in FIGS. 2A and 2B , the lever member 25 is shown here in its normal, relaxed state.

[0014] The unattached end portion 28 of the lever member 25 preferably has a substantially U-shaped or similar shape in cross section along its width, but is not limited to such a shape (see FIG. 5A). The attached end portion 30 of the lever member 25 preferably has a substantially L-shaped or similar shape in cross section along its width, but is not limited to such a shape (see FIG. 8A).

[0015] Furthermore, the lever member 25 has a protruding member 35 that abuts another protruding member 37 extending from the main body 5 (see FIG. 2A ). Both protruding members 35, 37 act as overstress protection for the lever member 25. That is, the protruding members 35, 37 impact against each other when the lever member 25 is in a deflected state. This thereby prevents or protects the lever member 25 from being deformed when the male terminal 1 contacts or mates with a connector assembly 90 or the like (see FIG. 14A ). Thus, the lever member 25 is operable to move substantially between the deflected state and a normal relaxed state without deformation (see FIGS. 14A and 14B ). When viewed in the side views of FIGS. 2A and 2B , the protruding members 35, 37 are preferably substantially rectangular, circular, trapezoidal, or the like, but their outline or shape is not limited thereto.

[0016] In operation, as the male electrical terminal 1 enters the connector assembly 90, the unattached end portion 28 of the lever member 25 is free to push downward, moving from a normally relaxed state to a deflected state (i.e., the protruding member 35 moves toward another protruding member 37) (see FIG. 14A). Once the male electrical terminal 1 is fully inserted into the connector assembly 90, the unattached end portion 28 of the lever member 25 is free to move upward, returning to the normally relaxed state of the lever member 25 (i.e., the protruding member 35 moves away from another protruding member 37) (see FIGS. 2A, 14B). The unattached end portion 28 thereby impacts a member (not shown) within the connector assembly 90, locking and securing the male electrical terminal 1 therein. Such a structural arrangement with the unattached end portion 28 of the lever member 25 impacting within the connector assembly acts as a locking and securing mechanism for the male electrical terminal 1.

[0017] Additionally, when the male electrical terminal 1 is fully inserted into the connector assembly 90, the clamp or crimp area 3 has a space or transition area 50 above the neck member 52 (see FIGS. 2A and 2B) and between the wire clamp tab or core crimp wing portions 10, 11 and the body 5. The space or transition area 50 may be utilized to accommodate a terminal position assurance (TPA) device (not shown) therein to ensure that the male terminal 1 remains locked, secured, and properly positioned within the connector assembly 90.

[0018] Also shown in Figure 2A is a panel shielding member 40 at the front end portion 20 of the body 5, which protrudes from a portion of the body's front end portion 20. Also shown in Figure 2B is a tapered portion 17 of the front end portion 20 of the body 5. Together, the panel shielding member 40 and tapered portion 17 (as well as the protruding guide member 53 shown in Figures 6A and 6B, described below) help guide and position the blade 7 and body 5 when mating the male electrical terminal 1 with the connector assembly 90.

[0019] A top view of the clamping or crimping area 3, body 5, and blades 7 is shown in FIG. 3A. As also shown in FIG. 3A and as described above, the pair of wire insulation clamping tabs or insulation crimp wing portions 13, 14 are not aligned, directly aligned, or substantially opposed to one another. Furthermore, as noted above, the position of one of the pair of wire insulation clamping tabs or insulation crimping wing portions 13 is closer to the wire clamping tabs or core crimping wing portions 10, 11 of the male electrical terminal 1 than the position of the other of the pair of wire insulation clamping tabs or insulation crimping wing portions 14. This is to maximize the surface area of ​​the insulation portion 120 of the electrical wire or cable 100 that is connected and attached when the pair of wire insulation clamping tabs or insulation crimping wing portions 13, 14 are clamped or crimped. As described below, another embodiment of the male electrical terminal 1 is possible with a pair of bendable wire insulation clamping tabs or insulation wing portions 213, 214 that are substantially directly opposed or substantially symmetrical (see FIGS. 12A and 12B). As can be seen in FIG. 9, between the pair of wire insulation clamping tabs or insulation crimping wing portions 13, 14 is a floor member 40 that receives the insulation portion 120 of the electrical wire or cable 100 thereon. After receiving the wire or cable 100, the pair of wire insulation clamping tabs or insulation crimping wing portions 13, 14 deform, clamp, or bend and crimp against the insulation portion 120 of the electrical wire or cable 100 without completely penetrating the insulation portion 120 or contacting the core portion 110 (see FIG. 11). Furthermore, the shape of the floor member 40 is preferably substantially concave or rounded (see FIG. 8B).

[0020] Also shown in FIG. 3A are a pair of wire clamp pads or core crimp wing portions 10, 11 of clamp or crimp area 3. The pair of wire clamp pads or core crimp wing portions 10, 11 are substantially aligned or substantially opposite one another (see also FIGS. 2A and 2B, in which male electrical terminal 1 is seen in side view) and are substantially symmetrical. Between the pair of wire clamp tabs or core crimp wing portions 10, 11 is a floor member 45 having a plurality of cutouts 48. The shape of floor member 45 may be substantially flat (or substantially concave, rounded, similar to the shape of floor member 40). As shown in more detail, floor 45 of wire clamp tabs or core crimp wing portions 10, 11 is substantially flat in shape (as shown in the cross-sectional view of FIG. 4C), although floor 45 may alternatively be substantially concave or rounded (similar to the shape of floor member 40) (as shown in the cross-sectional view of FIG. 4D). Each of the plurality of cutouts 48 may be substantially elongated in shape (as shown in FIGS. 2A, 2B, 4A, and 4B), but the shape of each of the cutouts 48 is not limited thereto. A minimum of two cutouts 48 is possible, but at least three cutouts 48 are preferred. A minimum of one protruding member 60 is possible, but at least two protruding members 60 are preferred. The combination of the cutouts 48 and the protruding members 60 forms serrations on the floor member 45 and the pair of wire clamp pads or core crimp wing portions 10, 11. This arrangement ensures reliable contact and gripping of the wire core portion 110 (see FIG. 9) of the electrical wire or cable 100 between the floor member 45 and the pair of wire clamp pads or core crimp wing portions 10, 11.Once the wire core is inserted, the clamping or crimping area 3 substantially grips the wire core portion 110 of the electrical wire or cable 100, preventing it from sliding away from the floor member 45 and the pair of wire clamp pads or core crimping wing portions 10, 11, which then further deform, clamp, or bend toward the floor member 45 and crimp against the wire core portion 110 of the electrical wire or cable 100. This process ensures positive contact and grip of the clamping or crimping area 3 of the male electrical terminal 1 with the wire core portion 110 of the electrical wire or cable 100, preventing the wire core portion 110 of the electrical wire or cable 100 from sliding away from the male electrical terminal 1.

[0021] 10, the wire core portion 110 then substantially conforms to the shape of the wire clamp tab or core crimp wing portions 10, 11 to be deformed, clamped, or folded and crimped. That is, when the pair of wire clamp tabs or core crimp wing portions 10, 11 are deformed, clamped, or folded and crimped against the wire core portion 110 of the electrical wire or cable 100 (the clamping or crimping process), the protruding members 60 between the notches 48 (see FIGS. 4A and 4B), as well as the protruding members 68 at each end (see also FIGS. 4A and 4B), are embedded or pressed into the outer surface of the wire core portion 110 of the electrical wire or cable 100.

[0022] As further shown in Figure 4A, each elongated cutout 48 extends completely along the floor member 45 between the pair of wire clamp tabs or core crimp wing portions 10, 11, and each elongated cutout 48 further extends partially into, and substantially near the end of, the pair of wire clamp tabs or core crimp wing portions 10, 11 at its end portion 49. Alternatively, a further embodiment shown in Figure 4B has the end portion 49 of the elongated cutout 48 extending into, and substantially out of, the end or tip of, the pair of wire clamp tabs or core crimp wing portions 10, 11, respectively.

[0023] Shown in Figure 3B is a bottom view of the clamping or crimping area 3, body 5, and blade 7 of the male electrical terminal 1. A front end portion 20 of the body 5 transitions from the body 5 to the blade 7, which is connected to and integral with the body 5 (Figure 3B). Also shown in Figure 3B are a pair of wire clamping tabs or core crimping wing portions 10, 11 that are substantially symmetrical and extend from the sides of the floor member 45 of the clamping or crimping area 3, respectively. The embodiment of the male electrical terminal 1 shown in Figure 3B shows a pair of wire insulation clamping tabs or insulation crimping wing portions 13, 14 that are substantially misaligned, which is also apparent when viewed in its side view (see also Figures 2A and 2B).

[0024] Also shown in each of Figures 4A and 4B is a forward portion 51 of the clamping or crimping area 3. The forward portion 51 of the clamping or crimping area 3 includes a space or transition area 50 above the neck member 52 and between the main body 5 and the wire clamp tab or core crimp wing portions 10, 11. The neck member 52 has a narrow, tapered shape that tapers from the floor member 45 and the wire clamp tab or core crimp wing portions 10, 11 to where the neck member 52 meets the main body 5. The narrow, tapered shape of the neck member 52 at the forward portion 51 also allows the wire core portion 110 of the electrical wire or cable 100 to remain seated or attached within the floor member 45, preventing the entire wire core portion 110 of the electrical wire or cable 100 from seating or attaching to the neck member 52. Preferably, the narrow, tapered shape of neck member 52 in clamping or crimping area 3 allows only a forward portion of wire core portion 110 of electrical wire or cable 100 to protrude into neck member 52. That is, the narrow, tapered shape of neck member 52 further prevents wire core portion 110 from substantially entering space or transition area 50. Transition area 50, as previously described, is available to accommodate a TPA device (not shown) therein to ensure that male terminal 1 remains locked, secured, and properly positioned when inserted into connector assembly 90. Thus, at this time, only a forward portion of wire core portion 110 enters or protrudes into space or transition area 50, and wire core portion 110 does not interfere with or prevent the TPA device (not shown) from being accommodated therein.

[0025] Shown in FIG. 5A are tongue member 15 and attached end 30 and unattached end portion 28 of lever member 25. As described above with reference to FIGS. 2A and 2B, FIG. 5A also shows protruding member 35 at unattached end portion 28 of lever member 25, which can impinge against another protruding member 37 extending from body 5 to prevent deformation of lever member 25 when main terminal 1 is mated with connector assembly 90. The structural arrangement described herein protects lever member 25 from being overstressed (and thereby prevents deformation) as it flexes upon entering connector assembly 90. Also shown in FIG. 5A is panel shielding member 40 at front end portion 20 of body 5. Panel shielding member 40 will be described in more detail in FIGS. 6A and 6B.

[0026] 5B shows both the front portion 69 and the rear portion 71 of the body 5, each having a first support member 70 and a second support member 75. More specifically, the upper portion 69a of the front portion 69 of the body 5 includes the first support member 70, while the upper portion 71a of the rear portion 71 of the body 5 includes the second support member 75. A gap 76 separates the first support member 70 from the lower portion 80 of the body 5. A pair of gaps 78a, 78b separate the second support member 75 from the lower portion 80 of the body 5. When the male electrical terminal 1 enters the connector assembly 90, the first support member 70 and the second support member 75 are resiliently pushed downward toward the lower portion 80 of the body 5 through the gaps 76, 78a / 78b located therebetween. Due to the structural arrangement described above, the first support member 70 and the second support member 75 provide the resilience necessary to prevent the male electrical terminal 1 of the present invention from being overstressed and deformed when mated within the connector assembly 90, thereby maintaining the polarity of the male terminal 1 (see Figures 14A and 14B).

[0027] The panel shielding member 40 is further shown in Figures 6A and 6B. The panel shielding member 40 is shown herein as extending from the side of the front end portion 20 of the body 5, but is not so limited. The panel shielding member 40 has an upper surface 55, shown here as slanted, with the lower end of the upper surface 55 pointing towards the blade 7 and the upper end of the upper surface 55 pointing towards the tongue member 15.

[0028] Also shown in Figures 6A and 6B is a protruding guide member 53 extending from and attached to the tongue member 15 of the main body 5. The panel shielding member 40 protects the protruding guide member 53 from deformation, for example, during transportation of the male electrical terminal 1, or preferably when the male electrical terminal 1 is mated with and inserted into the connector assembly 90. As shown in more detail in Figure 6B, it is preferred that the height of an upper surface 55 extending entirely along the panel shielding member 40 is substantially higher than or equal to the upper surface 58 of the protruding guide member 53 (see Figure 6B). That is, it is preferred that the height of the upper surface 55 of the panel guide member 40 is higher than or equal to the upper surface 58 of the protruding guide member 53 overall. Similarly, the upper surface 58 of the portion of the protruding guide member 53 that lies along the panel shielding member 40 is lower than or equal to the upper surface 55 of the panel guide member 40, and the protruding guide member 53 tapers substantially downward from its attachment point with the tongue member 15 toward the front end portion 20.

[0029] The front end portion 20 of the body 5 transitions into a blade 7, as shown in FIG. 6A. The blade 7 serves as a male contact for the male electrical terminal 1 within a male connector assembly 90, as also shown in FIG. 7, and may have a substantially rectangular, square, or other cross-sectional shape, but is not limited thereto. The end portion of the blade 7 has a tapered tip 60, which may include a lower portion 62 that is substantially symmetrical to an upper portion 64, although the lower and upper portions 62, 64 of the blade are not limited thereto, so long as the tip 60 of the blade 7 has a narrow, tapered shape. The tapered tips 60 narrowly taper toward the ends of the blade 7 at the ends of the male electrical terminal 1, further preventing the blade 7 from being bumped or deformed.

[0030] FIG. 8A is a front view of male electrical terminal 1. Shown here are lower and upper portions 62, 64, and tip 60 of blade 7 extending from body 5. Also shown in FIG. 8A is upper surface 55 of panel shielding member 40, which has a higher or equal height along (preferably the entirety of) upper surface 58 of protruding guide member 53, which extends from tongue member 15 of body 5. Also shown in FIG. 8A are a pair of wire clamp tabs or core crimp wing portions 10, 11 and a pair of wire insulation clamp tabs or insulation crimp wing portions 13, 14, both of which extend from clamp or crimp area 3. Also visible in FIG. 8A is gap 76 separating first support member 70 from lower portion 80 of body 5, as well as gap 78a below second support member 75 (see also FIG. 5B).

[0031] FIG. 8B shows a rear view of male electrical terminal 1. Shown are a pair of wire insulation clamp tabs or insulation crimp wing portions 13, 14 extending from each side of floor member 40 of clamp or crimp area 3. Also shown are a pair of wire clamp tabs or core crimp wing portions 10, 11 extending from floor member 45. Second support member 75, as part of body 5, is positioned on upper portion 71a of rear portion 71 of body 5 as shown (see also FIG. 5B). Also shown in FIG. 8B are front end portion 20 of body 5, which transitions into blade 7, and substantially U-shaped, unattached end portion 28 of lever member 25.

[0032] 9 illustrates an exemplary electrical wire or cable 100 having a wire core portion 110 and an insulating portion 120 accommodated by a male electrical terminal 1 of the present invention. Without limitation, the wire core portion 110 of the electrical wire or cable 100 may rest on the serrated portion (formed by the notch 48 and the protruding members 60, 68; see FIGS. 4A and 4B ) and, as described above, the floor member 45 and the pair of wire clamp tabs or core crimp wing portions 10, 11, which are deformed, clamped, or folded and crimped against the wire core portion 110 of the electrical wire or cable 100 (see FIG. 10 ) to provide secure contact between the clamping or crimping area 3 of the male electrical terminal 1 and the wire core portion 110 of the electrical wire or cable 100.

[0033] Further, in FIG. 9, but not limited to, the insulation portion 120 of the electrical wire or cable 100 may rest on the floor member 40 of the clamping or crimping area 3 of the male electrical terminal 1 (see FIGS. 4A and 4B), and a pair of wire insulation clamping tabs or insulation crimping wing portions 13, 14 are clamped or folded and crimped against the insulation portion 120 of the electrical wire or cable 100.

[0034] As described (see Figures 4A and 4B), a pair of wire clamping tabs or core crimp wing portions 10, 11 are clamped or folded and crimped onto a wire core portion 110 of the electrical wire or cable 100 (see Figure 10), and a pair of wire insulation clamping tabs or insulation crimp wing portions 13, 14 are clamped or folded and crimped onto an insulation portion 120 of the electrical wire or cable 100 (see Figure 11), and the male electrical terminal 1 is then inserted into a connector assembly 90 or the like, as shown in Figure 14A.

[0035] 10 shows in more detail the orientation in which the pair of wire clamp tabs or core crimp wing portions 10, 11 are folded toward each other and toward the floor member 45 to deform, clamp, or bend and crimp around and within the wire core portion 110 of the electrical wire or cable 100, where the wire core portion 110 of the electrical wire or cable 100 is essentially crushed, deformed, compacted, and substantially surrounded by the pair of wire clamp tabs or core crimp wing portions 10, 11.

[0036] Figure 11 illustrates how a pair of bendable wire insulation clamping tabs or insulation wing portions 13, 14 are clamped or folded toward the floor 40 and crimped against the insulation portion 120 of the electrical wire or cable 100. As shown in more detail in Figure 11 , a gap A exists between the misaligned pair of bendable wire insulation clamping tabs or insulation wing portions 13, 14 when they are deformed, clamped, or folded and crimped against the insulation portion 120 of the electrical wire or cable 100. Alternatively, the pair of bendable wire insulation clamping tabs or insulation wing portions 13, 14 may contact each other at one or more points when they are clamped or folded and crimped against the insulation portion 120 of the electrical wire or cable 100 (see, for example, Figure 11 ).

[0037] As mentioned above, alternatively, another embodiment of a pair of bendable wire insulation clamp tabs or insulation wing portions 213, 214 is shown in Figures 12A and 12B, where the pair of bendable wire insulation clamp tabs or insulation wing portions 213, 214 are substantially aligned, directly opposite each other, or substantially symmetrical to each other. The pair of bendable wire insulation clamp tabs or insulation wing portions 213, 214 extend from a substantially concave or rounded floor member 245. After inserting the insulation portion 120 of the electrical wire or cable 100, the pair of bendable wire insulation clamp tabs or insulation wing portions 213, 214 are bent toward each other and toward the floor 245, as shown in Figure 13, to embed into the insulation portion 120 of the electrical wire or cable 100. As further shown in FIG. 13, the end portions 220, 221 of the pair of bendable wire insulation clamp tabs or insulation wing portions 213, 214, respectively, preferably penetrate a portion of the insulation portion 120, but preferably do not entirely penetrate the insulation portion 120 of the electrical wire or cable 100 or contact the core portion 110.

[0038] 14A shows the male electrical terminal 1 in a pre-locked position during insertion and threading into a connector assembly 90 or the like, with the male electrical terminal 1 shown in a front view. Here, the blade 7 is inserted first into the connector assembly 90, as will be understood, in accordance with the mating orientation of the male electrical terminal 1 with the respective connector assembly 90. Here, before insertion begins, the pair of wire clamping tabs or core crimping wing portions 10, 11 are deformed, clamped, or folded over and crimped against the wire core portion 110 of the electrical wire or cable 100, and the pair of wire insulation clamping tabs or insulation crimping wing portions 13, 14 are clamped, or folded over and crimped against the insulation portion 120 of the electrical wire or cable 100. As discussed above in the elevation view of the male electrical terminal 1 in FIG. 8A, also shown here in FIG. 14A are the lower and upper portions 62, 64, and the tapered tip 60 of the blade 7 extending from the body 5. Also shown is an upper surface 55 of panel shielding member 40, which has a height (preferably in its entirety) greater than or equal to an upper surface 58 of protruding guide member 53. Protruding guide member 53 extends from tongue member 15 above front end portion 20. Lever member 25 is now deflected downwardly by connector assembly 90, which allows body 5 of male electrical terminal 1 to be inserted into upper portion 90a of connector assembly 90, guided by protruding guide member 53 (see FIG. 14A).

[0039] As explained above and as can be seen in FIG. 14A , during insertion of the male electrical terminal 1 into the connector assembly 90, the protruding members 35, 37 (see, e.g., FIGS. 2A and 5A ) and the first and second support members 70, 75 (see, e.g., FIG. 5B ) prevent or protect at least the lever member 25 and the male terminal 1 from being overstressed or deformed (see FIGS. 14A and 14B ). Also, as explained above, the tapered portion 17 (see, e.g., FIG. 2A ) of the front end portion 20 of the body and the protruding guide member 53 help guide the male terminal 1 into the connector assembly 90 (see FIG. 14A ). The panel shielding member 40 protects the protruding guide member 53 (see, e.g., FIGS. 6A and 6B ) during insertion of the male electrical terminal 1 into the connector assembly 90 (see FIG. 14A ).

[0040] Figure 14B shows the male electrical terminal 1 fully inserted into connector assembly 90. As shown in Figure 10B, lever member 25 retracts upward to its normal relaxed state and is locked or secured at unattached end portion 28 by a member (not shown) within connector assembly 90. After this or at this point, as explained above (see, e.g., Figure 2A), a TPA device (not shown) is then received within space 50 above neck member 52 positioned between clamp or crimp area 3 and body 5 to ensure that male electrical terminal 1 remains locked, secured, and properly positioned within connector assembly 90.

[0041] Also shown in more detail in Figures 14A and 14B are upper and lower portions 90a, 90b of connector assembly 90. The orientation or polarity of male terminal 1 of the present invention is such that when male electrical terminal 1 of the present invention is oriented with connector assembly 90, with blades 7 entering first and respective front end portions 20 entering further, and inserted and mated into connector assembly 90, upper portion 69a at front portion 69 of body 5 and upper portion 71a at rear portion 71 are respectively received by upper portion 90a of connector assembly 90, while lower portion 80 of body 5 is respectively received by lower portion 90b of connector assembly 90. Upper portion 69a is guided within upper portion 90a by protruding guide member 52. Lower portion 80 is guided within lower portion 90b by tapered portion 17 and panel shielding member 40. 14A and 14B, the structural orientation or polarity of the male electrical terminal 1 of the present invention is such that the upper portions 69a, 71a of the body 5 reside within or are nested within the narrower upper portion 90a. Furthermore, here, the upper portions 69a and 71a are offset to one side compared to the lower portion 80 of the body 5. The lower portion 80 is wider than the upper portions 69a, 71a and resides within the wider lower portion 90b of the male electrical terminal 1. However, such structural orientation or polarity of the male electrical terminal 1 of the present invention when inserted into or nested within the connector assembly 90 is not limited thereto. That is, when oriented with connector assembly 90 and inserted into connector assembly 90 for mating, with blades 7 entering first and respective front end portions 20 entering further, male electrical terminal 1 of the present invention can have upper portions 69a, 71a of body 5 and upper portion 90a of connector assembly 90 that are wider than lower portions 80 of body 5 and lower portion 90b of connector assembly 90. Similarly, upper portions 69a and 71a can be centered or offset compared to lower portion 80 of body 5 during mating orientation, with blades 7 entering connector assembly 90 first.The polarity or orientation of the male electrical terminal 1 and the connector assembly 90 are substantially similar, thereby allowing them to substantially mate together.

[0042] While the above description is of preferred embodiments of the invention, it should be noted that other variations and modifications will be apparent to those skilled in the art and can be made without departing from the spirit or scope of the invention. Furthermore, features described in connection with one embodiment of the invention can be used with other embodiments, even if not explicitly stated above.

Claims

1. A male electrical terminal for insertion into a connector assembly comprising: a clamping or crimping area having a pair of wire clamping tabs or core crimping wing portions and a pair of wire insulation clamping tabs or insulation crimping wing portions, the clamping or crimping area having a plurality of cutouts extending on the floor member between at least said pair of wire clamping tabs or core crimping wing portions; a body attached to the clamp or crimp area, the body having a tongue member and a tapered portion; and a blade extending from the body It is characterized by the main body further includes a protruding guide member and a panel shielding member that shields the protruding guide member when the male electrical terminal enters the connector assembly; A portion of the panel shielding member is at the same height as the protruding guide member or is closer to the blade than the protruding guide member; the protruding guide member protrudes from the tongue member and is attached to the tongue member; The body has a front end and a rear end; The panel shielding member protrudes from the front end, the clamping or crimping area is attached to the rear end by a neck member; the tapered portion is disposed at the forward end; The upper surface of the panel shielding member is higher than the upper surface of the protrusion guide member, A male electrical terminal in which the protruding guide member tapers downward from the attachment point with the tongue member toward the front end so that the upper surface of the portion of the protruding guide member that fits along the panel shielding member is lower than the upper surface of the panel shielding member.

2. 2. The male electrical terminal according to claim 1, wherein an upper surface of said panel shielding member extending entirely along said panel shielding member is higher in height than an upper surface of said protruding guide member.

3. 2. The male electrical terminal of claim 1, wherein said tongue member comprises a lever member having an unattached end portion and an attached end portion.

4. the unattached end portion is characterized by a substantially U-shaped cross section; and 4. The male electrical terminal of claim 3, wherein said attached end portion is substantially L-shaped in cross section.

5. the unattached end portion of the lever member including a first projecting member extending therefrom; and 5. The male electrical terminal of claim 4, wherein the body includes a second projecting member extending therefrom, the first projecting member and the second projecting member substantially contacting each other upon downward movement of the lever member as the male electrical terminal enters the connector assembly.

6. 2. The male electrical terminal according to claim 1, wherein the body includes a support member at either a front portion or a rear portion of the body for supporting the body.

7. 2. The male electrical terminal of claim 1, wherein the blade has a substantially rectangular or substantially square cross-section.

8. A male electrical terminal for insertion into a connector assembly, the terminal comprising: a clamp or crimping area having a pair of wire clamping tabs or core crimping wing portions and a pair of wire insulation clamping tabs or insulation crimping wing portions; a body attached to the clamp or crimping area; and a blade extending from the body, the body including a protruding guide member and a panel shielding member for shielding the protruding guide member when the male electrical terminal enters the connector assembly; A portion of the panel shielding member is at the same height as the protruding guide member or is closer to the blade than the protruding guide member; When the male electrical terminal is fitted into the connector assembly, an upper portion of the male electrical terminal and a lower portion of the male electrical terminal are fitted into the upper portion of the connector assembly and the lower portion of the connector assembly, respectively, and the upper portion and the lower portion of the male electrical terminal have different widths; The body has a tongue member; the protruding guide member protrudes from the tongue member and is attached to the tongue member; The body has a front end and a rear end; The panel shielding member protrudes from the front end, the clamping or crimping area is attached to the rear end by a neck member; a tapered portion disposed at the forward end; The upper surface of the panel shielding member is higher than the upper surface of the protrusion guide member, A male electrical terminal to be inserted into a connector assembly, wherein the protruding guide member tapers downward from the attachment point with the tongue member toward the front end so that the upper surface of the portion of the protruding guide member that fits along the panel shielding member is lower than the upper surface of the panel shielding member.

9. 9. The male electrical terminal to be inserted into the connector assembly of claim 8, wherein the orientation or polarity of the male electrical terminal and the connector assembly is such that the width of the upper portion of the body of the male electrical terminal that fits within the upper portion of the connector assembly is narrower than the width of the lower portion of the body that fits within the lower portion of the connector assembly.

10. 9. The male electrical terminal to be inserted into the connector assembly according to claim 8, wherein an upper surface extending entirely along the panel shielding member is higher in height than an upper surface of the protruding guide member.

11. 9. The male electrical terminal for insertion into the connector assembly of claim 8, wherein the body includes a lever member and the tapered portion, the lever member having an unattached end portion and an attached end portion, the unattached end portion of the lever member including a first protruding member extending therefrom, and the body includes a second protruding member extending therefrom, the first protruding member and the second protruding member substantially contacting each other upon downward movement of the lever member as the male electrical terminal enters the connector assembly, preventing the male electrical terminal from being subjected to undue stress and deformation when fitted into the connector assembly.

12. 9. The male electrical terminal to be inserted into the connector assembly of claim 8, wherein the body includes a support member at either the front or rear portion of the body to support the body, and the support member at either the front or rear portion of the body provides elastic force at either the front or rear portion of the body, thereby preventing the male electrical terminal from being subjected to excessive stress and deformation when inserted into the connector assembly.

13. 2. The male electrical terminal of claim 1, wherein the floor member of the clamping or crimping area from which the pair of wire clamping tabs or core crimping wing portions extend is characterized by one of a substantially flat shape and a substantially rounded shape, and another floor member of the clamping or crimping area from which the pair of wire insulation clamping tabs or insulation crimping wing portions extend is characterized by a substantially rounded shape.

14. 2. The male electrical terminal of claim 1, wherein the pair of wire clamp tabs or core crimping wing portions include the plurality of notches that bite into wire core portions of the electric wire or cable to prevent the wire core portions from being pulled out from the pair of wire clamp tabs or core crimping wing portions, and the notches extend along the floor member to substantially near the ends of the wire clamp tabs or core crimping wing portions.

15. 15. The male electrical terminal of claim 14, wherein the pair of wire clamp tabs or core crimping wing portions include the plurality of notches that bite into a wire core portion of an electric wire or cable to prevent the wire core portion from being pulled out from the pair of wire clamp tabs or core crimping wing portions, and the notches extend along the floor member substantially to the ends of the wire clamp tabs or core crimping wing portions.

16. 15. The male electrical terminal of claim 14, wherein the pair of wire insulation clamp tabs or insulation crimp wing portions extend from opposite sides of the floor member, and one of the pair of wire insulation clamp tabs or insulation crimp wing portions is closer to a rear of the male electrical terminal than the other of the pair of wire insulation clamp tabs or insulation crimp wing portions.

17. 15. The male electrical terminal of claim 14, wherein the pair of wire insulation clamp tabs or insulation crimp wing portions extend from opposite sides of the floor member, the pair of wire insulation clamp tabs or insulation crimp wing portions substantially directly facing each other.

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