terminal connector

Abstract

The first terminal connector (300) comprises a component (302) including a first terminal post (306) oriented substantially perpendicular to a component surface (322), and a cap member (304) including a cap member surface (324) and a first borehole (310) oriented substantially perpendicular from the cap member surface (324), the first borehole (310) including a chamfer volume (328) configured to compress multiple windings of one or more wires (332, 334a, 334b) wound around the first terminal post (306) together between the component surface (322) and the chamfer volume (328) when the first terminal post (306) is inserted into the first borehole (310). The second terminal connector (500) comprises a component (502) including a component surface (522) and a cap member (504) including a cap member surface (524), a first groove (550) disposed on one of the component surface (522) or the cap member surface (524), a first tongue (556) protruding from the other of the cap member surface (524) or the component surface (522), the first tongue (556) including a chamfer volume (528) along a ridge of the first tongue (556), the chamfer volume (528) configured to compress one or more wires between the first groove (550) and the chamfer volume (528) when the first tongue (556) is inserted into the first groove (550).

Description

[Technical Field]

[0001] TECHNICAL FIELD This application relates to terminal connectors, and more particularly to terminal connectors with terminal posts and caps. [Background technology]

[0002] Vibrating conduit sensors, such as Coriolis mass flowmeters and vibrating densitometers, typically operate by vibrating one or more conduits in the presence of a fluid and then detecting the movement of the one or more vibrating conduits. For example, Figures 1A and 1B show an example of a Coriolis flowmeter 100. Figure 1A shows a front view of Coriolis flowmeter 100 with the top of the case cut off, and Figure 1B shows a side view of Coriolis flowmeter 100 without the case.

[0003] The exemplary Coriolis flowmeter 100 includes a case 102, conduits 104, 106, manifolds 108, 110, and a spacer 112. Fluid enters through an inlet and passes through the manifold 108, which splits the fluid into U-shaped conduits 104, 106. After passing through the conduits, the fluid eventually recombines through manifold 110 and exits the flowmeter through an outlet.

[0004] Coriolis flowmeter 100 further includes a driver 114 and pickoffs 116 and 118. Driver 114 and pickoffs 116 and 118 each include a coil and a magnetic component. In the exemplary embodiment of Coriolis flowmeter 100, the coil and magnetic components of driver 114 and pickoffs 116 and 118 are coupled to adjacent, opposing conduits 104 and 106, respectively. Driver 114 is positioned substantially centrally along the axial length of conduits 104 and 106, and pickoffs 116 and 118 are positioned on opposite sides of driver 114. Driver 114 vibrates the flow tubes in opposite directions, and pickoffs 116 and 118 detect a phase difference or twist of the flowmeter due to the Coriolis effect that occurs when the flowing fluid is vibrated by driver 114. The phase difference measured via pickoffs 116 and 118 can be used to determine mass flow or volumetric flow measurements. Alternatively, as will be appreciated by those skilled in the art, the frequency determined via either pickoff 116 or 118 can be used to determine the density of the fluid being measured.

[0005] Those skilled in the art will appreciate that Coriolis flowmeter 100 is merely one example of a vibrating conduit sensor. In other embodiments, the Coriolis flowmeter may have a single flow tube, and portions of driver 114 and pickoffs 116, 118 may be coupled to a support instead of the opposing flow tube. In further embodiments, the Coriolis flowmeter may have three or more flow tubes, and driver 114 and pickoffs 116, 118 may be coupled to any combination of flow tubes and supports. Those skilled in the art will further appreciate that some vibrating densitometers use components of driver 114 and pickoffs 116, 118 to drive and sense the vibration of a vibrating member immersed in a fluid.

[0006] As mentioned above, the driver 114 and pickoffs 116, 118 typically comprise a coil and magnet assembly. The coil portion typically comprises a bobbin spindle with a coil wire wound around it and is used as an electromagnet to drive or sense the vibration of one or more conduits / vibration members. The ends of the coil wire must be coupled to input / output wires that connect the coil portion of the driver / pickoff to the control electronics. In conventional vibrometers, the respective ends of the coil wire and input / output wires are soldered or crimped to terminals located on the bobbin spindle.

[0007] For example, FIG. 2 illustrates a conventional coil section 200. The coil section 200 includes a substantially cylindrical body with a bobbin spindle 202 on which the coil wire can be wound. The conventional coil section 200 further includes terminals 204 and 206. The coil and / or terminal wires are coupled to the terminals 204 and 206 using crimps 208 and 210. In some embodiments, a vibrometer with one driver and two pickoffs may require six to twelve wire bonds to the electromagnet terminals of the coil section 200. However, soldering the wires to the terminals requires additional labor during assembly and can become more difficult as the wires become smaller in smaller meters / components. Additionally, there is increasing pressure to remove lead solder from flowmeter assemblies. Furthermore, the crimps 208 and 210 pinch the wire, causing stress concentrations and increasing the likelihood of the wire breaking and failing. For at least these reasons, achieving good contact between the wire and the terminals, either by soldering or crimping, can be difficult. Furthermore, once the meter is in operation, it may be used in a corrosive or thermally dynamic environment, which may further exacerbate weaknesses in the wire connections.

[0008] What is needed is a method of coupling one or more wires to a terminal that is easy to assemble, is robust, and works well with smaller wires. Summary of the Invention

[0009] According to a first aspect, a terminal connector is provided. The terminal connector includes a component member and a cap member. The component member has a component member surface with a first terminal post oriented substantially perpendicular to the component member surface. The cap member has a cap member surface and a first borehole oriented substantially perpendicular from the cap member surface. The first borehole includes a chamfer volume configured to compress multiple windings of one or more wires wound around the first terminal post between the component member surface and the chamfer volume when the first terminal post is inserted into the first borehole.

[0010] A method of assembling a terminal connector according to a first aspect is provided. The terminal connector according to the first aspect includes a component member and a cap member. The component member has a component member surface having a first terminal post oriented substantially perpendicular to the component member surface. The cap member has a cap member surface and a first borehole oriented substantially perpendicular from the cap member surface. The first borehole includes a chamfer volume configured to compress multiple windings of one or more wires wound around the first terminal post between the component member surface and the chamfer volume when the first terminal post is inserted into the first borehole. The method includes the step of inserting the first terminal post into the first borehole.

[0011] A terminal connector according to a second aspect is provided. The terminal connector according to the second aspect includes a component and a cap member. The component includes a component surface, and the cap member includes a cap member surface. A first groove is disposed on one of the component surface or the cap member surface. A first tongue protrudes from the other of the cap member surface or the component surface. The first tongue includes a chamfer volume along a ridge of the first tongue, and the chamfer volume is configured to compress one or more wires between the first groove and the chamfer volume of the first tongue when the first tongue is inserted into the first groove.

[0012] A method of assembling a terminal connector according to a second aspect is provided. The terminal connector according to the second aspect includes a component member and a cap member. The component member includes a component member surface, and the cap member includes a cap member surface. A first groove is disposed on one of the component member surface or the cap member surface. A first tongue protrudes from the other of the cap member surface or the component member surface. The first tongue includes a chamfer volume along a ridge of the first tongue, and the chamfer volume is configured to compress one or more wires between the first groove and the chamfer volume of the first tongue when the first tongue is inserted into the first groove. The method includes the step of inserting the first tongue into the first groove.

[0013] [Aspect] According to one aspect of the terminal connector of the first aspect, the first terminal post can include plastic, and the first borehole and the first terminal post can be configured to facilitate a heat crimp fit when the first terminal post is inserted into the first borehole and heat is applied to the first terminal post.

[0014] According to one aspect of the terminal connector of the first aspect, the component member may further include a bobbin spindle.

[0015] According to one aspect of the terminal connector of the first aspect, the chamfer volume may have a conical annular shape.

[0016] According to one aspect of the terminal connector of the first aspect, the component may further include a second terminal post oriented substantially perpendicular to the component surface, and the cap may further include a second borehole oriented substantially perpendicular from the cap surface and positioned to be inserted by the second terminal post when the first terminal post is inserted into the first borehole.

[0017] According to one aspect of the terminal connector of the first embodiment, the terminal connector may further comprise a first terminal wire wound with one or more first terminal wire windings around the first terminal post.

[0018] According to one aspect of the terminal connector of the first aspect, the terminal connector may further comprise a first electronic wire comprising one or more first electronic wire windings around the first terminal post.

[0019] According to one aspect of the terminal connector of the first aspect, the first terminal wire can have a first gauge that is lower than the second gauge of the first electronic wire.

[0020] According to the method of the first aspect, the method may further include winding a first terminal wire around the first terminal post to create one or more first terminal wire windings.

[0021] According to the method of the first aspect, the method may further include winding a first electronic wire around the first terminal post to create one or more windings of the first electronic wire.

[0022] According to one aspect of the method of the first aspect, the first terminal wire may have a first gauge that is lower than a second gauge of the first electronic wire.

[0023] According to one aspect of the method of the first aspect, the component may further comprise a second terminal post oriented substantially perpendicular to the component surface, the cap member may further comprise a second borehole oriented substantially perpendicular from the cap member surface, and the step of inserting the first terminal post into the first borehole may further comprise inserting the second terminal post into the second borehole.

[0024] According to one aspect of the method of the first aspect, the component may further comprise a bobbin spindle, and the method may further include winding the first electronic wire around the bobbin spindle and winding the second electronic wire around the second terminal post, the first electronic wire and the second electronic wire being opposite ends of a single electronic wire.

[0025] According to one aspect of the method of the first aspect, the method may further include applying heat to the first terminal post.

[0026] According to one aspect of the terminal connector of the second aspect, the component may further include a second groove disposed on one of the component surface or the cap member surface, and a second tongue portion protruding from the other of the component surface or the cap member surface.

[0027] According to one aspect of the terminal connector of the second aspect, the component member may further include a bobbin spindle.

[0028] According to one aspect of the terminal connector of the second aspect, when the first tongue is disposed within the first groove, the chamfer volume can form a void with a triangular cross section.

[0029] According to one aspect of the terminal connector of the second aspect, the component member may further include a first alignment post, and the cap member may further include a first alignment borehole, the first alignment post configured to substantially fill the first alignment borehole when mated with each other.

[0030] According to one aspect of the terminal connector of the second aspect, the first alignment post may comprise plastic, and the first alignment post and the first alignment borehole may be configured to facilitate a heat crimp fit when the first alignment post is inserted into the first alignment borehole and heat is applied to the first alignment post.

[0031] According to one aspect of the terminal connector of the second aspect, the component member may further include a second alignment post, and the cap member may further include a second alignment borehole, the second alignment post configured to substantially fill the second alignment borehole when mated with each other.

[0032] According to one aspect of the terminal connector of the second aspect, the terminal connector can further include a first terminal wire disposed between the first tongue and the first groove.

[0033] According to one aspect of the terminal connector of the second aspect, the first electronic wire may be disposed between the first tongue and the first groove.

[0034] According to one aspect of the terminal connector of the second aspect, the first terminal wire may have a first gauge that is lower than a second gauge of the first electronic wire.

[0035] According to one aspect of the method of the second aspect, the method may further include the step of positioning a first terminal wire along the first groove.

[0036] According to one aspect of the method of the second aspect, the method may further include the step of arranging a first electronic wire along the first groove.

[0037] According to one aspect of the method of the second aspect, the component may further comprise a bobbin spindle, and the method may further include winding the first electronic wire onto the bobbin spindle.

[0038] According to one aspect of the method of the second aspect, the component member may further comprise a first alignment post and the cap member may further comprise a first alignment borehole, the first alignment post being configured to substantially fill the first alignment borehole when mated with each other, and the method may further include the step of inserting the first alignment post into the first alignment borehole.

[0039] According to one aspect of the method of the second aspect, the method may further include applying pressure to secure the cap member onto the component and applying heat to the first alignment post to create a heat staked fit between the cap member and the component. [Brief explanation of the drawings]

[0040] Like reference numbers represent like elements in all drawings. The drawings are not necessarily to scale. [Figure 1A] FIG. 1A shows a front view of a Coriolis flowmeter 100 according to one embodiment. [Figure 1B] FIG. 1B illustrates a side view of Coriolis flowmeter 100 according to one embodiment. [Figure 2] FIG. 2 shows a conventional coil section 200. [Figure 3A] FIG. 3A illustrates a terminal connection 300 according to one embodiment. [Figure 3B] FIG. 3B illustrates a terminal connection 300 according to one embodiment. [Figure 3C] FIG. 3C illustrates a terminal connection 300 according to one embodiment. [Figure 3D] FIG. 3D illustrates a terminal connection 300 according to one embodiment. [Figure 3E] FIG. 3E illustrates component 302 according to one embodiment. [Figure 3F] FIG. 3F illustrates component 302 according to one embodiment. [Figure 4] FIG. 4 illustrates a method 400 according to one embodiment. [Figure 5A] FIG. 5A illustrates a terminal connection 500 according to one embodiment. [Figure 5B] FIG. 5B illustrates a terminal connection 500 according to one embodiment. [Figure 5C] FIG. 5C illustrates a terminal connection 500 according to one embodiment. [Figure 6] FIG. 6 illustrates a method 600 according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0041] 3A-6 and the following description depict specific examples to teach those skilled in the art how to make and use the best mode of the present application. For the purpose of teaching inventive principles, some conventional aspects have been simplified or omitted. Those skilled in the art will recognize variations from these examples that fall within the scope of the present application. Those skilled in the art will understand that the features described below can be combined in various ways to form multiple variations of the present application. Consequently, the present application is not limited to the specific examples described below, but only by the claims and their equivalents.

[0042] 3A-3F illustrate a terminal connector 300, or a portion thereof, according to one embodiment of the present application. FIG. 3A illustrates an exploded view of the disassembled terminal connector 300, and FIG. 3B illustrates a perspective view of the assembled terminal connector 300. FIG. 3C illustrates a cross-sectional view of the terminal connector 300 taken along section A-A' shown in FIG. 3B. FIG. 3D illustrates a detailed cross-section of FIG. 3C. FIGS. 3E and 3F illustrate a component 302, with FIG. 3E illustrating the component 302 wrapped with a first terminal wire 332 and FIG. 3F illustrating the component 302 wrapped with a first terminal wire 332 and at least a first electronic wire 334a.

[0043] Terminal connector 300 can comprise any electronic device that can be coupled to one or more input / output wires. In further embodiments, terminal connector 300 can be connected to an electronic device or computer that controls and / or monitors the electronic device. In further embodiments, terminal connector 300 can couple portions of one or more electronic devices together.

[0044] Terminal connector 300 includes a component 302. Component 302 may include an electronic device or element. In some embodiments, component 302 may further include, for example, a bobbin spindle 314. In some embodiments, bobbin spindle 314 may include an annular recess in a substantially cylindrical body of component 302 or a flanged or flangeless spindle member. However, in further embodiments, bobbin spindle 314 may have any form or shape known to those skilled in the art.

[0045] Component 302 further includes a component surface 322, best seen in FIG. 3A. In an embodiment of terminal connector 300, component surface 322 includes, but is not intended to be limited to, a substantially flat, circular surface on one end of a substantially cylindrically shaped component body. In some embodiments, component surface 322 can include any shape capable of coupling to cap member 304.

[0046] In the exemplary embodiment of component 302, component surface 322 includes four notches for wire passages 323. Wire passages 323 may allow wires to pass through component surface 322. In some embodiments, wire passages 323 may allow wires coupled to one or more terminal posts to pass through the body of component 302 and be wound, for example, around bobbin spindle 314. In some embodiments, wire passages 323 allow input / external wires to pass through the body of component 302. While four elongated wire passages 323 are depicted on component surface 322 in FIGS. 3A-3F , one skilled in the art will appreciate that this is not intended to be limiting. In some embodiments, terminal connector 300 may have zero or any number of wire passages 323, each having any shape.

[0047] Component 302 further includes a first terminal post 306 oriented substantially perpendicular to component surface 322. By substantially perpendicular, it is meant that the axis of first terminal post 306 is oriented within 0, 5, 10, 15, or 20 degrees of a normal to component surface 322. First terminal post 306 may include any cylinder, tab, or extension that can be used to secure or electrically couple any wires associated with terminal connector 300.

[0048] In some embodiments, component 302 may be fabricated from a metal such as copper or aluminum. However, in further examples, it may be fabricated from plastic or any other material known to those skilled in the art. In some embodiments, first terminal post 306 may be fabricated from metal or plastic, with other portions of component 302 being fabricated from the same or different materials. In embodiments in which first terminal post 306 comprises metal, this may help to facilitate an electrical connection between wires coupled between component 302 and cap member 304. In embodiments in which first terminal post 306 comprises plastic, this may help to facilitate a heat stake bond between component 302 and cap member 304, as will be further described below. In further embodiments, first terminal post 306 may comprise a combination of metal and plastic, as will be understood by those skilled in the art.

[0049] Terminal connector 300 further includes cap member 304. Cap member 304 may include any cover operable to couple to post 306 and apply pressure to wires wrapped around the terminal posts of component 302. Cap member 304 includes cap member surface 324 (the back side of cap member 304 in FIG. 3A ; see also FIG. 3C ). In embodiments of terminal connector 300, cap member surface 324 includes a substantially flat, circular surface on the component-facing end of a substantially cylindrically shaped cap member body. However, this is not intended to be limiting. In some embodiments, cap member surface 324 may include any shape capable of coupling to component 302.

[0050] In some embodiments, cap member surface 324 and component surface 322 can be configured to contact when terminal connector 300 is fully assembled. In some embodiments, cap member surface 324 and component surface 322 can be configured to be in close proximity but not actually touch when terminal connector 300 is fully assembled. In such examples, cap member surface 324 and component surface 322 can be configured to provide minimal space between component 302 and cap member 304 when terminal connector 300 is assembled.

[0051] The cap member 304 further comprises a first borehole 310 oriented substantially perpendicular from the cap member surface 324. By substantially perpendicular, it is meant that the axis of the first borehole 310 is oriented within 0°, 5°, 10°, 15°, or 20° of the normal to the cap member surface 324. The first borehole 310 passes through the cap member surface 324. In some embodiments, the first borehole 310 may or may not penetrate completely through the opposing end surface 326 of the cap member 304.

[0052] 3D , first borehole 310 can be seen to include a chamfer volume 328 between first borehole 310, first terminal post 306, and component surface 322. Chamfer volume 328 comprises an annular portion of material removed between a corner of first borehole 310 and component surface 322. Chamfer volume 328 can comprise a control volume of any shape configured to contain or compress together multiple windings 330 of one or more wires wound around first terminal post 306 between component surface 322, first borehole 310, and first terminal post 306 when first terminal post 306 is inserted into first borehole 310. In some embodiments, chamfer volume 328 can apply sufficient pressure to provide secure contact between one or more wire windings contained within chamfer volume 328 or between one or more wire windings and component 302. In some embodiments, the first chamfer volume 328 can be configured to prevent damage to one or more windings of the wire.

[0053] In some embodiments, the chamfer volume 328 has a conical annular shape, best seen in FIG. 3D . The conical annular shape has a triangular cross-section on each side of the terminal post 306. One skilled in the art will recognize that the conical annular shape can provide sufficient volume to compress but not deform two different gauge wires wound together when the cap member 304 is installed. The conical annular shape can further enable the advantage of easier removal of the cap member 304 from a mold during a plastic injection molding process when manufacturing the cap member 304.

[0054] The conical annular shape shown in Figure 3D is not intended to be limiting, and one skilled in the art will readily appreciate that the chamfer volume 328 can be configured to include any cross-sectional shape suitable for accommodating a desired wire gauge with a desired number of wire turns.

[0055] In some embodiments, the portion of the terminal post 306 that forms the outer edge of the chamfered volume 328 may be fabricated from metal to facilitate connections between the wires bonded thereto.

[0056] 3D , it can be seen that terminal connector 300 can further include a plurality of windings 330. In some embodiments, plurality of windings 330 can include a first terminal wire 332 having one or more first terminal wire windings around first terminal post 306. In some embodiments, first terminal wire 332 can connect an electronic component of component 302 to an external electronic component.

[0057] In some embodiments, the plurality of windings 330 may further include a first electronic wire 334a having one or more first electronic wire windings around the first terminal post 306. In some embodiments, the first electronic wire 334a may include a coil wire or any other wire associated with the component 302.

[0058] In some embodiments, the first terminal wire 332 may have a first gauge that is lower than the second gauge of the first electronic wire 334a. This may occur, for example, when a higher gauge wire is used for the coil wire and a lower gauge wire is used for the input / output wire. In some embodiments, the coil wire may be 34-46 gauge and the input / output wire may be 32 gauge.

[0059] In some embodiments, a first electronic wire 334a having a higher gauge may be wound between the component 302 and a first terminal wire 332 having a lower gauge. The conical annular chamfer volume 328 provides an improved fit for this particular configuration, providing reliable electrical contact between the first electronic wire 334a and the first terminal wire 332 having different gauges, while providing different spatial volumes for each wire to avoid crimping and damage.

[0060] In some embodiments, component 302 may further include a second terminal post 308 oriented substantially perpendicular to component surface 322. Second terminal post 308 may be used to couple a second terminal wire 335 to component 302, as shown in FIG.

[0061] In some embodiments, each of the first and second terminal posts 306, 308 may be paired with a separate cap member 304. However, in further embodiments, the cap member 304 may include a second borehole 312 oriented to be substantially perpendicular from the cap member surface 324 and positioned to couple around the second terminal post 308 when the first terminal post 306 is inserted into the first borehole 310. In some embodiments, the second terminal post 308 may have similar features to the first terminal post 306, and the second borehole 312 may have similar features to the first borehole 310.

[0062] In some embodiments, the first borehole 310 and the first terminal post 306 may be configured to facilitate a heat stake fit when the first terminal post 306 is inserted into the first borehole 310 and heat is applied to the first terminal post 306. In such embodiments, the cap member 304 may be fabricated from plastic.

[0063] The heat staking fit may include applying heat to the first terminal post 306 of the component 302 until the terminal post 306 is at least partially melted around the first bore hole 310. In embodiments in which the component 302 further includes a second terminal post 308, heat may also be applied to the second terminal post 308. In some embodiments, the heat staking fit may further include applying pressure between the component 302 and the cap member 304 to bring the members closer together during the melting operation. The pressure and applied heat allow the melted regions of the terminal posts 306, 308 to reform around the one or more bore holes 310, 312. In this manner, the heat staking fit may firmly join the component 302 to the cap member 304.

[0064] In some embodiments, first terminal post 306 and first borehole 310 may be substantially cylindrical in shape. In other embodiments, first terminal post 306 and first borehole 310 may comprise loosely conical shaped members designed to fit snugly together when fully inserted. However, in further embodiments, first terminal post 306 and first borehole 310 may comprise any elongated shape configured to fit snugly together when pressure is applied between component member 302 and cap member 304.

[0065] In further embodiments, first borehole 310 and terminal post 306 may be coupled to one another by pressure or a press fit. In further embodiments, fasteners or adhesives may be used to couple component 302 to cap member 304. In some embodiments, silicone adhesive may be used. In some embodiments, any combination of heat staking, adhesive, and fasteners may be used to couple component 302 to cap member 304. In further embodiments, component 302 and cap member 304 may be coupled to one another using any method known to one of ordinary skill in the art.

[0066] 4 illustrates a method 400 for assembling the terminal connection 300 according to one embodiment. The method 400 includes a step 412 in which the first terminal post 306 is inserted into the first borehole 310, as described above.

[0067] In some embodiments, method 400 may include additional steps. For example, method 400 may include any combination of steps 402-411 or 414.

[0068] In some embodiments, the method 400 may further include step 402. In step 402, the first electronic wire 334a may be wrapped around the first terminal post 306. For example, FIG. 3E shows the first electronic wire 334a wrapped around the first terminal post 306.

[0069] In some embodiments, the method 400 can further include step 404. In step 404, the first electronic wire 334a can be wrapped around the bobbin spindle 314. This can enable the component 302 to be used as an electromagnet, as described above. Figure 3E also shows the first electronic wire 334a wrapped around the first terminal post 306.

[0070] In some embodiments, the method 400 can further include step 406. In step 406, the first electronic wire 334a can be wrapped around the second terminal post 308. For example, FIG. 3E also shows the second electronic wire 334b ​​wrapped around the second terminal post 308.

[0071] In some embodiments of step 406, a second electronic wire 334b ​​may be wrapped around the second terminal post 308 instead of the first electronic wire 334a as described above.

[0072] In some embodiments, method 400 may further include step 408. In step 408, first terminal wire 332 may be wrapped around first terminal post 306 to create one or more first terminal wire windings, as described above. For example, FIG. 3E shows first terminal wire 332 wrapped once around first terminal post 306.

[0073] In some embodiments, method 400 can further include step 410. In step 410, a second terminal wire 335 can be wrapped around second terminal post 308, as shown in FIG. 3F. This configuration can be used to create an electromagnet that connects to two input / output wires, as described above.

[0074] In some embodiments, the first electronic wire 334a and the second electronic wire 334b ​​can comprise opposite ends of the same electronic wire. For example, if the component 302 includes a bobbin spindle 314, the first electronic wire 334a and the second electronic wire 334b ​​can comprise opposite ends of a wire used to wind the bobbin spindle 314.

[0075] In some embodiments, the method 400 can further include step 412. In step 412, an adhesive can be applied to the cap member surface 324 or the component member surface 322, as described above.

[0076] In some embodiments, the method 400 may further include step 414. In step 414, heat may be applied to the first terminal post 306, as described above.

[0077] In embodiments of the terminal connection 300 that include a second terminal post 308, the method 400 may further include inserting the second terminal post 308 into the second borehole 312. In some embodiments, the method 400 may further include applying heat to the second terminal post 308, as described above.

[0078] Figures 5A-5C illustrate a further terminal connection 500, according to one embodiment. Figures 5A and 5B illustrate an exploded view of the disassembled terminal connector 500, and Figure 5C illustrates a cross-sectional view of the assembled terminal connector 500 taken along section B-B' shown in Figure 5B.

[0079] Similar to terminal connector 300, terminal connector 500 can comprise any electronic device capable of being coupled to one or more terminal wires. In some embodiments, terminal connector 500 can be connected to electronic equipment or a computer that controls and / or monitors the electronic device. In further embodiments, terminal connector 500 can couple portions of one or more electronic devices together.

[0080] Terminal connector 500 includes a component 502. Component 502 may include an electronic element. In some embodiments, component 502 may further include, for example, a bobbin spindle 514. In some embodiments, bobbin spindle 514 may include an annular recess in the substantially cylindrical body of component 502.

[0081] Component 502 further comprises component surface 522, which can be best seen in FIG. 5B . In an embodiment of terminal connector 500, component surface 522 comprises, but is not intended to be limited to, a substantially flat, circular surface at one end of a substantially cylindrically shaped component body. In some embodiments, component surface 522 can comprise any shape capable of coupling to cap member 504.

[0082] Terminal connector 500 further includes a cap member 504. Cap member 504 may comprise any cover operable to couple to component 502 to provide a wire connection. Cap member 504 includes a cap member surface 524. In embodiments of terminal connector 500, cap member surface 524 comprises a substantially flat, circular surface on the component-facing end of a substantially cylindrically shaped cap member body. However, this is not intended to be limiting. In some embodiments, cap member surface 524 may include any shape capable of coupling to component 502.

[0083] Terminal connector 500 further includes a first groove 550 and a first tongue 556. First groove 550 can be located on one of component surface 522 or cap member surface 524, while first tongue 556 can be located on the other of component surface 522 or cap member surface 524, such that first groove 550 and first tongue 556 are aligned opposite each other when terminal connector 500 is assembled.

[0084] The first groove 550 comprises an elongated, linear depression in the surface in which it is disposed. In Figures 5A-5C, it can be seen that an example of the first groove 550 is substantially linear along its length and triangular in cross section across its length. However, this is not intended to be limiting. In some embodiments, the first groove 550 may follow a curved path. In some embodiments, the first groove 550 may traverse the entire surface of the terminal connector 500, or may traverse only a short portion of the terminal connector 500.

[0085] While the first groove 550 is depicted as having a triangular cross-section, this is also not intended to be limiting. In further embodiments, the first groove 550 may have a rectangular or semicircular cross-sectional area. Those skilled in the art will readily appreciate that other shapes or configurations of the first groove 550 are possible that allow wires to be bonded therein.

[0086] First tongue 556 comprises an elongated protrusion disposed on a surface thereof that substantially follows the locus of first groove 550. In the embodiment of terminal connector 500, first tongue 556 is substantially straight and linear along its length, and has a triangular cross section transverse to its length. Those skilled in the art will appreciate that the straight embodiment, as discussed above, is not intended to be limiting.

[0087] First tongue 556 includes a chamfer 528 extending along the tip of its projection from the surface on which it is disposed, configured to compress one or more wires between first groove 550 and component 502 coupled to cap member 504.

[0088] In some embodiments, the chamfer 528 may axially truncate the cross-sectional shape of the first tongue 556. In some embodiments, the chamfer 528 can form a triangular cross-sectional control volume, or void, between the first tongue 556 and the first groove 550 when the cap member 504 is coupled to the component 502, as seen in FIG.

[0089] Those skilled in the art will readily appreciate that the example of terminal connector 500 is not intended to be limiting. In some embodiments, the shape of chamfer 528 can comprise any suitable cross-sectional shape operable to compress the wire between first groove 550 and first tongue 556. For example, chamfer 528 can further comprise a rectangular or semicircular cross-sectional area.

[0090] In some embodiments, component 502 may be fabricated from a metal, such as copper or aluminum. In some embodiments, component 502 may be fabricated from plastic or any other material known to one of ordinary skill in the art. In some embodiments, portions of component 502 may comprise different materials. For example, first tongue 556 may be formed from metal to facilitate connection between wires coupled thereto, while the remainder of component 502 or cap member 504 may comprise plastic.

[0091] By mating first groove 550 with first tongue 556, terminal connector 500 can provide a connection between a wire and either an electronic device or another wire.

[0092] In some embodiments, the first tongue 556 and the first groove 550 may be constructed from any combination of metal, plastic, or resin, hi further embodiments, the first tongue 556 and the first groove 550 may be constructed from any material known to one of ordinary skill in the art.

[0093] In some embodiments, terminal connector 500 may further include a second groove 552 located on one of component surface 522 or cap member surface 524, and a second tongue 554 protruding from the other of component surface 522 or cap member surface 524. Second groove 552 and second tongue 554 may be similar to first tongue 556 and first groove 550 described above. However, in further embodiments, second tongue 554 and second groove 552 may have a different shape or layout than first tongue 556 and first groove 550.

[0094] The second groove 552 and second tongue 554 can function to couple the second terminal wire to the second electronic wire, similar to the second terminal post 308 and second borehole 312 described above. In some embodiments, the first electronic wire and the second electronic wire can comprise opposite ends of a single electronic wire. In some embodiments, this single electronic wire can be further wound around the bobbin spindle 314.

[0095] In some embodiments, component 502 further comprises a first alignment post 506 oriented to be substantially perpendicular to component surface 522. By substantially perpendicular, it is meant that the axis of first alignment post 506 is oriented 0, 5, 10, 15, or 20 degrees from the normal to component surface 522. First alignment post 506 can comprise any cylinder, tab, or extension that can be used to align or couple component 502 to cap member 504.

[0096] The cap member 504 further comprises a first alignment borehole 510, and the first alignment post 506 is configured to, when inserted, substantially fill the first alignment borehole 510. In some embodiments, the first alignment borehole 510 may or may not extend completely through the opposing face 526 of the cap member 504.

[0097] In some embodiments, first alignment post 506 and first alignment borehole 510 may be configured to facilitate a heat stake fit when first alignment post 506 is inserted into first alignment borehole 510 and heat is applied to first alignment post 506. In some embodiments, first alignment post 506 may include plastic to facilitate the heat stake fit, as described above.

[0098] In some embodiments, component 502 can further comprise a second alignment post 508 similar to first alignment post 506, and cap member 504 can further comprise a second alignment borehole 512 similar to first alignment borehole 510. Second alignment post 508 can be configured to substantially fill second alignment borehole 512 when mated together.

[0099] As shown in FIG. 5C, in some embodiments, the terminal connector 500 may further include a first terminal wire 516 disposed between the first tongue 556 and the first groove 550.

[0100] In a further embodiment, the first electronic wire 518 may be disposed between the first tongue 556 and the first groove 550 .

[0101] In some embodiments, first terminal wire 516 may have a first gauge that is lower than a second gauge of first electronic wire 518 .

[0102] 6 illustrates a method 600 for assembling the terminal connection 500 according to one embodiment. The method 600 includes a step 614. In the step 614, the first tongue 556 is inserted into the first groove 550.

[0103] In some embodiments, method 600 can include additional steps, for example, method 600 can include any combination of steps 602-612 or 616-618.

[0104] In some embodiments, method 600 can further include step 602. In step 602, first electronic wire 518 can be positioned along first groove 550. This allows terminal connector 500 to reliably electrically couple first terminal wire 516 and first electronic wire 518 to one another, as described above.

[0105] In embodiments in which the component 502 includes an electromagnet, the method 600 may further include a step 604. In step 604, the first electronic wire 518 may be wrapped around the bobbin spindle 514, as described above.

[0106] In some embodiments, the method 600 may further include a step 606. In the step 606, the first electronic wire 518 may be disposed within the second groove 552.

[0107] In an embodiment of step 606 , a second electronic wire can be placed in the second groove 552 in place of the first electronic wire 518 .

[0108] In some embodiments, the method 600 may further include a step 608. In the step 608, the first terminal wire 516 may be placed along the first groove 550, as described above.

[0109] In some embodiments, the method 600 may further include step 610. In step 610, a second terminal wire may be placed along the second groove 552, as described above.

[0110] In some embodiments, the method 600 can further include step 611. In step 611, an adhesive can be applied to the cap member surface 524 or the component member surface 522, as described above.

[0111] In some embodiments, the method 600 may further include step 612. In step 612, the first alignment post 506 may be inserted into the first alignment borehole 510, as described above.

[0112] In some embodiments, the method 600 can further include step 616. In step 616, pressure can be applied to seat the cap member 504 onto the component 502, as described above.

[0113] In some embodiments, the method 600 can further include step 618. In step 618, heat can be applied to the first alignment post 506 to create a heat stake fit between the cap member 504 and the component member 502, as described above.

[0114] Embodiments of the present application can enable robust, easy-to-assemble, solderless terminal connections. The embodiments provide terminal connections that allow wires to be coupled to each other or to electronic components without damaging the wires themselves. The embodiments provide terminal connections that are particularly suitable for connecting wires of different gauges to each other. The embodiments provide terminal connections that are particularly suitable for use in driver or pick-off electromagnetic coils for vibratory flow meters.

[0115] The detailed description of the above embodiments is not an exhaustive description of all examples contemplated by the inventors to be within the scope of the present application. Indeed, those skilled in the art will recognize that certain elements of the above examples can be combined or deleted in various ways to create further examples, and that such further examples will fall within the scope and teachings of the present application. It will also be apparent to those skilled in the art that the above examples can be combined, in whole or in part, to create additional examples within the scope and teachings of the present application. Accordingly, the scope of the present application should be determined from the claims that follow.

Claims

1. a component (302) including a component surface (322) having a first terminal post (306) oriented substantially perpendicular to said component surface (322); a cap member (304) including a cap member surface (324) and a first borehole (310) oriented substantially perpendicularly from the cap member surface (324); Equipped with The terminal connector (300) includes a chamfer volume (328), and when the first terminal post (306) is inserted into the first borehole (310), the chamfer volume (328) is configured to compress multiple windings of one or more wires (332, 334a, 334b) wound around the first terminal post (306) together between the component surface (322) and the chamfer volume (328).

2. 2. The terminal connector (300) of claim 1, wherein the first terminal post (306) comprises plastic, and the first bore hole (310) and the first terminal post (306) are configured to facilitate a heat crimp fit when the first terminal post (306) is inserted into the first bore hole (310) and heat is applied to the first terminal post (306).

3. The terminal connector (300) of claim 1 or 2, wherein the component (302) further comprises a bobbin spindle (314).

4. The terminal connector (300) of any of claims 1 to 3, wherein the chamfer volume (328) has a conical annular shape.

5. 5. The terminal connector (300) of claim 1, wherein the component (302) further comprises a second terminal post (308) oriented substantially perpendicular to the component surface (322), and the cap member (304) further comprises a second borehole (312) oriented substantially perpendicular from the cap member surface (324) and positioned to be inserted by the second terminal post (308) when the first terminal post (306) is inserted into the first borehole (310).

6. 6. The terminal connector (300) of claim 1, further comprising a first terminal wire (332) wound with one or more first terminal wire windings around the first terminal post (306).

7. The terminal connector (300) of claim 6, further comprising a first electronic wire (334a) comprising one or more first electronic wire windings around the first terminal post (306).

8. The terminal connector (300) of claim 7, wherein the first terminal wire (332) has a first gauge that is lower than a second gauge of the first electronic wire (334a).

9. A method for assembling a terminal connector (300) according to any one of claims 1 to 5, comprising the steps of: The method includes inserting the first terminal post (306) into the first borehole (310).

10. 10. The method of claim 9, further comprising winding a first terminal wire (332) around the first terminal post (306) to create one or more first terminal wire windings.

11. The method of claim 10, further comprising winding a first electronic wire (334a) around the first terminal post (306) to create one or more first electronic wire windings.

12. The method of claim 11, wherein the first terminal wire (332) has a first gauge that is lower than a second gauge of the first electronic wire (334a).

13. the component (302) further comprises a second terminal post (308) oriented substantially perpendicular to the component surface (322); the cap member (304) further comprising a second borehole (312) oriented substantially perpendicularly from the cap member surface (324); 13. The method of any of claims 9 to 12, wherein the step of inserting the first terminal post (306) into the first borehole (310) further comprises inserting the second terminal post (308) into the second borehole (312).

14. the component (302) further comprising a bobbin spindle (314); Winding a first electronic wire (334a) around the bobbin spindle (314); wrapping a second electronic wire (334b) around said second terminal post (308); further comprising The method of claim 13, wherein the first electronic wire (334a) and the second electronic wire (334b) are opposite ends of a single electronic wire.

15. The method of any of claims 9 to 14, further comprising applying heat to the first terminal post (306).

16. a component (502) including a component surface (522); a cap member (504) including a cap member surface (524); Equipped with a first groove (550) disposed in one of the component surface (522) or the cap member surface (524), and a first tongue (556) protruding from the other of the cap member surface (524) or the component surface (522); A terminal connector (500) wherein the first tongue (556) includes a chamfer volume (528) along a ridge of the first tongue (556), the chamfer volume (528) being configured to compress one or more wires between the first groove (550) and the chamfer volume (528) when the first tongue (556) is inserted into the first groove (550).

17. The component (502) a second groove (552) disposed on one of the component surface (522) or the cap member surface (524); a second tongue (554) protruding from the other of the component surface (522) or the cap member surface (524); The terminal connector (500) of claim 16, further comprising:

18. 18. The terminal connector (500) of claim 16 or 17, wherein the component (502) further comprises a bobbin spindle (514).

19. 19. The terminal connector (500) of claim 16, wherein the chamfer volume (528) forms a void of triangular cross section when the first tongue (556) is disposed within the first groove (550).

20. 20. The terminal connector (500) of claim 16, wherein the component (502) further comprises a first alignment post (506), and the cap member (504) further comprises a first alignment borehole (510), the first alignment post (506) configured to substantially fill the first alignment borehole (510) when mated together.

21. 21. The terminal connector (500) of claim 20, wherein the first alignment post (506) comprises plastic, and the first alignment post (506) and the first alignment borehole (510) are configured to facilitate a heat staking fit when the first alignment post (506) is inserted into the first alignment borehole (510) and heat is applied to the first alignment post (506).

22. 22. The terminal connector (500) of claim 16, wherein the component (502) further comprises a second alignment post (508), and the cap member (504) further comprises a second alignment borehole (512), the second alignment post (508) configured to substantially fill the second alignment borehole (512) when mated together.

23. 23. The terminal connector (500) of any of claims 16 to 22, further comprising a first terminal wire (516) disposed between the first tongue (556) and the first groove (550).

24. 24. The terminal connector (500) of claim 23, further comprising a first electronic wire (518) disposed between the first tongue (556) and the first groove (550).

25. 25. The terminal connector (500) of claim 24, wherein the first terminal wire (516) has a first gauge that is lower than a second gauge of the first electronic wire (518).

26. 26. A method of assembling a terminal connector (500) according to any one of claims 16 to 25, comprising the steps of: The method includes inserting the first tongue (556) into the first groove (550).

27. 27. The method of claim 26, further comprising the step of positioning a first terminal wire (516) along the first groove (550).

28. 28. The method of claim 27, further comprising the step of placing a first electronic wire (518) along the first groove (550).

29. the component (502) further comprising a bobbin spindle (514); 30. The method of claim 28, further comprising winding the first electronic wire (518) onto the bobbin spindle (514).

30. the component (502) further comprising a first alignment post (506), and the cap member (504) further comprising a first alignment borehole (510); the first alignment posts (506) are configured to substantially fill the first alignment boreholes (510) when mated together; 30. The method of any of claims 26 to 29, further comprising inserting the first alignment post (506) into the first alignment borehole (510).

31. applying pressure to secure the cap member (504) onto the component (502); applying heat to the first alignment post (506) to create a heat stake fit between the cap member (504) and the component (502); 31. The method of claim 30, further comprising:

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