Single blade terminal power connector system

[0002] This invention relates generally to electrical power connectors, and more particularly to a terminal system for power connectors of the type used in automotive vehicle batteries, power electronics, alternators, electric motors and the like.

[0003] High power terminals can be made by stamping or on a screw machine. Present stamped terminals are expensive and difficult to manufacture. What is needed is a terminal system which lends itself to normal processing methods, can be made at a lower cost, and permits more convenient mating of the terminal parts with one another.

[0004] The terminal connection system of this invention overcomes the shortcomings of previous systems. It is cost competitive with ring terminals and eliminates the need for bolt-on fasteners. The system includes a single blade male contact which is relatively easy to manufacture. The connection system of this invention is fully stampable in a progressive die, can be readily installed in a particular application, and is easy to inspect and to service. The single blade connector system of this invention can replace ring terminals for a multitude of applications where “toolless” assembly is required. The single blade design allows for smaller packaging. The single blade design also permits the blade to be inserted into the female counterpart from various directions allowing for more cable options due to the design of the contact spring element.

[0005] It accordance with the present invention, the female connector part is in the form of a U-shaped channel for receiving the contact spring element. The contact spring element is itself U-shaped enabling the single blade to be inserted from more than one direction, greatly facilitating assembly.

[0006] One object of this invention is to provide a terminal system for power connectors having the foregoing features and capabilities.

[0007] Another object is to provide a terminal system composed of a relatively few simple parts, which are rugged and durable in use, and capable of being easily manufactured and assembled.

[0008] These and other objects, features and advantages of the invention will become more apparent as the following description proceeds, especially when considered with the accompanying drawings.

[0009] FIG. 1 is a perspective view of a terminal connector system constructed in accordance with the invention.

[0010] FIG. 2 is an exploded view of the terminal connector system shown in FIG. 1.

[0011] FIG. 3 is a sectional view taken on the line 3—3 in FIG. 1.

[0012] FIG. 4 is a perspective view showing a modification.

[0013] Referring now more particularly to the drawings, the power terminal connector system 10 of this invention includes a male member 12, a female member 14 and a spring contact member 16.

[0014] The male member 12 is preferably an electrically conductive metal stamping and has an elongated bar 18 formed adjacent one end with a pair of laterally spaced fingers 20 and a second pair of laterally spaced fingers 22 which are bent over an end of a cable 24 to secure the cable to the bar. The male member 12 has an integral, single blade 28 at the opposite end of the bar 18 which in FIG. 1 extends perpendicular to the bar. The blade is an elongated, thin, flat plate-like member which is beveled at the free end 30 to facilitate its entry into the contact member 16 as described more fully hereinafter.

[0015] The blade preferably has laterally outwardly projecting nibs 32 along opposite side edges to position a seal when needed or desired, and laterally spaced apart shoulders 34 to form abutments limiting the insertion of the blade into a connector housing (not shown). The blade also has a slot 36 which may receive a latch (not shown) to retain the blade in the connector housing.

[0016] The female member 14 is preferably an electrically conductive metal stamping and has an elongated bar 38 formed adjacent one end with an integral ring 40 having radially inwardly extending flexible tabs 42 defining an opening for receiving a battery post, for example. The opposite end portion 44 of the female member 14 is formed to provide an integral, elongated U-shaped channel 46. The channel 46 includes a base 48 which extends generally in straight line continuation of the end portion 44 of the bar 38, and laterally spaced apart rectangular parallel side walls 50 and 52 extending perpendicular to the base. The base and side walls form a rectangular recess 54 within the channel. The side walls 50 and 52 have outer edges 56 and 58 which are parallel to the base 48 and define an outer opening 60 to the recess 54. The side walls have end edges 62 and 64 at one end of the channel forming an end opening 66 to the recess 54. End edges 68 and 70 at the opposite end of the channel form a second end opening 72 to the recess 54. The end edges 62, 64, 68 and 70 have notches 72 and 74 for releasably retaining the contact member 16 as more filly described hereinafter.

[0017] The contact member 16 is preferably an electrically conductive, U-shaped metal stamping having a base 76, and laterally spaced apart, rectangular, parallel side walls 78 and 80 extending perpendicular to the base. The base and side walls of the contact member 16 form a recess 82. The side walls 78 and 80 have outer edges 84 and 86 which are parallel to the base 76 and define an outer opening 88 to the recess 82. The side walls 78 and 80 have end edges 90 and 92 at one end forming an end opening 94 to the recess 82. End edges 98 and 100 at the opposite end form a second end opening 102 to the recess. Each of the side walls 78 and 80 of the contact member 16 is slotted at spaced points to form flexible webs 104 which are twisted as shown to extend transversely of the plane of the side wall for contact with the side walls 50 and 52 of the channel 46 of the female member.

[0018] Along the outer edges of the two side walls 78 and 80 of the contact member 16 are laterally outwardly extending flanges 106 and 108. Along each end edge of each of the side walls 78 and 80 of the contact member 16 is a laterally outwardly extending flange 110 having at the outer end thereof an inwardly inclined tab 114.

[0019] The contact member 16 has a transverse dimension generally similar to the width of the recess 54 in the channel 46 so that the contact member may be inserted into the recess with the base 76 of the contact member contacting the base 48 of the channel 46 and the webs 104 of the side walls 78 and 80 of the contact member in electrical contact with the side walls 50 and 52 of the channel. The contact member when fully inserted causes the flanges 106 and 108 along the outer edges of the side walls 78 and 80 of the contact member to engage the outer edges 56 and 58 of the side walls of the channel, and the flanges 110 along the end edges of the side walls 78 and 80 of the contact member to engage the end edges 62 and 64 of the side walls of the channel 46, with the tabs 114 engaging in the notches 72 and 74 of the side walls of the channel locating and releasably locking the contact member within the recess 54 of the channel.

[0020] When the contact member 16 is fully inserted into the recess 54 in the channel 46 of the female member 14, the outer opening 88 to the recess 82 of the contact member registers with the outer opening 60 of the channel 46, the end opening 94 of the recess 82 registers with the end opening 66 of the channel, and the end opening 102 of the recess 82 registers with the end opening 72 of the channel.

[0021] The blade 28 of the male member 12 is insertable into the recess 82 of the contact member 16, as will be apparent in FIG. 1, in a direction perpendicular to the base 76 of the contact member as indicated by the arrow 120 through the registering openings 60 and 88 of the channel and the contact member, or in a direction perpendicular to the direction 120 as indicated by the arrow 122 though the registering openings 66 and 94 between the side edges of the channel and the contact member. It will be understood that if the bar 38′ of the female member 14′ is substantially straight as indicated in FIG. 4 rather than bent as shown in FIG. 1, the blade may also be inserted through the registering openings 72 and 102 in the opposite end of the channel and contact member as indicated by the arrow 130 which is generally aligned with the direction of insertion indicated by the arrow 122 but in the opposite direction. The blade, when fully inserted in the contact member 16, is in electrical contact with the webs 104 of the contact member. Except for the substantially straight bar 38′ of the female member 14′, the construction in FIG. 4 is the same as in FIG. 1.