Electrical assemblies including female electrical terminal

• US 4,921,456 A
• Filed: 07/29/1988
• Issued: 05/01/1990
• Est. Priority Date: 07/29/1988
• Status: Expired due to Fees

• Current Assignee: AMP Limited, Mechatronics Inc.
• Original Assignee: AMP Limited
• Inventors: French, Jay L.
• Primary Examiner(s): MCGLYNN, JOSEPH
• Application Number:
  US07/225,990
• Time in Patent Office: 641 Days
• Field of Search: 439/851, 439/877
• US Class Current: 439/851
• CPC Class Codes: H01R 13/111 co-operating with pins having a circular transverse section

Abstract

An electrical assembly (10) includes a female electrical terminal (12) having a first sleeve portion (13) provided with four longitudinally-extending inwardly-directed convex lobes (18), each of which has a substantial line contact along the length of a male pin (11) adapted to be slidably received within the first sleeve portion (13) of the female electrical terminal (12). The four lobes (18) are arranged in the pairs of lobes, including a first lobe pair (A) and a second lobe pair (B). The first lobe pair (A) is symmetrically disposed about a first longitudinal slot (16) in the first sleeve portion (13), and the second lobe pair (B) is substantially diametrically oppositely of the first lobe pair (A) and is substantially symmetrical about a diametrical axis (19) of the first sleeve portion (13) of the female electrical connector (12) which includes the first longitudinal slot (16) therein. The second sleeve (14) has an integral portion (20, 31) providing a stop for the pin (11). In one embodiment, the pin (11) is substantially-solid and provides a heat sink for the electrical assembly.

Claims

1. An electrical assembly, comprising:

a male electrical terminal;

a cooperating female electrical terminal adapted to slidably receive the male electrical terminals and including a generally-cylindrical first sleeve portion having a longitudinal slot formed therein, such that the first sleeve may flex radially outwardly when the male electrical terminal is slidably received within the first sleeve portion of the female electrical terminal, said first sleeve being generally cylindrical and free of outwardly extending protrusions, so that the effective outer diameter thereof is only slightly larger than the inner diameter thereof;

the first sleeve portion having four longitudinally-extending inwardly-directed substantially convex lobes formed thereon at respective selected locations; and

the four lobes being arranged in two pairs of lobes, including a first lobe pair on respective slides of the longitudinal slot in the first sleeve portion of the female electrical terminal, and further including a second lobe pair disposed substantially diametrically opposite to the longitudinal slot;

wherein, when the male electrical terminal is slidably received into the female electrical terminal, the male electrical terminal engages the four lobes and makes electrical contact with the four lobes substantially along the entire length thereof.

2. The assembly of claim 1 wherein each of said lobes extends inwardly of the inner surface of the sleeve only a slight distance, whereby upon mating with a male terminal and engagement by said male terminal with said lobes, said sleeve is expanded outwardly only a slight amount and the resultant outer diameter of the sleeve after mating is only slightly larger than the original generally outer diameter prior to mating.

3. The electrical assembly of claim 1, wherein each pair of lobes is substantially symmetrical about a diametrical axis of the first sleeve portion of the female electrical terminal that includes the longitudinal slot therein.

4. The electrical assembly of claim 3, wherein the first lobe pair subtends an angle which is less than the corresponding angle subtended by the second lobe pair.

5. The electrical assembly of claim 4, wherein the angle subtended by the first lobe pair is approximately 34 degrees and the angle subtended by the second lobe pair is approximately 90 degrees.

6. An electrical assembly, comprising:

a male electrical terminal comprising a substantially cylindrical pin;

a cooperating female electrical terminal adapted to slidably receive the pin and including a generally-cylindrical first sleeve portion having a longitudinal slot formed therein, such that the first sleeve may flex radially outwardly when the pin is slidably received within the first sleeve portion of the female electrical terminal, said first sleeve being generally cylindrical and free of outwardly extending protrusions, so that the effective outer diameter thereof is only slightly larger than the inner diameter thereof;

the first sleeve having four longitudinally-extending inwardly-directed substantially convex lobes formed thereon at respective selected locations;

the four lobes being arranged in two pairs of lobes, including a first lobe pair on respective sides of the longitudinal slot in the first sleeve portion of the female electrical terminal, and further including a second lobe pair disposed substantially diametrically opposite to the longitudinal slot,

each pair of lobes being substantially symmetrical about a diametrical axis of the first sleeve portion of the female electrical terminal which includes the longitudinal slot therein;

the first lobe pair subtending an angle which is substantially less than the corresponding angle subtended by the second lobe pair; and

wherein, when the pin is slidably received into the female electrical terminal, the male electrical engages the four lobes and makes electrical contact with the four lobes substantially along the entire length thereof.

7. The electrical assembly of claim 6, further including a pair of radiating fins formed integrally with the first sleeve portion of the female electrical terminal and extending rearwardly therefrom in the direction in which the pin is slidably inserted into the first sleeve;

the heating radiating fins including first and second radiating fins on respective sides of the longitudinal slot in the first sleeve portion of the female connector.

8. The assembly of claim 6 wherein each of said lobes extends inwardly of the inner surface of the sleeve only a slight distance, whereby upon mating with a pin terminal and engagement by said pin terminal with said lobes, said sleeve is expanded outwardly only a slight amount and the resultant outer diameter of the sleeve after mating is only slightly larger than the original generally outer diameter prior to mating.

9. The electrical assembly of claim 6, wherein the female electrical terminal further includes a generally-cylindrical second portion extending rearwardly of the first sleeve portion of the female electrical terminal, and

wherein the second sleeve portion is adapted to receive at least one electrical conductor therein.

10. The electrical assembly of claim 9, further including a conductive tube press-fitted over the second sleeve portion of the female electrical terminal.

11. An electrical assembly, comprising:

a male electrical terminal;

a cooperating female electrical terminal including a sleeve portion adapted to slidably receive the male electrical terminal, said sleeve portion being generally cylindrical and free of outwardly extending protrusions, so that the effective outer diameter thereof is only slightly larger than the inner diameter thereof, the sleeve portion having at least four longitudinally-extending inwardly-directed substantially convex lobes formed thereon at respective selected locations;

the four lobes being arranged in two pairs of lobes disposed substantially diametrically opposite to each other;

the first pair of lobes subtending an angle which is substantially less than the corresponding angle subtended by the second pair of lobes; and

wherein, when the male electrical terminal is slidably received in the female electrical terminal, the male electrical terminal engages the four lobes and makes electrical contact with the four lobes substantially along the entire length thereof.

12. The assembly of claim 11 wherein each of said lobes extends inwardly of the inner surface of the sleeve only a slight distance, whereby upon mating with a male terminal and engagement by said male terminal with said lobes, said sleeve is expanded outwardly only a slight amount and the resultant outer diameter of the sleeve after mating is only slightly larger than the original general outer diameter prior to mating.

13. The electrical assembly of claim 11, wherein the sleeve portion of the female electrical terminal has a longitudinal slot formed thereon;

the first pair of lobes straddling the longitudinal slot symmetrically thereof; and

wherein the second pair of lobes is further disposed substantially symmetrically about a diametrical axis of the sleeve portion which includes the longitudinal slot.

14. The electrical assembly of claim 13, wherein the angle subtended by the first pair of lobes is approximately 34 degrees;

and

wherein the angle subtended by the second pair of lobes is approximately 90 degrees.

15. An electrical assembly, comprising:

a male electrical terminal including an elongated substantially-solid pin portion thereof;

a cooperating female electrical terminal including a first sleeve portion adapted to slidably receive the pin, and further including a second sleeve portion adapted to receive at least one conductor therein said first sleeve portion being generally cylindrical and free of outwardly extending protrusions, so that the effective outer diameter thereof is only slightly larger than the inner diameter thereof;

the first sleeve portion having means at respective selected locations therearound to assure a plurality of line contacts between the first sleeve portion and the pin, substantially along the length thereof;

the means for retaining the conductor within the second sleeve portion of the female electrical terminal;

wherein an electrical current may flow from the pin through the female electrical terminal to the conductor with reduced contact resistance and heat losses therebetween;

the conductor being provided with an insulating jacket having an outer diameter;

wherein the second sleeve and its retaining means are "under designed" with reference to a thermally matched system, said thermally matched system being one in which the temperature rises of the mated contact terminals under load, when considered as an assembly, is matched to the temperature rise of wires attached to the respective mated terminals, the female terminal generating heat when subjected to load, said sleeve and retaining means having an outer diameter that is substantially equal to or less than the outer diameter of the insulating jacket on the conductor, thereby saving space and contributing to the miniaturization of any associated apparatus using the electrical assembly;

wherein the substantially-solid pin is "over designed" with reference to a thermally matched system in that said pin provides a heat sink for removal of heat from the assembly; and

wherein relatively-economical readily-available materials may be used for the male and female terminals, respectively.

16. The electrical assembly of claim 15, wherein the means on the first sleeve to assure a plurality of line contacts between the first sleeve and the pin, comprises four longitudinally-extending inwardly-directed convex lobes formed on the first sleeve;

and wherein the four lobes are arranged in two pairs of lobes, including a first lobe pair and a second lobe pair disposed substantially diametrically opposite to each other.

17. The assembly of claim 15 wherein each of said lobes extends inwardly of the inner surface of the sleeve only a slight distance, whereby upon mating with a pin terminal and engagement by said pin terminal with said lobes, said sleeve is expanded outwardly only a slight amount and the resultant outer diameter of the sleeve after mating is only slightly larger than the original general outer diameter prior to mating.

18. An electrical assembly, comprising:

a male electrical terminal comprising a pin;

a cooperating female electrical terminal including a first sleeve portion adapted to slidably receive the pin, said first sleeve portion being generally cylindrical and free of outwardly extending protrusions, so that the effective outer diameter thereof is only slightly larger than the inner diameter thereof;

the first sleeve including a first longitudinal slot, such that the first longitudinal slot may open circumferentially, and the first sleeve flex radially outwardly, as the pin is slidably inserted into the first sleeve portion of the female electrical terminal;

means on the first sleeve portion at respective selected locations therearound for establishing a plurality of substantially line contacts between the first sleeve and the pin, and substantially along the length thereof;

the female electrical terminal further having a second sleeve portion integrally joined to the first sleeve portion and extending rearwardly therefrom;

the second sleeve having a second longitudinal slot formed therein, substantially aligned axially with the first longitudinal slot on the first sleeve, and having a substantially greater circumferential opening than the circumferentially opening of the first longitudinal slot in the first sleeve;

at least one conductor received within the second sleeve portion of the female electrical terminal;

a tube fitted over the second sleeve and crimped thereon, thereby securely retaining the conductor within the second sleeve of the female electrical terminal; and

the second sleeve having at least one inwardly-bent tab formed thereon, thereby providing a step for limiting the insertion of the pin into the female electrical terminal.

19. The assembly of claim 18 wherein each of said lobes extends inwardly of the inner surface of the sleeve only a slight distance, whereby upon mating with a pin terminal and engagement by said pin terminal with said lobes, said sleeve is expanded outwardly only a slight amount and the resultant outer diameter of the sleeve after mating is only slightly larger than the original general outer diameter prior to mating.

20. In an electrical assembly having cooperating male and female terminals, respectively, wherein the male and female terminals are to be terminated to respective conductors, each conductor comprised of at least one wire having an O.D. and an insulation jacket having a given O.D., the improvement which comprises:

a first sleeve on the female terminal for receiving a male terminal, said first sleeve being generally cylindrical and free of outwardly extending protrusions, so that the effective outer diameter thereof is only slightly larger than the inner diameter thereof;

a second sleeve on the female terminal for receiving the at least one wire, the second sleeve having an O.D. which is not larger than the O.D. of the insulation jacket on the conductor to which it is to be terminated, such that the female terminal is deliberately "under designed" from the standpoint of electrical and thermal conductivity with reference to a thermally matched system, said thermally matched system being one in which the temperature rise of the mated contact terminal under load, when considered as an assembly, is matched to the temperature rise of wires attached to the respective mated terminals, said female terminal generating heat when subjected to load; and

the male terminal has an O.D. that is substantially equal to or smaller than the O.D. of the insulation jacket of its respective conductor, and has a substantially greater mass than the female terminal such that the male terminal is deliberately "over designed" from the standpoint of electrical and thermal conductivity, with reference to a thermally matched system, and such that the male terminal provides a heat sink to draw out heat from the assembly;

whereby the electrical assembly has an interconnection envelope that is substantially equal to or less than the O.D. of the conductor jacket and wherein the assembly has an "over and under" design, thereby facilitating the use of readily available relatively-economical materials, and thereby facilitating relatively costs effective automated manufacture.

21. The improvement of claim 20, wherein the first sleeve has four longitudinally-extending inwardly-oriented convex lobes, each of which has a line of contact with the male terminal substantially along the length thereof.

22. The improvement of claim 21, wherein the first sleeve has a longitudinal slot formed therein, and wherein the four convex lobes are arranged in two pairs of lobes, including a first lobe pair straddling the longitudinal slot, and further including a second lobe pair arranged substantially diametrically opposite to the first lobe pair.

23. The improvement of claim 22, wherein each lobe pair is substantially symmetrical about a diametrical axis of the first sleeve which includes the longitudinal slot therein.

24. The improvement of claim 23, wherein the first lobe pair subtends an angle which is substantially less than the angle subtended by the second lobe pair.