Method and assembly of member and terminal

• US 5,611,709 A
• Filed: 08/10/1995
• Issued: 03/18/1997
• Est. Priority Date: 08/10/1995
• Status: Expired due to Term

• Current Assignee: Covidien AG (Medtronic Plc)
• Original Assignee: Valleylab Inc. (Medtronic Plc)
• Inventors: McAnulty, Michael J.
• Primary Examiner(s): Abrams, Neil
• Assistant Examiner(s): BIGGI, BRIAN JOSEPH
• Application Number:
  US08/513,287
• Time in Patent Office: 586 Days
• Field of Search: 439/77, 439/421, 439/422-424, 439/492-493, 439/498, 174/84 C, 174/84 R, 174/88 R
• US Class Current: 439/422
• CPC Class Codes: H01R 12/616 having contacts penetrating insulation for making contact with conductors, e.g. needle points
• CPC Class Codes: H01R 2201/12 for medicine and surgery
• CPC Class Codes: H01R 4/70 Insulation of connections end caps H01R4/22

Abstract

A method and assembly for electrically and mechanically connecting one or more flexible conductive members, with one or more insulated wires using one or more insulation piercing terminals. The flexible conductive member may have one or more electrically conductive layers attached to a pliable backing. The insulated wire may have one or more conductors. The insulation piercing terminal provides a low impedance electrical connection between the flexible conductive member and the insulated wire, while also providing a mechanical connection between the flexible conductive member and the insulated wire which minimizes movement of the insulated wire due to any axial and/or longitudinal forces that may be applied to the insulated wire or the flexible member during manufacturing and use. The insulation piercing terminal combines one or more piercing members with an integral mechanical securing means and an electrical contact for engaging the flexible conductive member. The insulation piercing terminals, used in this method and assembly, eliminate the need to prepare either the flexible conductive member or the insulated wire prior to assembly. The method and assembly are of particular advantage to medical equipment manufacturers involved in designing and manufacturing flexible electrode type circuits, such as the return electrodes for use with electrosurgical generators or other electrodes or sensors associated with patient monitoring procedures and devices.

Claims

1. An assembly of a member and terminal comprising;

a flexible conductive member;

an insulated wire carrying one or more conductors therethrough;

an insulation piercing terminal, for both;

extending through the flexible conductive member,

and compressively holding the flexible conductive member against the insulated wire;

a piercing member on the insulation piercing terminal extending through the flexible conductive member and into the insulated wire to engage the wire by piercing the insulation thereof for providing an electrically conductive connection with one or more conductors therein, and

one or more securing tabs on the insulation piercing terminal wherein the one or more securing tabs extending through the flexible conductive member for retaining and compressively engaging against the insulated wire to hold the insulated wire against the flexible conductive member.

2. The assembly of a member and terminal in claim 1 wherein the flexible conductive member has one or more electrically conductive layers attached to a pliable backing.

3. The assembly of a member and terminal in claim 1 wherein the insulation piercing terminal includes:

a body with an upper side and a lower side;

one or more piercing members extending from the lower side, each piercing member having a rigid end connected to the lower side and a penetrating end extended outwardly from the lower side; and

the one or more securing tabs extending from the lower side, each securing tab having a fixed end connected to the lower side and a retaining end extended outwardly from the lower side, wherein one or more of the securing tabs extends through the flexible conductive member with its retaining end compressively engaging against the insulated wire to hold the insulated wire against the flexible conductive member.

4. The assembly of a member and terminal in claim 3 wherein the insulation piercing terminal further includes one or more electrical contacts connected to the body and extended outwardly from the lower side for conductively contacting the electrically conductive layer.

5. The assembly of a member and terminal in claim 3 wherein the insulation piercing terminal includes:

two piercing members extending through the flexible conductive member and into the insulated wire, and

a conductor engaging channel between the two piercing members extending from the penetrating ends towards the lower side, wherein a conductor is compressively held between the two piercing members within the conductor engaging channel.

6. The assembly of a member and a terminal in claim 1 further including a non-conductive material covering, the non-conductive material covering extending over the assembly.

7. The assembly of a member and a terminal in claim 1 further including a corrosion protective substance applied to seal the assembly.

8. An assembly of a member and terminal comprising:

a flexible conductive member, having an electrically conductive layer attached to a pliable backing;

an insulated wire carrying two conductors therethrough;

an insulation piercing terminal having;

a body with an upper side and a lower side;

two piercing members extending from the lower side, each piercing member having a rigid end connected to the lower side and a penetrating end extended outwardly from the lower side, wherein each of the piecing members extends through the flexible conductive member and into the insulated wire;

a conductor engaging channel between the two piercing members extending from the penetrating ends towards the lower side, wherein one conductor is compressively held between the two piercing members within the conductor engaging channel;

an electrical contact connected to the body and extended outwardly from the lower side and conductively contacting the electrically conductive layer, and

two securing tabs extending from the lower side, each securing tab having a fixed end connected to the lower side and a retaining end extended outwardly from the lower side, wherein each of the securing tabs extends through the flexible conductive member and has its retaining end compressively engaged against the insulated wire to hold the insulated wire against the pliable backing.

9. An insulation piercing terminal comprising:

a body having an upper side and a lower side;

one or more securing tabs extending from the lower side, each securing tab having a fixed end connected to the lower side and a retaining end extended outwardly from the lower side;

one or more piercing members extending from the lower side;

a penetrating end at the extremity of the extended piercing member, and

engaging means on the one or more piercing member to engage compressively one or more insulated wires, the engaging means designed to directly penetrate through insulation layers of the one or more wires for making electrical contact.

10. The insulation piercing terminal in claim 9 further including one or more electrical contacts connected to the body and extended outwardly from the lower side.

11. The insulation piercing terminal in claim 9 further including:

two piercing members as the engaging means, and

a conductor engaging channel between the two piercing members, the conductor engaging channel extending from the penetrating ends towards the lower side.

12. The insulation piercing terminal in claim 9 wherein the insulation piercing terminal is made of a continuous piece of electrically conductive metal.

13. The insulation piercing terminal in claim 9 wherein the insulation piercing terminal is made of a pre-tin plated phosphor bronze alloy.

14. The insulation piercing terminal in claim 9 wherein one or more of the securing ends extends further from the lower side then does the longest piercing member.

15. A method for assembling a member and a terminal including the following steps:

gathering a flexible conductive member, an insulation piercing terminal and an insulated wire;

placing the flexible conductive member between the insulation piercing terminal and the insulated wire;

penetrating through the flexible conductive member with the insulation piercing terminal;

piercing into the insulated wire with the insulation piercing terminal to engage the wire by piercing the insulation thereof for providing an electrically conductive connection wire therein, and

shaping the insulation piercing terminal to secure, retain and compressively hold the insulated wire against the flexible conductive member.

16. The method for assembling a member and a terminal in claim 15 further including the step of covering the assembly with a non-conductive material.

17. The method for assembling a member and a terminal in claim 15 further including the step of sealing the assembly with a corrosion protective substance.