High power terminal block assembly

• US 7,527,523 B2
• Filed: 05/02/2007
• Issued: 05/05/2009
• Est. Priority Date: 05/02/2007
• Status: Expired due to Fees

• Current Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Inventors: Oh, Lawrence Se-Jun, Flaig, Robert Charles, Yohn, Brent David
• Primary Examiner(s): Leon; Edwin A.
• Application Number:
  US11/743,248
• Publication Number:
  US 20080274645A1
• Time in Patent Office: 734 Days
• Field of Search: 439/595, 439/762, 439/772, 439/765, 439/770, 439/754, 439/76.1, 439/564, 439/722, 439/500, 439/108, 439/709
• US Class Current: 439/564
• CPC Class Codes: H01R 13/40 Securing contact members in or to a base or case; Insulating of contact members
• CPC Class Codes: H01R 4/30 utilising a screw or nut clamping member H01R4/50 takes precedence; utilising a clamping member acted on by screw or nut H01R4/38; for coaxial cables H01R9/0521
• CPC Class Codes: H01R 9/24 Terminal blocks

Abstract

A power terminal and a method for making a power terminal having an electrically insulated connector body. A terminal insert is incorporated into the connector body and has at least one threaded electrically conductive member engaged with the terminal insert. The conductive member also includes a cap portion. The terminal insert is formed from a substantially rigid material and is configured to resist torque and pull out forces provided to the conductive member.

Claims

1. A power terminal comprising:

an electrically insulated connector body;

a terminal insert incorporated into the connector body and having at least one threaded electrically conductive member engaged with the terminal insert, the conductive member also having a cap portion incorporated into the connector body; and

wherein the terminal insert is formed from a substantially rigid material and is configured to resist torque and pull out forces applied to the conductive member.

2. The power terminal of claim 1, wherein the terminal insert comprises a metallic material.

3. The power terminal of claim 1, wherein the cap portion has a hexagonal geometry.

4. The power terminal of claim 1, wherein the cap portion includes a cavity configured to receive a portion of material making up the connector body.

5. The power terminal of claim 1, further comprising a mounting bar incorporated into the connector body.

6. The power terminal of claim 1, wherein the mounting bar is formed from a rigid material and is configured to provide rigidity to the connector body.

7. The power terminal of claim 1, further comprising a commoning washer disposed on the conductive member.

8. The power terminal of claim 1, further comprising a cover detachably engaged with the connector body.

9. The power terminal of claim 1, wherein the conductive member further includes a nut threadingly engaged with the conductive member.

10. The power terminal of claim 1, wherein one or both of the terminal insert and the conductive member comprises a corrosion resistant coating.

11. The power terminal of claim 1, wherein the connector body further comprises electrically insulative dividers engaged with the connector body and disposed to arrange groups of electrically conductive members.

12. The power terminal of claim 1, wherein the terminal insert and conductive member are of unitary construction.

13. The power terminal of claim 12, wherein the cap portion has a cross-shaped geometry.

14. A method for forming a power terminal comprising:

providing a substantially rigid terminal insert having a threaded conductive member engaged thereto;

incorporating the terminal insert and a cap portion of the threaded conductive member into a connector body;

wherein the terminal insert is configured to resist torque and pull out forces applied to the conductive member.

15. The method of claim 14, wherein the cap portion has a hexagonal geometry.

16. The method of claim 14, further comprising incorporating a mounting bar into the connector body to provide rigidity to the connector body.

17. The method of claim 14, further comprising rotatably mounting a nut onto a conductive member.

18. The method of claim 14, further comprising applying a corrosion resistant coating on one or both of the terminal insert and the conductive member.

19. The method of claim 14, wherein the providing includes providing a terminal insert and conductive member of unitary construction.

20. The method of claim 19 wherein the cap portion has a cross shaped geometry.