Terminal weld tab having a wire squeeze limiter

• US 9,634,405 B2
• Filed: 05/31/2013
• Issued: 04/25/2017
• Est. Priority Date: 07/19/2006
• Status: Active Grant

• Current Assignee: Solero Technologies LLC
• Original Assignee: BorgWarner Incorporated
• Inventors: Horn, Thomas A.
• Primary Examiner(s): Leon, Edwin A.
• Application Number:
  US13/907,249
• Publication Number:
  US 20140011412A1
• Time in Patent Office: 1,425 Days
• Field of Search: 439874, 439873, 439876, 439888, 439395, 439 82, 439556, 439572, 439746, 29879
• CPC Class Codes: H01F 2007/062 Details of terminals or connectors for electromagnets
• CPC Class Codes: H01R 4/029 Welded connections H01R4/021 - H01R4/028 take precedence
• CPC Class Codes: H01R 4/14 by wrapping
• CPC Class Codes: H01R 4/188 having an uneven wire-receiving surface to improve the contact

Abstract

One variation may include an electrical connection terminal (20) including at least a first weld tab (22). The first weld tab (22) including an outer face (23) and a weldable inner face (33). The weldable inner face (33) includes a substantially planar first portion (25) and a substantially planar second portion (27), and wherein the first portion (25) and second portion (27) are not in the same plane. Another variation may include an electrical connection post (56) having a first post portion (64) and a second post portion (404), the first post portion having a first width and the second post portion having a second width, and wherein the first width is greater than the second width.

Claims

1. A product comprising:

an electrical connection post (56) having a first post portion (64) and a second post portion (404), the first post portion having a first width and the second post portion having a second width, and wherein the first width is greater than the second width, wherein the second post portion is connected to a bobbin;

a wire wound around the second post portion; and

an electrical connection terminal (20) comprising at least a first weld tab (22), the first weld tab (22) comprising an outer face (23) and a weldable inner face (33), the weldable inner face (33) comprising a substantially planar first portion (25).

6. A product as set forth in claim 1 wherein the post comprises a base material and at least a first coating thereon comprising tin.

7. A product as set forth in claim 1 further comprising a terminal (20) comprises a base with material and at least a first coating comprising tin, and wherein the post (56) comprises a base material and at least a first coating comprising tin.

8. A product as set forth in claim 1 wherein the first weld tab (22) comprises a first flared tab portion (300) and a second flared tab portion (302), wherein each of the flared tab portions are positioned outside of a post 56, and each constituting the second portion (27).

2. A product comprising:

an electrical connection post (56) having a first post portion (64) and a second post portion (404), the first post portion having a first width and the second post portion having a second width, and wherein the first width is greater than the second width, wherein the second post portion is connected to a bobbin; and

an electrical connection terminal (20) comprising at least a first weld tab (22), the first weld tab (22) comprising an outer face (23) and a weldable inner face (33), the weldable inner face (33) comprising a substantially planar first portion (25).

4. A product as set forth in claim 2 wherein the post (56) has four sides (62, 64, 66, 68) and the first weld tab (22) is constructed and arranged to wrap around at least three sides of the four sides of the post (56).

5. A product as set forth in claim 2 wherein the weld tab (22) is constructed and arranged to wrap over the top (63) of a post and at least a portion of the wire.

9. A product as set forth in claim 5 wherein the first flared tab portion (300) extends from a first tab segment (24) of the first weld tab (22), and the second flared tab portion (302) extends from a second tab segment (26) of the first weld tab (22).

3. A product comprising:

an electrical connection post (56) having a first post portion (64) and a second post portion (404), the first post portion having a first width and the second post portion having a second width, and wherein the first width is greater than the second width, further comprising an electrical connection terminal (20) comprising at least a first weld tab (22), the first weld tab (22) comprising an outer face (23) and a weldable inner face (33), the weldable inner face (33) comprising a substantially planar first portion (25), wherein the first weld tab (22) is wrapped around a portion of a post (56), and wherein the post (56) has a first flat face (62) and a second flat face (64), and wherein the weld tab (22) is welded to both of the first flat face (62) and second flat face (64) of the post (56).

10. A process comprising:

providing a post (56) having a first post portion (64) and a second post portion (404), the first post portion having a first width and the second post portion having a second width, and wherein the first width is greater than the second width, and a portion of a wire (60) wound around the second portion of the post;

providing an electrical connection terminal (20) comprising at least a first weld tab (22) comprising an outer face (23) and a weldable inner face (33), the weldable inner face (33) comprising a substantially planar first portion (25);

welding a portion the substantially planar first portion (25) to the first portion of the post.

11. A process as set forth in claim 10 further comprising welding the a portion of the substantially planar second portion (25) to the portion of the wire (60) wound around the post (56).

12. A process as set forth in claim 10 wherein the post (56) has four sides (62, 64, 66, 68), and wherein the first weld tab (22) is constructed and arranged to wrap around three sides of the post (56).

13. A product comprising an electrical connection post (56) having a first post portion (64) and a second post portion (404), the first post portion having a first width and the second post portion having a second width, and wherein the first width is greater than the second width, and wherein the first post portion has a flat face and wherein the second post portion has a flat face;

and

an electrical connection terminal (20) comprising at least a first weld tab (22), the first weld tab (22) comprising an outer face (23) and a weldable inner face (33), the weldable inner face (33) comprising a substantially planar first portion (25).

14. A product comprising:

an electrical connection post (56) having a four flat sides, and wherein the electrical connection post is connected to a bobbin; and

further comprising a wire wound around the post, further comprising an electrical connection terminal (20) comprising at least a first weld tab (22), the first weld tab (22) comprising an outer face (23) and a weldable inner face (33), the weldable inner face (33) comprising a substantially planar first portion (25), wrapped around a portion of a post (56), and wherein the post (56) has a first flat face (62) and a second flat face (64), and wherein the weld tab (22) is welded to both of the first flat face (62) and second flat face (64) of the post (56).