LOW RESISTANCE INSERT

• US 20150041211A1
• Filed: 08/12/2013
• Published: 02/12/2015
• Est. Priority Date: 08/12/2013
• Status: Active Grant

• Current Assignee: TE Connectivity Solutions GmbH (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Inventors: FABIAN, David James, DEBOCK, Kimberly, KLINGER, Brian Todd
• Granted Patent: US 9,653,194 B2
• Time in Patent Office: Days
• US Class Current: 174/74.R
• CPC Class Codes: B64D 45/02 Lightning protectors; Static dischargers in general H01T
• CPC Class Codes: F16J 15/064 the packing combining the sealing function with other functions
• CPC Class Codes: H01B 1/023 Alloys based on aluminium
• CPC Class Codes: H01B 5/00 Non-insulated conductors or conductive bodies characterised by their form
• CPC Class Codes: H01R 11/12 End pieces terminating in an eye, hook, or fork
• CPC Class Codes: H01R 13/533 Bases, cases made for use in extreme conditions, e.g. high temperature, radiation, vibration, corrosive environment, pressure H01R13/52 takes precedence
• CPC Class Codes: H01R 4/06 Riveted connections by explosion H01R4/08
• CPC Class Codes: H01R 4/26 Connections in which at least one of the connecting parts has projections which bite into or engage the other connecting part in order to improve the contact H01R4/188, H01R4/203, H01R4/5075 take precedence; using shape memory materials H01R4/01
• CPC Class Codes: H01R 4/34 Conductive members located under head of screw
• CPC Class Codes: H01R 4/62 Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors H01R4/68 takes precedence

Abstract

A conductive insert which provides a low resistance bond between low conductive materials. The insert includes a first surface and an oppositely facing second surface. A plurality of openings extends between the first surface and the second surface. At least one first projection extends from the first surface proximate respective first openings, the at least one first projections extend from the first surface in a direction away from the second surface. At least one second projection extends from the second surface proximate respective second openings, the at least one second projections extend from the second surface in a direction away from the first surface. The insert provides a stable, low resistance electrically conductive path between the conductive materials.

Claims

1. A conductive insert which provides a low resistance bond between low conductive materials, the insert comprising:

a first surface and an oppositely facing second surface;

a plurality of openings extending between the first surface and the second surface;

at least one first projection extending from the first surface proximate respective first openings, the at least one first projections extending from the first surface in a direction away from the second surface;

at least one second projection extending from the second surface proximate respective second openings, the at least one second projections extending from the second surface in a direction away from the first surface;

wherein the insert provides a stable, low resistance electrically conductive path between the conductive materials.

2. The conductive insert as recited in claim 1, wherein three or more at least one first projections are provided proximate the first openings, and three or more at least one second projections are provided proximate the second openings.

3. The conductive insert as recited in claim 1, wherein the respective first openings are surrounding be respective second openings, whereby the at least one first projections alternate with the at least one second projections across the first surface and second surface.

4. The conductive insert as recited in claim 1, wherein the insert is made from conductive material which has a conductivity equal to or higher than the conductivity of aluminum.

5. The conductive insert as recited in claim 1, wherein the openings are selectively staggered.

6. The conductive insert as recited in claim 1, wherein the at least one first projections and the at least one second projections are disposed in a patterned relationship.

7. The conductive insert as recited in claim 1, wherein the plurality of openings are disposed along substantially the entire first surface and entire second surface.

8. The conductive insert as recited in claim 1, wherein at least one mounting opening extends through the first surface and the second surface of the insert, the mounting opening configured to cooperate with mounting hardware.

9. The conductive insert as recited in claim 1, wherein the at least one first projections and the at least one second projections extend at an angle relative to the longitudinal axis of the insert.

10. A conductive insert made from conductive material which has a conductivity equal to or higher than the conductivity of aluminum, the conductive insert provides a low resistance bond between conductive materials, the insert comprising:

a first surface and an oppositely facing second surface;

a plurality of openings extending between the first surface and the second surface;

at least one first projection extending from the first surface proximate respective first openings, the at least one first projections extending from the first surface in a direction away from the second surface;

at least one second projection extending from the second surface proximate respective second openings, the at least one second projections extending from the second surface in a direction away from the first surface;

at least one mounting opening extending through the first surface and the second surface, the mounting opening configured to cooperate with mounting hardware;

wherein the insert provides a stable, low resistance electrically conductive path between the conductive materials.

11. The conductive insert as recited in claim 10, wherein three or more at least one first projections are provided proximate each respective first opening, and three or more at least one second projections are provided proximate each respective second opening.

12. The conductive insert as recited in claim 11, wherein the respective first openings are surrounding be respective second openings, whereby the at least one first projections alternate with the at least one second projections across the first surface and second surface.

13. The conductive insert as recited in claim 10, wherein the openings are selectively staggered.

14. The conductive insert as recited in claim 10, wherein the at least one first projections and the at least one second projections are disposed in a patterned relationship.

15. The conductive insert as recited in claim 14, wherein the plurality of openings are disposed along substantially the entire first surface and entire second surface.

16. The conductive insert as recited in claim 15, wherein the at least one first projections and the at least one second projections extend at an angle relative to the longitudinal axis of the insert.

17. An assembly comprising:

a terminal;

a conductive surface;

a conductive insert made from aluminum or an aluminum alloy, the insert comprising;

a first surface and an oppositely facing second surface;

a plurality of openings extending between the first surface and the second surface;

at least one first projection extending from the first surface proximate respective first openings, the at least one first projections extending from the first surface in a direction away from the second surface;

at least one second projection extending from the second surface proximate respective second openings, the at least one second projections extending from the second surface in a direction away from the first surface;

at least one mounting opening extending through the first surface and the second surface, the mounting opening configured to cooperate with mounting hardware;

wherein the at least one first projection penetrates any sealants or oxides present on the terminal and the at least one second projection penetrates any sealants or oxides present on the conductive surface, thereby providing a stable, low resistance electrically conductive path between the terminal and the conductive surface.

18. The assembly as recited in claim 17, wherein the at least one first projections and the at least one second projections extend at an angle relative to the longitudinal axis of the insert.

19. The conductive insert as recited in claim 17, wherein three or more at least one first projections are provided proximate the first openings, and three or more at least one second projections are provided proximate the second openings.

20. The conductive insert as recited in claim 17, wherein the respective first openings are surrounding be respective second openings, whereby the at least one first projections alternate with the at least one second projections across the first surface and second surface.