Method of forming an electrical terminal and an electrical terminal assembly

Patent metadata

Field	Value
Publication number	US-11043767-B2
Application number	US-202016863925-A
Country	US
Kind code	B2
Filing date	Apr 30, 2020
Priority date	Mar 26, 2019
Publication date	Jun 22, 2021
Grant date	Jun 22, 2021

Abstract

A method of forming an electrical terminal is presented herein. The method includes the step of stamping an electrical terminal preform from a sheet of metal. The electrical terminal preform having a base plate, a plurality of contact arms radially extending from the base plate, a wire attachment feature radially extending from the base plate, and a carrier strip. The base plate defines crimp wings. The method also includes the step of bending each of the plurality of contact arms to form a socket configured to receive a mating electrical terminal.

First claim

We claim:

1. A method of forming an electrical connector assembly, comprising the steps of:
stamping an electrical terminal preform from a sheet of metal, said electrical terminal preform having a base plate, a plurality of contact arms radially extending from the base plate, a wire attachment feature radially extending from the base plate and defining crimp wings, and a carrier strip;
bending each of the plurality of contact arms to form a socket configured to receive a mating electrical terminal; and
bending a portion of the wire attachment feature to form one of the contact arms in the plurality of contact arms.

2. The method according to claim 1 , further comprising the step of:
forming a first aperture in the base plate.

3. The method according to claim 2 , further comprising the step of:
disposing the base plate and the plurality of contact arms within a cavity of a cover formed of dielectric material.

4. The method according to claim 3 , further comprising the step of:
inserting an attachment stud extending from the cover through the first aperture in the base plate, wherein the attachment stud has a flexible first tapered member extending outwardly from the attachment stud and tapered upwardly toward a cover cap of the cover and wherein the first tapered member engages the base plate, thereby securing the cover to the base plate.

5. The method according to claim 4 , wherein the cover defines a second aperture in the cover cap axially aligned with the first aperture in the base plate and wherein the method further comprises the step of inserting the attachment stud through the second aperture in the cover cap.

6. The method according to claim 5 , wherein the mating electrical terminal has a generally cylindrical shape with a tapered outer sidewall, wherein the mating electrical terminal defines a third aperture axially aligned with the first aperture in the base plate and the second aperture in the cover cap, wherein the attachment stud has a pointed tip opposite the head, wherein the attachment stud has a flexible second tapered member extending outwardly from the attachment stud and tapered upwardly away from the pointed tip of the attachment stud, wherein the method further includes the steps of:
inserting the mating electrical terminal within the socket of the electrical terminal; and
inserting the attachment stud extends through the third aperture in the mating electrical terminal, wherein the second tapered member engages the mating electrical terminal, thereby further securing the cover to the mating electrical terminal.

7. An electrical connector assembly, formed by a process comprising the steps of:
stamping an electrical terminal preform from a sheet of metal, said electrical terminal preform having a base plate, a plurality of contact arms radially extending from the base plate, a wire attachment feature radially extending from the base plate and defining crimp wings, and a carrier strip;
bending each of the plurality of contact arms to form a socket configured to receive a mating electrical terminal; and
bending a portion of the wire attachment feature to form one of the contact arms in the plurality of contact arms.

8. The electrical connector assembly according to claim 7 , wherein the process further comprises the step of:
forming a first aperture in the base plate.

9. The electrical connector assembly according to claim 7 , wherein the process further comprises the step of:
disposing the base plate and the plurality of contact arms within a cavity of a cover formed of dielectric material.

10. The electrical connector assembly according to claim 7 , wherein the process further comprises the step of:
inserting an attachment stud extending from the cover through the first aperture in the base plate, wherein the attachment stud has a flexible first tapered member extending outwardly from the attachment stud and tapered upwardly toward a cover cap of the cover and wherein the first tapered member engages the base plate, thereby securing the cover to the base plate.

11. The electrical connector assembly according to claim 10 , wherein the cover defines a second aperture in the cover cap axially aligned with the first aperture in the base plate and wherein the method further comprises the step of inserting the attachment stud through the second aperture in the cover cap.

12. The electrical connector assembly according to claim 11 , wherein the mating electrical terminal has a generally cylindrical shape with a tapered outer sidewall, wherein the mating electrical terminal defines a third aperture axially aligned with the first aperture in the base plate and the second aperture in the cover cap, wherein the attachment stud has a pointed tip opposite the head, wherein the attachment stud has a flexible second tapered member extending outwardly from the attachment stud and tapered upwardly away from the pointed tip of the attachment stud, wherein the process further includes the steps of:
inserting the mating electrical terminal within the socket of the electrical terminal; and
inserting the attachment stud extends through the third aperture in the mating electrical terminal, wherein the second tapered member engages the mating electrical terminal, thereby further securing the cover to the mating electrical terminal.

Assignees

• Antaya Techologies Corp
• Aptiv Tech Ltd

Inventors

• Martins David B
• Lucci Marco M
• Craven Timothy S
• Palombo Michael J

Classifications

• H01R11/284

  comprising means for preventing corrosion, e.g. covers, enclosures filled with gel · CPC title

• H01R11/282

  comprising means for facilitating engagement or disengagement, e.g. quick release terminal · CPC title

• H01R43/16

  for manufacturing contact members, e.g. by punching and by bending · CPC title

• H01R13/11 Primary

  Resilient sockets (carrying separate resilient parts H01R13/15) · CPC title

• H01R4/64 Primary

  Connections between or with conductive parts having primarily a non-electric function, e.g. frame, casing, rail · CPC title