Electrical terminal with connection to flexible circuit conductor

Patent metadata

Field	Value
Publication number	US-12155137-B2
Application number	US-202117559376-A
Country	US
Kind code	B2
Filing date	Dec 22, 2021
Priority date	Jun 16, 2021
Publication date	Nov 26, 2024
Grant date	Nov 26, 2024

Abstract

Systems and methods for an electrical connector (e.g., of a vehicle) include a housing and a terminal at least partially disposed in the housing, defining a set of angled blade terminals, and configured to electrically connect to (i) an electrical system along a first axis and (ii) a set of exposed conductive circuit traces of a flexible circuit (FC) arranged along a second axis, wherein an acute angle is defined between the first and second axes and corresponds to the set of angled blade terminals.

First claim

What is claimed is:

1. An electrical connector, comprising:
a housing; and
a terminal at least partially disposed in the housing, defining a set of angled blade terminals, and configured to electrically connect to (i) an electrical system along a first axis and (ii) a set of exposed conductive circuit traces of a flexible substrate (FC) arranged along a second axis, wherein an acute angle is defined between the first and second axes and corresponds to the set of angled blade terminals.

2. The electrical connector of claim 1 , wherein each angled blade terminal defines a larger surface area for electrical contact with a respective exposed conductive circuit trace compared to a perpendicular connection.

3. The electrical connector of claim 1 , wherein the acute angle provides for a low-profile installation arrangement of the electrical system, the electrical connector, and the FC.

4. The electrical connector of claim 1 , wherein the electrical system is a set of round wires or an electrical device comprising the set of round wires.

5. The electrical connector of claim 1 , wherein the electrical system, the electrical connector, and the FC are all part of a vehicle electrical system.

6. The electrical connector of claim 1 , wherein:
the housing includes a first surface extending in a direction parallel to the first axis and defining an aperture; and
a blade terminal of the set of blade terminals is disposed within the aperture and includes a second surface extending in the direction parallel to the second axis.

7. The electrical connector of claim 1 , wherein the set of angled blade terminals are welded to the set of exposed conductive circuit traces via a welding process to form the electrical connection therebetween.

8. The electrical connector of claim 7 , wherein the welding process is laser welding.

9. The electrical connector of claim 7 , wherein each angled blade terminal comprises a set of nibs that electrically contact a respective exposed conductive circuit trace.

10. The electrical connector of claim 9 , wherein the sets of nibs are formed of a welding material utilized in the welding process.

11. An electrical connection method, comprising:
providing a housing;
providing a terminal at least partially disposed in the housing, the terminal defining a set of angled blade terminals and being configured to electrically connect to (i) an electrical system along a first axis and (ii) a set of exposed conductive circuit traces of a flexible substrate (FC) arranged along a second axis, wherein an acute angle is defined between the first and second axes and corresponds to the set of angled blade terminals;
electrically connecting the set of angled blade terminals to the set of exposed conductive circuit traces of the FC; and
electrically connecting an opposing end of the terminal to the electrical system.

12. The method of claim 11 , wherein each angled blade terminal defines a larger surface area for electrical contact with a respective exposed conductive circuit trace compared to a perpendicular connection.

13. The method of claim 11 , wherein the acute angle provides for a low-profile installation arrangement of the electrical system, the housing, and the FC.

14. The method of claim 11 , wherein the electrical system is a set of round wires or an electrical device comprising the set of round wires.

15. The method of claim 11 , wherein the electrical system, the housing, and the FC are all part of a vehicle electrical system.

16. The method of claim 11 , wherein electrically connecting the set of angled blade terminals to the set of exposed conductive circuit traces comprises welding the set of angled blade terminals to the set of exposed conductive circuit traces via a welding process to form the electrical connection therebetween.

17. The method of claim 16 , wherein the welding process is laser welding.

18. The method of claim 16 , wherein each angled blade terminal comprises a set of nibs that electrically contact a respective exposed conductive circuit trace.

19. The method of claim 18 , wherein the sets of nibs are formed of a welding material utilized in the welding process.

20. An electrical system of a vehicle, the electrical system comprising:
an electrical device having a set of three round wires arranged along a first axis;
a flexible substrate (FC) arranged along a second axis and comprising a set of conductive circuit traces disposed within an insulation layer, wherein at least a portion of the insulation layer has been removed thereby providing a set of exposed conductive circuit traces; and
a terminal at least partially disposed in a housing, defining a first and a second opposing end forming a set of angled blade terminals, and configured to electrically connect to the set of three round wires of the electrical device and the set of exposed conductive circuit traces of the FC, wherein an acute angle is defined between the first and second axes and corresponds to the set of angled blade terminals.

21. The electrical system of claim 20 , wherein the electrical device is a vehicle sensor or actuator and wherein the set of three round wires correspond to ground, power, and signal.

Assignees

• Aptiv Tech Ltd
• Aptiv Technologies AG

Inventors

• Brantingham Duane L
• Peterson David R
• Bilas Jared

Classifications

• H01R43/0221

  Laser welding (H01R43/0228 takes precedence) · CPC title

• H01R2201/26

  for vehicles · CPC title

• B60R16/02

  electric {constitutive elements} · CPC title

• H01R43/0256

  for soldering or welding connectors to a printed circuit board · CPC title

• H01R13/10

  Sockets for co-operation with pins or blades · CPC title