Power contact clamp. RU patent 2507649.

FIELD: electricity.

SUBSTANCE: female contact clamp for an electric contactor comprises at least one pair of opposite leads providing for compression of a knife-type contact with the first compressing force. Each adjacent pair of opposite leads has a groove between them and a clamping element arranged at least partially in each groove for application of the second compressing force, which is added to the first compressing force, to the adjacent pair of opposite leads. The clamping element also comprises a setting part formed by a wave-shaped bend of the clamping element. In the alternative version of the contact clamp the setting part comprises a tooth stretching downwards into the groove. The setting part limits rotation and/or longitudinal rolling of the clamp. The electrical connector comprises at least one pair of opposite legs stretching from the body part. Each leg of the pair stretches towards the contact point, in which inner surfaces of opposite legs engage. A spring clamp may be installed above one or more legs.

EFFECT: increased compressing force without thickening and expansion of a contact clamp with simultaneous provision of required permissible current load.

17 cl, 12 dwg

CROSS-REFERENCE TO RELATED APPLICATIONS

Priority is claimed according to preliminary request of the US patent # 61/416894, filed on November 24, 2010, and application DE 102011011151.4, filed February 14, 2011, the descriptions of which is wholly incorporated in this document by reference.

THE TECHNICAL FIELD

This invention relates to a designated terminals, for example, but without limitation, force designated terminals with the possibility of working inside the vehicle to ensure the transfer currents of high power.

BACKGROUND OF THE INVENTION

Terminals constructively can be made of copper, thanks to its high conductivity. However, as the temperature rises, copper may become softer (i.e. lose elasticity). As the current increases in electrical circuits temperature of the contact terminals may increase, copper terminals under such conditions, may have a reduced ability to maintain a large effort of a clip. In the case of covering the copper contact clip, providing squeeze effort specified softening of copper can reduce the overall contact area covered by the knife contact, which can lead to a decrease in the electrical conductivity, increased the resistance and the further increase of temperature. In the normal case, it is desirable to support the dimensions of the junction box or other connective means possible small, while ensuring the required Ampacity. Thus, the increase in compressive force simple thickening or contact terminals of extension may not be appropriate. When using copper imposed on size restrictions can lead to does not fulfil the requirements of force. Usually use copper alloys, which are not amenable to softening up to higher temperatures, but they have lower conductivity.

THE ESSENCE OF THE INVENTION

Covering the clamp for electrical connector, which provides connection of the period covered by the knife contact can contain at least one pair of opposite conclusions providing compression covered knife contact with the first squeeze effort, with each adjacent pair of opposite conclusions is deepening between them, and clamping element located at least partially, in each of the mentioned deepening for the application of the second compressive force to an adjacent pair of opposite conclusions, and the second compressive force is added to the first effort with the creation of the third compressive force, and clamping element contains at least one attachment part conducive to its positioning in the above-mentioned deepening.

Covering the clamp may contain at least one attachment part, formed by wave-shaped bend of the clamping element, and the lower part of the specified wave-like bend comes below the outer surface of the adjacent pair of opposite conclusions.

Covering the clamp may contain clamping element with at least one pair of opposite legs attached one end to the base, with undulating bend is located between the base and opposite the front end of the foot.

Covering the clamp may contain at least one attachment part containing the first row of side extensions held outside on top of the outer surface of the adjacent pair of opposite conclusions, moreover, these side extensions together with the wave-shaped bend limit longitudinal swing and rotation clamping element.

Covering the clamp may contain at least one attachment part containing tooth, which goes down in the mentioned deepening at least on the first distance below the outer surface of the adjacent pair of opposite conclusions to limit the rotation.

Covering the clamp may contain tooth, which has a wave-like form.

Covering the clamp may contain at least one attachment part containing the first row of side extensions, passing outside relatively wave over the outer surface of the adjacent pair of opposite conclusions.

Covering the clamp may contain clamping element containing at least two pairs of opposite legs attached at one end to the appropriate grounds, and transversal element, connecting each pair of opposite legs, with each pair of opposite legs contains one foot, attached to the transversal element, and one foot, not attached to the cross member.

Covering the clamp may contain opposed conclusions that the first composition of metal, and the clamping element has the second composition of the metal, and the first composition of the metal has higher conductivity than the second composition of the metal.

Covering the clamp can have a second composition of metal, having higher temperature of a softening than the first composition of the metal.

Covering the clamp may contain at least two pairs of opposite conclusions, where at least one of the two pairs of opposite conclusions gradually shifted relative to another of at least two pairs of opposite conclusions.

Covering the clamp may contain conclusions flowing in one direction from the hull, which defines the boundaries of the cavity between opposing the upper and lower sides. spaced relatively opposing sides, and referred to the conclusions of the attached only to the upper and lower sides.

Covering the clamp may contain the contact area that contains upper and lower pins extending from the hull, for the connection of a conducting element, and conclusions, body part, top pin and the lower pin are made of a single sheet of bent metal.

Covering the clamp can contain a header pin, which mechanically or electrically connected to the lower contact riveting and/or welding.

Covering the clamp may contain upper and lower terminals, passing, one above another at right angles to the hull, particular in relation to those of opposite conclusions.

Covering the clamp may have a third squeeze effort, sufficient to ensure touch the front end of each pair of opposite conclusions in the absence covered by the contact, and under the influence only of the first compressive force opposed conclusions do not touch each other in the absence covered by the contact.

Electric connector can contain at least one or more pairs of opposite legs off the hull, each leg has essentially the same thickness and tilted inwards relative to the outer perimeter of the hull towards the point of contact of the inner surface of each pair of opposite legs are in contact, and the spring clip, mounted on top of the outer surface of each of the opposite legs to increase the compressive force between the opposite legs, and the spring clip has an undulating wave passing inside relative to the outer surface of the adjacent pairs opposite legs to limit the rotation of the spring clip.

Electric connector can contain legs off in one direction, from hull, which defines the cavity between opposing the upper and lower sides, spaced relatively opposing sides, and these legs attached only to the upper and lower sides of the hull, and the contact area with the upper and lower pins extending from the hull, for the connection of a conducting element, with the upper and lower pins depart, one on top of another, under a right angle from hull defined relative to the opposite legs.

Electric connector can be done in a way that includes cutting a piece of sheet metal, including an even number of legs, part of the Cabinet and the contact part, processing of flat piece of sheet metal so that the opposite side of a piece of sheet metal bring together on the line folding, each leg aligned as one opposite the legs, and each leg bend towards the inside of the hull to ensure contact with the opposite one leg, and the installation of the spring clip for the application of squeezing effort to legs.

Production of this connector may include the formation of a spring clip with a plot of wave-shaped, contributing to the positioning of the spring clip between the opposite legs.

BRIEF DESCRIPTION OF DRAWINGS

The invention was precisely formulated in the appended claims. However, other features in this invention will be more obvious, this invention will be more clear when examining a subsequent detailed description together with the drawings, which

Figure 1 illustrates the site covering contact clamp in accordance with a private aspect of this invention.

Figure 2 illustrates the U-shaped clamping element, in accordance with a private aspect of this invention.

Fig.3-5b illustrate sites covering contact clamp in accordance with a private aspect of this invention.

Figure 6 illustrates the clamping plate in accordance with a private aspect of this invention.

Fig.7 illustrates node stepped covering contact clamp in accordance with a private aspect of this invention.

Fig.8, 8b illustrate site covering contact clip wave form in accordance with a private aspect of this invention.

DETAILED DESCRIPTION OF THE INVENTION

Figure 1 illustrates the site 10 covering contact clip electrical connector, providing connection covered by the contact in accordance with a private aspect of this invention. Site consists of 10 pin clamp 12 with building 14, made with the contact area 16 at one end for connection to any other electrical connector or cable, and multiple pairs of 18, 20 opposite conclusions at the other end of the enclosure, providing a connection with a flat knife covered by the contact, for example, a contact that is connected to the junction box located inside the vehicle (not shown). It is shown that the clamp 12 contains the first and second pair of 18, 20 opposite conclusions, which are spaced to ensure the application of squeezing effort to knife contact. The magnitude of the force generated opposite conclusions 18, 20, can be increased by using the clamping element 24. Figure 2 illustrates the U-shaped clamping element 24 in accordance with a private aspect of this invention, which can be inserted in the clamp 12 to increase the force of contraction of opposite conclusions 18, 20.

Clamping element, 24 may have basic part 26 of which goes first and second paws 28, 30. Clamping element 24 in the transverse direction can be located in deepening 34 formed between adjacent pairs 18, 20 conclusions. Clamping element, 24 may contain the first and second part of the installation 38, 40, standing on top of at least one of the opposite conclusions 18, 20 for the application specified compressive force. Clamping element, 24 may constitute a metal that is different from the composition of the metal pin on the clamp one composition is more conductivity compared with the second, and the second part has higher temperature of a softening than the first, although such a decision is not required as both the composition of the metal may be the same, and/or the clamping element 24 can be made of material not having conductivity. The first composition of the metal can contain any possessing high conductivity of the material, and preferably it can consist of almost pure copper (for example, copper 102), or copper slight inclusions of other substances (e.g., copper 151, which contains about 0.1% zirconium). The second composition of the metal may be a stainless steel, for example SS301, which contains about 17% chromium, 10% of carbon, 7% of Nickel, and the rest of iron.

One of the factors determining force insertion, required for putting the site 10 pin clamp covered by contact, is the amount of additional effort applied clamping element of 24 couples 18, 20 opposite conclusions. Because the 24 provides compressive force, amending the squeeze effort par 18, 20 conclusions, it may be desirable to regulate the resulting normal force by an appropriate selection of materials 14, and/or by selecting the size (length, width, angle, etc.) par 18, 20 conclusions. When determining the amount of the required normal force must also be accounted for electrical requirements to contact the clamp 10, as it may be desirable to increase the effort insert and, accordingly, the normal force to maximize the permissible current loads to provide working modes with high-capacity (for example, at 80, 100 VDC).

For example, a pair of 18, 20 conclusions can ensure the normal force in 4 Newton (N) in the absence of clamping element 24. The addition of clamping element 24 you can increase the normal force on the contact square to 12-15 N. These parameters can be controlled by the choice to achieve a balance between the magnitude of the normal force and temperature rise relative to the temperature of the environment in the area of connection for a given value of the current. Rising temperatures may depend on the amount of current that can pass through the contact area between the pair of conclusions and covered by their knife contact at a specific normal effort to occur temperature increase relative to the ambient temperature in over 55 degrees C. the following table illustrates one example of this relationship.

The normal force (H)

Current (A)

Couples conclusions 18, 20, building 14 and contact platform 16 can be made from the same piece of material. This material can be the same or variable thickness (for example, portions of it may be thicker or thinner to improve rigidity, regulation efforts, etc). This material can be processed cutting, punching, or otherwise forming a continuous material to contain the deepening, reliefs, holes and other structures necessary for ease of folding, bending or other processing to give a flat piece of material illustrated configuration. Opposite hand side of the material can be added together so that the line 44 section or folding is formed between the two parties, when placed in a configuration illustrated. After giving pin terminal 12 illustrated form, clamping element, 24 may be located in deepening 34 using the slopes with expanding mandrel or other device for cultivation of Tarsus 28, 30 on the distance, allowing the insertion of a window of the United end of Tarsus 28, 30 in deepening 34 on far enough for the passage of the front divorced ends feet above the front ends pairs conclusions 18, 20, to the front ends of the paws 28, 30 were over the site of contact between terminals 18, 20 in V-shaped deepening.

The first and second installation sections 38, 40 may contain teeth 46, 48, contributing to the positioning in the deepening 34. Teeth 46, 48 may go down below the outer surface of 52, 54 related findings in deepening 34 to restrict the motion of rotation. Clamping element, 24 may contain additional installation sections 58, 60, 62, 64, made in the form of lateral extensions, contributing to the positioning in the deepening 34 or together with one or more teeth, 46, 48, or instead of them. Lateral expansion 58, 60, 62, 64 can be 28 feet, 30 out over the exterior surfaces 52, 54 adjacent pairs conclusions 18, 20. Figure 2 shows the clamping element 24 contains the installation parts on both legs 28, 30, with the purpose of illustration. The invention involves the use of any number and combination used installation sites.

Teeth 46, 48 may be close to depression V-shaped grooves, available in each pair, 18, 20 conclusions. Teeth 46, 48 can be in a deepening 34 some distance inside relative to the outer surfaces of 52, 54 conclusions 18, 20. Width of teeth, 46, 48 may be approximately equal to the width of deepening 34 to provide between them landing with a slight tightness. Positioning of teeth, 46, 48 in deepening 34 can be helpful to prevent or severe restriction of rotation clamping element. Lateral expansion 58, 60, 62, 64 can be located close to each spike 46, 48. Lateral expansion 58, 60, 62, 64 can pass out on far enough to limit the longitudinal swing/swing around the vertical axis of the spring clip 220. It is shown that the teeth 46, 48 and lateral extensions 58, 60, 62, 64 have the thickness of the material, the same with thick legs 28, 30, however, the invention provides for the possibility of variation in their size and shape.

Fig.3-5b illustrate the kinds of top and bottom nodes 70, 72, 74 covering contact clip, where the clamp 78, 80, 82 contains additional four rows of opposite pairs 86, 88, 90, 92 conclusions to facilitate the accession to the second covered the contact and/or to provide additional accession to the same covered knife contact. Each node 76, 72, 74 contact clip can be made and acts like the above site 10 pin clamp, at least in relation to the existence of a similar clamping element 96, 98, 100, providing pressure of opposite pairs 86, 88, 90, 92 conclusions the knife contact. It is shown that every clamping element, 96, 98, 100 contains two rows of clamping claws 102, 104, 106, 108, 110, 112,114, 116, 118, 120, 124, 126,United on one side of the transversal element 128, 130, 132. Transversal element 128, 130, 132 can be used to provide the relative position of each of a number of related clamping claws 102, 104, 106, 108, 110, 112, 114, 116, 118, 120, 124, 126. However crossbar 128, 130, 132 is an optional feature that can be replaced by individual, that is not United, clamping elements. It is shown that the clamping element, 96, 98, 100, located on the first side of the hull 136, 138, 140, opposite pad 142, 144, 146.

Fig.3-5b illustrate various design pads 142, 144, 146, which connect the connection. It is shown that the contact area 142, 144, 146 is located opposite the opposite conclusions 86, 88, 90, 92 relatively hull 136, 138, 140. Contact Playground 142, 144, 146 can be shaped into the form of illustrated configuration from a flat piece of material by stamping or by any other method of processing. Part of this process may include the formation of a contact clip 78, 80, 82 bending flat piece of material with the creation of illustrated configuration so that one side of the hull 136, 138, 140 formed opposed conclusions 86, 88, 90, 92, and on the other hand formed a contact platform 142, 144, 146. Hull 136, 138, 140 can be shaped into the form with the formation of the opposite side walls 150, 152, 154, 156, 158, 160 and the upper and lower surfaces 162, 164, 166, 168, 170, 172 around the cavity 176, 178, 180. The upper part 162, 166, 170 can go down and rely on the lower part 164, 168, 172 with the creation thereby pad 142, 144, 146. Depending on the required surface contours, for mechanical and electrical connection of the upper and lower parts can be used flat rivet (fig.3), convex rivet (fig.4) and/or welded connection.

Figure 6 illustrates the clamping plate 180, of which may be carved elements 182, 184, 186, 188 with a pair of legs as above clamping element, in accordance with a private aspect of this invention. Couples 182, 184, 186, 188 clamping claws can be accomplished in a process in which the first form every clamping paw, and then give them the illustrated U-shaped. Material, or more specifically, cross-pieces 190, 192, 194, 196 and stripes 200, 202, 204, 206, 208, 210, can be cut with the required intervals for the creation of the clamping elements with any number opposite clamping feet for ease of Assembly, making perform cutting may be delivered rolls or sheets clamping elements. Then roll can be cut to the desired number of terminals depending on the specific configuration of the corresponding contact of the clip. Naturally, it is not assumed that the invention is limited to the U-shaped clamping elements or creating clamping elements in accordance with the specified technological process, as this invention also involves the use of molding or other technological processes.

Fig.7 illustrates node 216 contact clip, in which the clamp 218 contains a pair of opposite conclusions 224, 226, 228, 230, 232, 234, located in a staggered configuration. The value of insertion force may become more critical, if you increase the number of pairs 224, 226, 228, 230, 232, 234 conclusions as each pair 224, 226, 228, 230, 232, 234 conclusions included in connection with knife contact, at the same time increases the value of effort insertion. The specified speed configuration corresponds to the displacement of at least one of the pairs 228, 230 conclusions on the front end (the end from which to insert a knife contact) other couples 224, 226, 232, 234 conclusions. This offset may be useful to reduce and/or control the insertion force required for the introduction of a covered knife contact between the opposite pairs 224, 226, 228, 230, 232, 234 the findings, by limiting the number of pairs 224, 226, 228, 230, 232, 234 conclusions simultaneously incoming in connection with the front end of the period covered by the knife contact. This implies creating a device with the ability to scale, in which a number of conclusions 224, 226, 228, 230, 232, 234 can be increased simply by cutting out a larger number of legs conclusions from sheet material, because each neighbouring 224, 226, 228, 230, 232, 234 the conclusion may be a copy of one pair, made in accordance with the system of engineering criteria, i.e. if a mechanical unification of one pair is sufficient, then this pair can be reproduced as a number of copies.

Fig.8, 8b illustrate node 270 contact clamp contact clip 272, having located under a corner plot 274 contact and undulating clamping element 276. Located under a corner plot 274 contact can be made in a way similar to the method described above, in which the upper and lower parts of the 278, 280 are brought together with the provision of the mounting surface of the connector. Also it is shown that the plot 274 contains ledge 282, which can be used to facilitate the electrical connection or positioning contact clip. It is shown that the clamping element contains 276 undulating installation plot 284, 286 between the base 290, 292, and the front end of the two upper clamping claws of the two pairs of opposite clamping claws 294, 295, 296, 297 (such design can be maintained and clamping element with only one pair of opposite clamping claws). Also shows that the top two tabs 294, 295 are part of the installation 298, 300 in the form of side extensions, and the two bottom tabs 296, 297 contain the installation part in the form of cross member 302. These installation part 298, 300, 302 can be used together to facilitate the positioning of the clamping element 274 in contact clip 218.

Above described contact clip. The clamp may contain mounted along the main terminal and the spring clip. The clamp can contain a number of pins made of well-conductive current alloy (for example, 151, 102 or similar). One side of the contact clip can have one contact plot for accession layer/wire that has a vertical edge, providing mechanical rigidity/durability, and this edge can also have a cross-section of providing electrical characteristics and positioning of the wire during soldering. Other design the contact clip may contain details to facilitate installation/attach a contact clip directly to a printed circuit Board, for example with the use of die-cast housing contact clip with straight pins, which allows attaching of the conclusions of the circuit Board using a soldering. Optimum cross-section of the output can be calculated by summing the full cross-section of all its conclusions and dividing by the number of conclusions.

One design contact clip may contain fastener, having a direct conclusions that can be executed in the form of loops or needle ears to facilitate the connection with the reverse side of the PCB. Contact spring can be made of alloy with high elasticity (for example, stainless steel 301). Spring clip may contain the lining of the spring element for each contact output, where each pair of pads attached to parties couple of conclusions. Contact springs can provide a large normal force, in particular against high temperature of heating wires, mechanical and/or electrically attached to pin clamp to ensure maximum current surface and the maximum permissible load current at high temperatures. Wires can be connected to pin soldering terminal, compression or other means. Wires can be soldered to pin terminal in several directions can have conductor, separated and welded to each side of the contact clip. In addition, instead of stranded wires can be used tyres, to conclusions or squeezed between the conclusions for accession to contact the clamp.

First clamping element can be made of stainless steel, having the characteristics of small softening at elevated temperatures. As a result of the first clamping element may prevent the weakening of compression relevant contact legs clamp at elevated temperatures, which would otherwise reduce the area of contact with the appropriate knife contact. The result of this decision, there is no need for copper alloy or such replacement material with a lower electrical conductivity, since the weakening of the compression minimized.

Discussed above illustrative options for implementation do not describe all possible forms of this invention. The language used in the description, are not limitations, it should be understood that it is possible legislative changes without deviating from the essence and the scope of legal protection of the invention. You can use combinations of signs of different possibilities for creating additional embodiments of the present invention.

1. Covering the clamp for electrical connector that provides the connection with covered knife contact, containing at least one pair of opposite conclusions, providing compression covered knife contact with the first squeeze effort, with each adjacent pair of opposite conclusions is deepening between them, and clamping element located at least partially in each of the mentioned for deepening application of the second compressive force to an adjacent pair of opposite conclusions, and the second compressive force is added to the first effort with the creation of the third compressive force, and clamping element contains at least one attachment part conducive to its positioning in the above-mentioned deepening, and mentioned at least one installation part formed undulating curved clamping element, and the lower part of the specified wave-like bend comes below the outer surface of the adjacent pair of opposite conclusions.

2. Covering the clamp of claim 1, wherein the clamping element contains at least one pair of opposite legs attached one end to the base, with undulating bend is located between the base and opposite the front end of the foot.

3. Covering the clamp of claim 1, wherein at least one installation part contains the first number of side extensions held outside on top of the outer surface of the adjacent pair of opposite conclusions, moreover, these side extensions together with the wave-shaped bend limit longitudinal swing and rotation clamping element.

8. Covering the clamp of claim 1, wherein mentioned opposed the findings are the first composition of the metal, and clamping element has the second composition of the metal, and the first composition of the metal has higher conductivity than the second composition of the metal.

9. Covering the clamp on item 8, in which the second composition of the metal temperature is higher softening than the first composition of the metal.

10. Covering the clamp according to claim 1, containing at least two pairs of opposite conclusions, and at least one of these at least two pairs of opposite conclusions gradually shifted relative to the other of these at least two pairs of opposite conclusions.

11. Covering the clamp of claim 1, wherein the conclusions depart in one direction from the hull, which defines the cavity between opposing the upper and lower sides, spaced relatively opposing sides, and referred to the conclusions of the attached only to those of the upper and lower sides of the hull.

12. Covering the clamp on item 11, additionally contains the contact area that contains upper and lower pins extending from the hull, for the connection of a conducting element, and conclusions, body part, top pin and the lower pin are made of a single sheet of bent metal.

13. Covering the clamp on the 12 in which the upper pin mechanically and electrically connected to the lower contact riveting and/or welding.

14. Covering the clamp on item 13, in which the upper and lower pins are on top of one another at right angles to the hull, particular in relation to those of opposite conclusions.

15. Covering the clamp of claim 1, wherein the third squeeze effort is sufficient to touch the front end of each pair of opposite conclusions in the absence covered by the knife of the contact, and under the influence only of the first compressive force opposed conclusions do not touch each other in the absence covered by the knife contact.

16. Electric connector containing at least one or more pairs of opposite legs off the hull, each leg has essentially the same thickness and tilted inwards relative to the outer perimeter of the hull towards the point of contact of the inner surface of each pair of opposite legs are in contact, and the spring clip, mounted on top of the outer surface of each of the opposite legs to increase the compressive force between the opposite legs, and the spring clip has an undulating wave passing inside relative to the outer surface of the adjacent pairs of opposite legs to limit the rotation of the spring clip, mentioned feet away in one direction, from hull, which defines the cavity between opposing the upper and lower sides, spaced relatively opposite sides of the legs attached only to the upper and lower sides of the hull, with electric connector additionally contains the contact area with the upper and lower the contact surface, the exhaust from the hull, joining a conductive contact, the upper and lower the contact surfaces depart on top of each other at right angles from the hull defined relative to the opposite legs.

17. Covering the clamp for electrical connector that provides the connection with covered knife contact, containing at least one pair of opposite conclusions, providing compression covered knife contact with the first squeeze effort, with each adjacent pair of opposite conclusions is deepening between them, and clamping element located at least partially in each of the mentioned deepening for the application of the second compressive force to an adjacent pair of opposite conclusions, and the second compressive force is added to the first effort with the creation of the third compressive force, and clamping element contains at least one attachment part conducive to its positioning in the above-mentioned deepening, and mentioned at least one installation part contains tooth, which goes down in the mentioned deepening at least on the first distance below the outer surface of the adjacent pair of opposite conclusions to limit the rotation.