Patent Grant
10854999
Angled electrical header connectors are typically used in high-power transmission applications to provide an electrical connection between terminals in an angled orientation relative to one another. More particularly, this disclosure relates to right-angle electrical headers that are specially configured to have a reduced size and to provide a highly reliable and robust connection in such high-power transmission applications in a manner that is resistant to vibration.
The use of angled electrical header connectors, specifically right-angle electrical headers that are configured to provide an electrical connection between terminals oriented at a right-angle or 90 degrees relative to one another, is known in the art. In such conventional right-angle electrical headers, the two electrical terminals of the header are attached at right-angles to one another outside of the connector housing, and the combined terminals are then introduced into the housing to thereby form the right-angle header. Due to combining the electrical terminals together outside of the housing, the housing in such conventional right-angle headers is sized to accommodate insertion and positioning of the right-angle attached terminals within the housing. As a result, the housing ends up being relatively large to accommodate the 90 degree attached terminals. Additionally, such conventional right-angle electrical headers that utilize externally pre-assembled terminals often require the use of a multi-piece housing to fit size constraints. The use of such a multi-piece housing requires that the different pieces of the housing be properly assembled and then sealed, which increases cost and reduces reliability.
Right-angle headers are typically reserved for those end-use applications that are space constrained (e.g., where using electrical connectors with conventional axially opposed electrical terminals is not possible). Thus, the resulting relatively large size of such conventional right-angle headers may not provide a desired degree of space savings useful to meet the needs of certain space constrained end-use connector applications. While it may be possible to reduce the size of such conventional right-angle electrical headers by certain conventional approaches, the cost associated with such size reduction would be high, thereby making the part expensive and commercially undesirable.
Further, the construction of such conventional right-angle headers (making use of the externally pre-attached electrical terminals and insulating materials that are inserted into the housing during or after installation of the attached terminals) may not provide the highest degree of assurance that all sections of the electrical terminals are adequately electrically insulated from adjacent portions of the connector housing (e.g., to eliminate the possibility of a short circuit when used in high-power transmission applications subject to high levels of vibration) which is especially important both for safety reasons and for purposes of ensuring a desired effective service life of the connector.
It is therefore desired that angled electrical header connectors be constructed in a manner that provides a reduced packaging size when compared to conventional right-angle electrical header connectors to thereby increase the flexibility and spectrum of possible end-use applications. It is also desired that such angled electrical connectors be constructed having a housing that avoids the cost and reliability issues associated with assembly and sealing of conventional multi-piece housings. It is further desired that such angled electrical connectors be constructed in a manner ensuring an improved degree of insulation protection between the terminals and the connector housing, and providing a robust connection between the terminals, thereby ensuring an improved degree of vibration resistance and ensuring effective service life when used in high-power transmission end-use applications as compared to conventional right-angle electrical header connectors.
Angled electrical header connectors comprise a housing that includes a first electrical terminal port and a second electrical terminal port. In an example, the housing is a one-piece construction. In an example, the first electrical terminal port is oriented approximately 90 degrees from the second electrical terminal port. In an example, the first electrical terminal port and the second electrical terminal port are integral with the housing. A first electrical terminal is disposed within the first electrical terminal port, and a first electrical insulator is interposed between the first electrical terminal port and the first electrical terminal. A second electrical terminal is disposed within the second electrical terminal port, and a second electrical insulator is interposed between the second electrical terminal port and the second electrical terminal. In an example, the first electrical terminal is a round pin terminal and the second electrical terminal is a flat terminal. In an example, the housing first electrical terminal port and the housing second electrical terminal port are separated by a housing wall having a passage therein extending between the first and second electrical terminal ports. In an example, the first electrical terminal and the second electrical terminal each include axial ends extending outwardly from the respective first electrical terminal port and second electrical terminal port. The first electrical terminal and the second electrical terminal each include an attachment feature configured to complement one another for attaching and making an electrical-mechanical connection with one another while disposed within the housing. In an example, one attachment feature may be an axial end of one of the first electrical terminal or the second electrical terminal, and the other attachment feature may be an opening in the other of the first electrical terminal or second electrical terminal that is configured to accept placement of the axial end therein. In an example, the first electrical terminal includes the axial end that extends through the passage between the first electrical terminal port and the second electrical terminal port to the second electrical terminal and makes the electrical-mechanical connection second electrical terminal. In an example, the electrical-mechanical connection between the first electrical terminal and the second electrical terminal is made in situ within the housing by axial movement of one electrical terminal within its respective electrical terminal port into contact with the other electrical terminal disposed within its respective electrical terminal port.
A method for making angled electrical header connections comprises forming a first electrical terminal and insulator assembly and a second electrical terminal and insulator assembly, and inserting the first electrical terminal and insulator assembly and the second electrical terminal and insulator assembly into the respective first electrical terminal port and the second electrical terminal port. One of the first electrical terminal or second electrical terminal is displaced within its respective electrical terminal port to form the electrical-mechanical connection with the other of the first electrical terminal or the second electrical terminal in situ within the housing.
Angled electrical header connectors will now be described by way of example with reference to the accompanying figures, wherein like reference numerals refer to like elements, and of which:
Embodiments of angled electrical header connectors will be described herein in detail with reference to the attached drawings, wherein like reference numerals refer to the like elements. Angled electrical header connectors may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that the disclosure will be thorough and complete, and will fully convey the concept of angled electrical header connectors to those skilled in the art.
Angled electrical header connectors are generally configured for use as a right-angle electrical header for providing an electrical connection in high-power transmission applications. In an example, such right-angle electrical header connectors comprise a first electrical terminal 14 and a second electrical terminal 16 that are respectively in the form of a round pin terminal and a flat terminal. The first electrical terminal 14 and the second electrical terminal 16 are oriented at an about right-angle or about 90 degrees relative to one another inside of a housing of the connector. The right-angle header and the terminals are specially engineered to accommodate electrical and mechanical attachment of the terminals to one another in-situ while disposed in the housing, thereby reducing the overall packaging size of the right-angle header connector. Further, the first electrical terminal 14 and the second electrical terminal 16 are configured to include insulating members that have been specially developed to ensure that the terminals are thoroughly insulated from the housing, and to ensure that the terminals are aligned within the housing to facilitate an accurate connection point with an external connector. Configured in this manner, right-angle header connectors provide a reduced package size, while displaying an improved degree of resistance to high vibration in high-power transmission service when compared to conventional right-angle headers.
In an example, the housing 12 is formed from a structurally rigid material that may be either electrically conductive (e.g., metallic or the like) or that may be electrically nonconductive (e.g., a plastic or polymeric material or the like). In an example, the housing is formed from a metallic material. The housing may be formed by a molding process, a machining process or by other process depending on the particular housing configuration and/or material used to form the same. In an example, the housing is molded from aluminum. In an example, the housing is a one-piece integral construction, thereby avoiding the need to assemble and seal separate parts or pieces to form the housing, that provides an improved degree of reliability and cost savings.
Referring to
Referring to
In an example, the first electrical terminal 14 is provided in the form of a round or cylindrical pin terminal having a circular cross-section. In an example, the pin terminal may have a diameter of about 8 mm along the connecting portion 32. In an example, the pin terminal is made from conductive materials such as metals and metal alloys, and in a specific example is made from a copper alloy. However, it is to be understood that angled header connectors are intended to be used with first electrical terminals 14 that may be sized and shaped differently than as specifically described and illustrated depending on the particular end-use application. In an example where the first electrical terminal 14 is other than a pin terminal, the configuration of the first terminal port 18 may vary to accommodate such first electrical terminal 14 configuration, which variation is intended to be within the scope of angled header connectors as disclosed herein. For example, rather than being configured in the form of a pin terminal, first electrical terminals 14 as used in angled header connectors may be configured in the form of receptacle terminals or the like and be configured to provide attachment with the second electrical terminals 16 in situ within the connector housing, and such alternative configuration is intended to be within the scope of angled header connectors as disclosed herein.
In an example, the housing second terminal ports 20 each have an internal cavity 40 that is configured to accommodate the second electrical terminal 16 therein along with a second insulating element or insulator 42 disposed around the second electrical terminal 16. In an example, the second electrical terminal 16 is in the form of a flat terminal having a generally rectangular shape comprising opposed long sides 44 and opposed short sides 46. The second electrical terminal 16 may be formed from the same types of electrically conductive materials used to form the first electrical terminal 14, and in an example is formed from copper. In an example, the second terminal port internal cavity 40 is configured having a first section 48 that extends a distance vertically outwardly from the housing base 24 and that has a width as defined by opposed cavity wall sections 50 and 52 (as shown in
The second terminal port internal cavity 40 includes a second section 56 that extends vertically away from the first section 48 and that forms a closed end 58 of the cavity. In an example, the second section 56 is cylindrical in shape with a diameter matching that of the first section opposed wall sections 50 and 52. The internal cavity second section 56 extends horizontally from the connecting member 22 at one end to the backside wall at an opposed end. The second terminal port 20 includes an open end 60 disposed through the housing base 24 to accommodate placement of the second electrical terminal 16 into the internal cavity 40. In an example, the internal cavity 40 has a length sized to accommodate placement a desired partial longitudinal dimension of the second electrical terminal 16 therein. In an example, it is desired that at least 25 percent, between about 30 to 75 percent, and between about 40 to 60 percent of the total length of the second electrical terminal 16 be accommodated within the second terminal port internal cavity 40.
As best illustrated in
Referring to
In an example, the first insulator is a one-piece construction and the first electrical terminal 14 is combined therewith outside of the housing by a pressing process or the like to form a first terminal and first insulator assembly. With reference to
Alternatively, the first insulator may be formed from two or more elements that are combined around the first electrical terminal 14 before insertion into the housing. Still further, the first insulator may be configured for placement within the housing first terminal port, and thereafter the first electrical terminal 14 may be inserted into the first insulator. All such embodiments are understood to be within the scope of angled electrical header connectors as disclosed herein.
Referring to
Referring to
In an example, the second insulator is a one-piece construction and the second electrical terminal 16 is combined therewith outside of the housing by a pressing process or the like. Alternatively, the second insulator may be formed from two or more elements that are combined around the second electrical terminal 16 before insertion into the housing. Still further, the second insulator may be configured for placement within the housing second terminal port, and then the second electrical terminal 16 may be inserted therein. All such embodiments are understood to be within the scope of angled electrical header connectors as disclosed herein.
Further, while first and second insulators have been described in the form of a preformed element that is then combined with the respective first electrical terminal 14 and second electrical terminal 16, it is to be understood that the first and/or second insulators as used herein may be provided by an overmold process, whereby the desired nonconductive material is combined with the respective electrical terminal and the material is molded over the electrical terminal into a desired form for insertion of the so-formed electrical terminal and insulator assembly into the housing. Further, in an event that the housing is formed from a plastic material, the electrical terminal insulators may be made as part of the housing itself (e.g., the insulators may be integral with the housing), and may not be configured as a separate element combine therewith. It is to be understood that such alternative embodiment is within the scope of angled header connectors as disclosed herein.
Referring to
In an example, the angled header connector is assembled by first engaging and fully inserting the combined second electrical terminal 16 and second insulator into the housing second terminal port by pressing technique or the like. The combined first electrical terminal 14 and first insulator are next engaged with and installed into the housing first terminal port. With reference to
While first electrical terminals 14 and second electrical terminals 16 have been disclosed and illustrated having certain complementary attachment features, it is to be understood that other types and/or configurations of attachment features that are capable of performing the function of providing a strong mechanical attachment and electrical connection between the first and second electrical terminals 14 and 16 while each are disposed within the housing are intended to be within the scope of angled header connectors as disclosed herein. For example, while the use of an elongate cylindrical opening has been disclosed as an attachment feature of the second electrical terminal 16, alternatively the second electrical terminal 16 may be configured having a greater thickness than illustrated to thereby provide an equivalent attachment surface area with the first electrical terminal axial end 66.
Also, while the first electrical terminal attachment feature has been disclosed in the form of an axial end inserted into the second electrical terminal attachment feature in the form of an opening, alternatively the first electrical terminal attachment feature may be provided in the form of an opening that accepts a second electrical terminal attachment feature in the form of a pin or other projecting element extending therefrom for purposes of forming the desired in situ mechanical attachment and electrical connection therebetween while disposed within the housing.
A feature of angled electrical header connectors as disclosed herein is the ability to connect together the first and second electrical terminals 14 and 16 at a right-angle to one another while the electrical terminals are both disposed within the connector housing, thereby enabling use of a smaller sized housing and resulting header connector to expand the flexibility and spectrum of space-constrained end-use applications. Further features of such angled header connectors are the robust mechanical attachment and electrical connection provided between the first and second electrical connectors, and improved insulation between the electrical terminals and the housing, to thereby provide improved resistance to high vibration environments and facilitate use in high-power transmission applications. A still further feature of such angled header connectors is the use of a one-piece housing that reduces cost and increases reliability when contrasted with a multi-piece housing that requires proper assembly and sealing of the different pieces used to form the multi-piece housing.
The foregoing description and accompanying figures illustrate the principles, preferred embodiments and modes of operation of the angled electrical header connectors as disclosed herein. However, such angled electrical header connectors should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art. Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the angled header connectors as defined by the following claims.
For example, the steps recited in any of the method or process descriptions may be executed in any order and are not limited to the order presented. Moreover, any of the functions or steps may be outsourced to or performed by one or more third parties. Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the disclosure. For example, the components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components and the methods described may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order. As used in this document, “each” refers to each member of a set or each member of a subset of a set. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component may include a singular embodiment. Although specific advantages have been enumerated herein, various embodiments may include some, none, or all of the enumerated advantages.
In the detailed description herein, references to “in an example,” “various embodiments,” “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.
| Number | Name | Date | Kind |
|---|---|---|---|
| 6679728 | Huang | Jan 2004 | B1 |
| 9048587 | Marsh | Jun 2015 | B2 |
| 20040137790 | Lee | Jul 2004 | A1 |
