Aspects of the disclosed embodiments relate to electrical contacts in various applications, and more particularly to electrical contact assemblies that include a canted coil spring interface in a metal housing that is manufactured in a quick and cost-effective process.
Typical electrical contacts that use a canted coil spring generally have metal housings that are machined from metal rods or tubes. The manufacturing process of machining the housing from a rod or tube is both timely and costly, therefore the end product, which typically reflects the manufacturing cost, results in a relatively expensive unit.
The present disclosure provides an electrical contact assembly made from a stamped connector body, having a first end with a spring groove housing formed over a canted coil spring in order to provide spring retention to a pin or post inserted into the housing. A wire/cable crimp assembly is formed on the other end of the stamped connector body. The spring groove housing may be formed having an opening for insertion of the pin or post that is either substantially parallel or perpendicular to an axis defined at the base of the connector body.
In another aspect, a plastic housing, sleeve, or jacket may be formed over the electrical contact assembly, such as over part or all of the stamped housing, in order to provide insulation and protection.
The various embodiments of the present process for manufacturing electrical contact assemblies have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the present embodiments as expressed by the claims that follow, their more prominent features now will be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description” one will understand how the features of the present embodiments provide advantages, which include reduced complexity of manufacture and assembly, with concomitant cost savings.
In another feature of the present embodiment, a stamped electrical contact assembly is provided. The contact assembly has a first rolled section formed at a first end of a cut-out section and wherein at least a portion of the first rolled section is rolled along a first axis substantially tangent to an outer circumference of the first rolled section and wherein the first rolled section defines an open section and having a groove. The assembly further includes a second rolled section formed at a second end of the cut-out section and wherein at least a portion of the second rolled section is rolled along the first axis substantially tangent to an outer circumference of the second rolled section. The second rolled section coupled to the first rolled section via a bridge section and wherein a canted coil spring is retained in the groove and having a portion of the canted coil spring exposed within the open section.
In a specific feature of the present embodiment, the first rolled section, the bridge section, and the second rolled section are unitarily formed. In other embodiments, the assembly is integrally formed by welding several different pieces together.
The assembly may include a gap separating the first rolled section and exposing at least a portion of the spring that is retained in the groove. The spring can be an axial canted coil spring. In other embodiments, the spring is a radial canted coil spring.
In certain embodiments, the groove can be a V-bottom groove. Alternatively, the groove can have two side walls and a bottom wall located between the two side walls. The side walls may be parallel to one another or at an angle to one another. The bottom wall can be flat, i.e., perpendicular to one of the side walls, or tapered, i.e., angled relative to an axis defined by the open section.
Like the first rolled section, the second rolled section can comprise a gap.
In still yet another feature of the present embodiment, a stamped electrical contact assembly is provided. The assembly comprises a spring groove housing formed at a first end of a cut-out section having a circular body portion defining an open section. A groove is formed by bending a portion of the circular body portion along at least one line segment joining two points on a curve on the circumference of the circular section. A crimp assembly for retaining a cable or wire is formed at a second end of the cut-out section and coupled to the spring groove housing via a bridge section. A canted coil spring is retained in the groove and having a portion of the canted coil spring exposed within the open section.
In one example, the circular body portion comprises one or more cut sections to enable bending at least along two line segments.
The open section can define an axis that is generally perpendicular to an axis defined by the bridge section.
The groove can comprise at least two different groove configurations formed along the first end. For example, one groove section can have a V-shape configuration while the other section of the groove can have a straight wall with a single tapered wall, like a modified V-shape with one of the walls being generally straight, i.e., non-tapered.
A gap may be included at the second end, which defines a line that is generally perpendicular to an axis defined by the open section.
A further feature of the present embodiment is a method for making a stamped electrical contact assembly. The method comprises the steps of stamping a blank to create a preformed shape, forming a first rolled section at a first end of the preformed shape by rolling at least a portion of the preformed shape, the first rolled section defining an open section and a groove, and forming a second rolled section at a second end of the preformed shaped by rolling at least a portion of the second rolled section, the second rolled section coupled to the first rolled section by a bridge section. The method further comprising retaining a canted coil spring in the groove so that at least a portion of the canted coil spring is exposed within the open section. In one example, the first rolled section is rolled along an outer axis and the second section is rolled along the same outer axis.
The method further can comprise placing a cable at the second end before forming the second rolled section.
The first rolled section can comprise at least one cut section to enable folding at least two adjacent sections of the first rolled section.
In any of the described embodiments, the spring can be made from a multi-metallic wire. The wire can include a highly conductive inner core with a less conductive but higher tensile strength outer layer. For example, the wire can include a copper or copper alloy inner core with a stainless steel outer layer. Alternative, the metallurgy can reverse with the more conductive material on the outside.
The various embodiments of the present electrical contact assembly will be discussed in detail with an emphasis on highlighting the advantageous features. These embodiments depict the novel and non-obvious electrical contact assembly shown in the accompanying drawings, which are for illustrative purposes only. These drawings include the following figures, in which like numerals indicate like parts:
a shows a simplified cross-sectional view of an electrical contact assembly with a canted coil spring and a metal housing for connection in accordance with an embodiment;
b shows a simplified top view of the metal housing shown in
c shows simplified cut outs of cross-sectional views AA, BB, and CC from the electrical contact assembly of
a, 2b and 2c are simplified views of a manufacturing process for the electrical contact assembly in accordance with an embodiment;
d is a simplified cross-sectional view of the electrical contact assembly with a mating pin inserted in a direction relative to the base of the metal housing in accordance with an embodiment;
a and 3b are simplified cross-sectional views of an electrical contact assembly with a canted coil spring and a metal housing for connection in accordance with an embodiment;
a, 4b and 4c are simplified views of a manufacturing process for the electrical contact assembly in accordance with an embodiment;
d is a simplified cross-sectional view of the electrical contact assembly with a mating pin inserted in the metal housing in accordance with an embodiment;
a, 5b, 5c and 5d are simplified views of various groove shapes for use with the spring groove housing in accordance with an embodiment; and
The following detailed description describes the present embodiments with reference to the drawings. In the drawings, reference numbers label elements of the present embodiments. These reference numbers are reproduced below in connection with the discussion of the corresponding drawing features.
Metal stamping manufacturing is the process of creating metal parts by applying relatively high pressure to a blank piece of metal and pressing the blank into a desired shape, typically of the cutter used to press against the blank piece. The stamping machine incorporates a specially made form or die that gives the stamped part shape. The metal stamping manufacturing process is capable of high production manufacturing. Although typical stamping speeds do vary, many high production stamping manufacturers are capable of 30 to 80 stamping strokes per minute. Due to the extremely quick manufacturing process of each part, the cost-per-part may be significantly reduced, depending on the complexity of the part.
a shows a simplified cross sectional view of an electrical contact assembly 100 having a canted coil spring 102 housed within a connector body 104 in accordance with an embodiment. The canted coil spring 102 may have a curvilinear shape, such as a garter shape, provided by connecting the opposing ends of the canted coil spring 102. The canted coil spring 102 may be radial, axial, or positioned at a turn angle. The canted coil spring 102 may be made of any metal alloy or any conductive material known in the art, and may be made of a bimetallic or a multi-metallic spring wire. For example, the spring may a multi-metallic as disclosed in, for example, co-pending application Ser. No. 12/767,421, entitled Multilayered Canted Coil Springs and Associated Methods, filed Apr. 26, 2010, the contents of which are expressly incorporated herein by reference.
As described in detail below, the connector body 104 may be a metal stamped body, which may be made of a conductive metal, such as a copper, aluminum, steel, and combinations and alloys thereof, or the connector body 104 may be plated. Referring to
The spring groove housing 108 is sized, shaped and otherwise configured to retain the canted coil spring 102 (
Referring again to
In one embodiment, as shown in
As shown in
The rolling of the preformed shape 204 also rolls the first set of arms 215 into a substantially cylindrical portion (Section CC,
As shown in
In summary, the stamped electrical contact assembly 100 includes a first rolled section or the spring groove housing 108 formed at a first end of the connector body 104 by rolling at least a portion of the assembly along the axis 218 defined along the base of the connector body 104. The first rolled section has a first diameter. After being rolled, the axis 218 is substantially tangent to an outer circumference of the first rolled section. The first rolled section defines the open section 212 and also includes the groove 110. The second rolled section or crimp assembly 106 is formed at the second end of the assembly by rolling at least a portion of the assembly along the same axis 218 as the first rolled section. Thus, the axis 218 is substantially tangent to an outer circumference of the second rolled section as well. The second rolled section has a second diameter that is smaller than the first diameter. The second rolled section is coupled to the first rolled section via the bridge section 107. The canted coil spring 102 is retained in the groove 100 such that at least a portion of the canted coil spring 102 is retained in the groove 110 and at least another portion of the canted coil spring 102 is exposed within the open section.
Advantageously, since both the first set of arms 215 and the second set of arms 217 are rolled along the same axis 218, the rolling of the preformed shape 204 may simultaneously create both the crimp assembly 106 and the spring groove housing 108. In some embodiments, the crimp assembly 106 and the spring groove housing 108 may be created separately, such as rolled in sequential steps or when separately formed and subsequently welded together. Some electrical contact assemblies are manufactured by bending, folding or rolling portions of the assembly about multiple axes to create the connector body. However, creating the crimp assembly 106 and the spring groove housing 108 by rolling the preformed shape 204 along the same axis 218 as described above simplifies the manufacturing process by reducing the amount of manipulation of the preformed shape 204 that is needed.
Small tolerances between the engagement of the canted coil spring 102 and the male pin 214 may be accommodated by adjusting the diameter of the open section 212 by either stretching or compressing the spring groove housing 108 to increase or decrease the size of gap 115 (
d shows a simplified cross sectional view of the electrical contact assembly 100 for an in-line connection with the mating pin 214 inserted in the open section 212 in accordance with an embodiment. As used herein, in-line connection is understood to mean features of the electrical contact assembly 100 that allows it to receive the pin 214 with its central axis parallel, albeit offset, from the axis 218 defined along the base of the connector body. However, the electrical contact assembly 100 is capable of other configurations for receiving the pin 214 and the term is used to merely distinguish by name or reference from other contact assemblies discussed herein only. As shown, a wire or cable 216 may be crimped into the crimp assembly 106 to complete an electrical connection with the male pin 214, via the connector body 104 and the canted coil spring 102.
a and 3b show simplified cross-sectional views of an electrical contact assembly 300 with a canted coil spring 102 and a metal connector body 302 that may be used for creating a perpendicular connection (not in-line) to a pin or post in accordance with another embodiment. As used here, perpendicular connection is understood to mean that the electrical contact assembly 300 is capable of receiving a pin, which has its central axis perpendicular to the axis 218 of the connector body 302 (see
As shown in
In one embodiment, groove 310 retains the canted coil spring 102 such that the groove 310 retains at least an outer portion of the canted coil spring 102. Thus, the other portion of the spring is exposed within the open section 306 to allow the spring to capture the pin or post that is coupled to the electrical contact assembly 300. The spring is configured to provide electrical communication between the pill and the female terminal. In other embodiments, the groove captures more than or less than half of the spring so that the remaining part of the spring is exposed for receiving the pin. The assembly 300 may be used in a holding application as shown in
In one embodiment, as shown in
As shown in
The circular section 412 of the preformed shape 404 may have, fold lines, such as fold lines 408 at predetermined locations. The fold lines 408 allow for the folding, bending or rolling of at least a portion of the circular section 412 of the preformed shape 404 to form sidewalls 410 of the groove 310. The sidewalls 410 capture at least a portion of the canted coil spring 102. Fold lines may be added using conventional means, such as pressing against the blanks to create creases. The die for cutting the blank 402 may also be equipped with edges near the cutting edges to create weakened or deformed areas for folding the blank into a desired final shape.
In one embodiment, the fold lines 408 may embody a plurality of chords, which are straight line segments joining two points on a curve or arc on the circumference of the circular section 412. In other embodiments, only a single chord is incorporated. The portions of the circular section 412 outboard of the chord fold lines 408 may be rolled, bent or folded along the fold lines 408 toward the open section 306. Thus, there may be at least one to a plurality of sidewalls 410 created along the at least one to plurality of chords for capturing and retaining the canted coil spring 102. In one embodiment, the canted coil spring 102 may be positioned on the preformed shape 404 while the preformed shape 404 is being rolled and folded into the final position. More preferably, the spring is positioned in the groove of the housing after the folds and walls have been folded.
Referring again to
d shows a simplified cross sectional view of the electrical contact assembly 300 with a mating pin 416 inserted in the open section 306 in a perpendicular direction relative to the axis 218 of the base of the connector body 302 of the electrical contact assembly housing 300. This creates a perpendicular connection in accordance with the embodiment. As shown a wire or cable 420 may be crimped into the crimp assembly 106 to complete an electrical connection with the male pin 416, via the connector body 302 and the canted coil spring 102. The pin may be a plug or a node, such as a post on a battery terminal.
In summary, the stamped electrical contact assembly 300 includes a spring groove housing 304 formed at a first end of the assembly having a circular section 412 defining an open section 306, and at least a portion of a groove 310 formed by bending, rolling or folding a portion of the circular section 412 along at least one line segment joining two points on a curve on the circumference of the circular section. The crimp assembly 106 is formed at a second end of the assembly 300 and coupled to the spring groove housing 304 via the bridge section 107. The canted coil spring 102 is retained in the groove 310 such that at least a portion of the canted coil spring 102 is retained in the groove and at least another portion of the canted coil spring 102 is exposed within the open section 306.
Although shown in the embodiments above as having either an in-line or a perpendicular connection capability, it should be understood that the electrical contact assemblies might also be formed to have offset connections. The offset connection capability includes connection capability that is between the perpendicular and parallel connection capability by incorporating further fold lines, offset lines, etc.
In addition, the electrical contact assemblies described above may include multiple spring groove housings for accommodating multiple canted coil springs. Such embodiment may be incorporated to receive multiple pins in a multi-pin connector application.
a, 5b, 5c and 5d are simplified views of various groove shapes that may be incorporated in the spring groove housings.
The above description presents the best mode contemplated for the electrical contact assemblies, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use the assemblies. The assemblies, however, are susceptible to modifications and alternate constructions from that discussed above that are equivalent. Consequently, the electrical contact assemblies are not limited to the particular embodiments disclosed. On the contrary, the disclosure covers all modifications and alternate constructions coming within the spirit and scope of the disclosure as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the disclosure. Also, while specific features may be discussed with certain figures or embodiments of the present application, they may be incorporated in other figures or embodiments not expressly discussed provided they functions or features do not conflict.
This is a regular utility application of provisional application No. 61/334,427, filed May 13, 2010, the contents of which are expressly incorporated herein by reference.
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Number | Date | Country | |
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61334427 | May 2010 | US |