Electrical terminal connector and method of fabricating the same

Abstract

An electrical terminal connector and method of fabricating the same is provided. The electrical terminal connector includes an angled insulating housing, a conducting terminal and a cylindrical crimp ferrule positioned therein. Two ends of the insulating housing have a first opening and a second opening, while the angled insulating housing has a through passage therein. The conducting terminal includes a flat-ended connecting portion facing the first opening and a crimped-ended facing the second opening. The cylindrical crimp ferrule has a core-connecting end facing the second opening and a crimped portion facing the crimping end of the conducting terminal. The angled insulating housing further includes a window with a cover at the sidewall near the first opening. One end of the covers pivots at the side of the window, while the other end of the cover comprises a fastening means. The fastening means can be operationally fastened to the matching means forming an opening position and a closed position. The crimped portion of the conducting terminal extends towards the second opening with an elongation. The elongation comprises an axial slit to tolerate radial deformation. The crimping end of the cylindrical crimp ferrule has a diameter slightly larger than that of the extended length at the crimped portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an exploded view of the insulating housing and conducting terminal of the prior art (U.S. Pat. No. 4,298,243).

FIG. 1B is a top view drawing of the conducting terminal of the prior art (U.S. Pat. No. 5,203,726).

FIG. 1C is a sectional view of the cylindrical crimp ferrule of the prior art (U.S. Pat. No. 5,203,726).

FIG. 1D is a three-dimensional view of the conducting terminal of the prior art (U.S. Pat. No. 6,997,746).

FIG. 2A and FIG. 2B are three-dimensional views of a preferred embodiment of the insulating housing.

FIG. 3 is an exploded view of a preferred embodiment of the conducting terminal.

FIG. 4A is a sectional view of a preferred embodiment of deformable cylindrical crimp ferrule.

FIG. 4B is a sectional view of another preferred embodiment of deformable cylindrical crimp ferrule.

FIG. 4C is a sectional view of yet another preferred embodiment of deformable cylindrical crimp ferrule.

FIG. 5 is a flowchart of the connector fabricating process of this invention.

FIG. 6 is a sectional view of the assembled connector of this invention.

Claims

1. An electrical terminal connector, comprising: an angled insulating housing, said angled housing having a first opening and a second opening, a through passage formed within said housing;a conducting terminal positioned within said insulating housing, said conducting terminal having a flat-end connecting portion facing said first opening and a crimped portion facing said second opening; anda deformable crimp ferrule integrally formed in cylindrical shape and positioned within said insulating housing, said deformable crimp ferrule having a core-connecting end facing said second opening and a crimping end facing said crimped portion of said conducting terminal;characterized in that:said insulating housing comprises a window and a cover at a side near said first opening, one end of said cover pivots on a side of said window, the other end of said cover comprises a fastening means, said fastening means is fastened with a matching means of said window to provide an open position and a closed position, said cover is extended with a flange facing said window to provide electrical arc protection when said window and said cover are in said closed position;an elongation is extended from said crimped portion of said conducting terminal facing said second opening, said elongation comprises a axial slit and at least one annular crimping groove;the diameter of said crimping end of said crimp ferrule is slightly larger than that of the elongation of said conducting terminal, said crimp ferrule provided with an indented groove near the midpoint, and a radial enlarging portion provided between said core-connecting end and said indented groove.

2. An electrical terminal connector, comprising: an angled insulating housing, two ends of said angled curve having a first and second opening, having a through passage formed within said housing;a conducting terminal positioned within said insulating housing, said conducting terminal having a flat-ended connecting portion facing said first opening and a crimped-ended facing said second opening; anda deformable crimp ferrule integrally formed in cylindrical shape and positioned within said housing, said deformable crimp ferrule has a core-connecting end facing said second opening and a crimping end facing said crimped portion of said conducting terminal;characterized in that:said insulating housing comprises a window and a cover at a side near said first opening, one end of said cover pivots on a side of said window, the other end of said cover comprises a fastening means, said fastening means is fastened with a matching means of said window to provide an open position and a closed position;an elongation is extended from said crimped portion of said conducting terminal facing said second opening;the diameter of said crimping end of said crimp ferrule is slightly larger than that of the elongation of said conducting terminal.

3. The electrical terminal connector according claim 2, wherein said cover further comprises a flange extending from said cover facing said window to provide electrical arc protection when said window and said cover are in the closed position.

4. The electrical terminal connector according claim 2, wherein the area of said cover is larger than that of said window to provide electrical arc protection when said window and said cover are in the closed position.

5. The electrical terminal connector according claim 2, wherein said crimp ferrule further comprises an indented groove near the midpoint.

6. The electrical terminal connector according claim 2, wherein said core-connecting end of said crimp ferrule further comprises a radial enlarging portion.

7. The electrical terminal connector according claim 2, wherein said elongation of said conducting terminal further comprises at least one annular crimping groove.

8. The electrical terminal connector according claim 2, wherein said elongation of said conducting terminal further comprises at least one axial slit.

9. An angled insulating housing for an electrical terminal connector, said insulating housing comprising a first opening, a second opening, and a through passage formed within, characterized in that: said angled insulating housing comprises a window and a cover on the sidewall near said first opening, one end of said cover pivots on a side of said window, the other end of said cover comprises a fastening means, said fastening means is fastened with a matching means of said window to provide an open position and a closed position, said cover is extended with a flange facing said window to provide electrical arc protection when said window and said cover are in said closed position.

10. A fabricating method of an electrical terminal connector, comprising the following steps: (1) Providing an angled insulating housing which has a first opening, a second opening and a through passage therein, the insulating housing further including a window and a cover on the side wall of the housing adjacent to the first opening, the cover pivoted on the side of the window, a fastening means located on the other end of the cover and fastened to the matching means of window to operatically form an opening position and a closed position;(2) providing a conducting terminal which has a flat-end connecting portion facing the first opening and a crimped portion facing the second opening, the flat-end connecting portion for the external conducting terminal in flat shape to insert therein, while the crimped portion for assembling the crimp ferrule, the crimped portion facing the second opening extended with an elongation in order to being easily assembled in the crimp ferrule;(3) providing a deformable crimp ferrule which has a core-connecting end and a crimping end facing the conducting terminal, the diameter of the crimping end slightly larger than that of the elongation to make the insertion easier;(5) assembling conducting terminal with the deformable crimp ferrule by inserting the elongation of the conducting terminal in 5 the crimping end of the crimp ferrule to cause a partial deformation for a better combination;(5) placing the assembly of the conducting terminal and the deformable crimp ferrule through the window in the passage of the insulating housing, then fastening the cover with the window; and(6) using a preset apparatus from second opening to enlarge the diameter of the core-connecting end of the crimp ferrule, hence, an electrical terminal connector formed for connecting a flat conducting terminal and a conducting core with insulating cladding.

11. The fabricating method of an electrical terminal connector according claim 10, wherein said cover further comprises a flange extending from said cover facing said window to provide electrical arc protection when said window and said cover are in the closed position.

12. The fabricating method of an electrical terminal connector according claim 10, wherein said cover is larger than that of said window to provide electrical arc protection when said window and said cover are in the closed position.

13. The fabricating method of an electrical terminal connector according claim 10, wherein said crimp ferrule further comprises an indented groove near the midpoint.

14. The fabricating method of an electrical terminal connector according claim 10, wherein said elongation of said conducting terminal further comprises at least one annular crimping groove.

15. The fabricating method of an electrical terminal connector according claim 10, wherein said elongation of said conducting terminal further comprises at least one axial slit.