MULTIPATH ELECTRIC POWER CONNECTION ASSEMBLY

Abstract

 A multi-way power-connection assembly (10) used to simultaneously connect multiple power-cables (12) to a mating-connector (14) includes a socket-pin (22), and a terminal (30). Each of the multiple power-cables (12) has a conductive-shield (16) overlying and insulated from a single-cable (18) used to conduct power. The socket-pin (22) defines a socket-portion (24) used to make contact with a power-pin (26) of a mating-connector (14). The socket-pin (22) also defines a terminal-portion (28). The terminal (30) defines a crimp-end (32) that is wrapped and crimped around a single-cable (18). The terminal (30) also defines a contact-end (34) that includes a plurality of fingers (36) that surround and make elastic-contact with the terminal-portion (28) of the socket-pin (22).

Description

TECHNICAL FIELD OF INVENTION

[0001] This disclosure generally relates to a multi-way power-connection assembly, and more particularly relates to a terminal that defines a contact-end that includes a plurality of fingers that surround and make elastic-contact with a terminal-portion of a socket-pin.

BACKGROUND OF INVENTION

[0002] High-power connector assemblies are needed for automotive applications such as electric-only vehicles and hybrid vehicles. Because of the vibration, temperature variation, and exposure to contaminate such as water, salt, and dust experienced in automotive applications, the connector assemblies need to be robust but also cost-effective.

SUMMARY OF THE INVENTION

[0003] In accordance with one embodiment, a multi-way power-connection assembly used to simultaneously connect multiple power-cables to a mating-connector is provided. Each of the multiple power-cables has a conductive-shield overlying and insulated from a single-cable used to conduct power. The assembly includes a socket-pin, and a terminal. The socket-pin defines a socket-portion used to make contact with a power-pin of a mating-connector. The socket-pin also defines a terminal-portion. The terminal defines a crimp-end that is wrapped and crimped around a single-cable. The terminal also defines a contact-end that includes a plurality of fingers that surround and make elastic-contact with the terminal-portion of the socket-pin.

[0004] Further features and advantages will appear more clearly on a reading of the following detailed description of the preferred embodiment, which is given by way of non-limiting example only and with reference to the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

[0005] The present invention will now be described, by way of example with reference to the accompanying drawings, in which:

Fig. 1 is an isometric view of a multi-way power-connection assembly in accordance with one embodiment;

Fig. 2 is an exploded view of the assembly of Fig. 1 in accordance with one embodiment;

Fig. 3 is a sectional side view of the assembly of Fig. 1 in accordance with one embodiment;

Figs. 4A is an isometric view of a terminal used in the assembly of Fig. 1 in accordance with one embodiment;

Fig. 4B is a sectional side view of the terminal of Fig. 4A connected to a socket-pin of the assembly of Fig. 1 in accordance with one embodiment; and

Fig. 4C is a close-up sectional side view of the terminal of Fig. 4B in accordance with one embodiment;

Fig. 5A is an isometric view of a seal-retainer used in the assembly of Fig. 1 in accordance with one embodiment;

Fig. 5B is an isometric view of a high-voltage-interlock (HVIL) terminal that is inserted into the seal-retainer of Fig. 5A in accordance with one embodiment; and

Fig. 6 is an isometric view of an outer-ferrule in the assembly of Fig. 1 in accordance with one embodiment.

DETAILED DESCRIPTION

[0006] Fig. 1, Fig. 2, and Fig. 3 cooperatively illustrate a non-limiting example of a multi-way power-connection assembly 10, hereafter referred to as the assembly 10. In general, the assembly 10 is used to simultaneously connect multiple power-cables 12 to a mating-connector 14. Each of the multiple power-cables 12 individually includes a conductive-shield 16 (Fig. 2) overlying and insulated from a single-cable 18 by an insulation-layer 20 (Fig. 3). The single-cable 18 in each of the multiple power-cables 12 is typically used to conduct electrical power to or from the mating-connector 14. By way of example and not limitation, the assembly 10 described herein may be suitable for use in an electric vehicle or hybrid vehicle (not shown) where relatively high voltages (e.g. greater than 32V) and relatively large currents (e.g. greater than 20A) are present at the assembly 10 which may be used to interconnect with a battery and/or electric-motor used to propel the vehicle.

[0007] The conductive-shield 16 is provided to reduce the amount of radiated emissions emitted from the single-cable 18. The shielding of the signal carried by the single-conductor is continued by the assembly 10 to corresponding features on the mating connector 14.

[0008] The assembly 10 includes a socket-pin 22 that defines a socket-portion 24 used to make contact with a power-pin 26 of the mating-connector 14, and defines a terminal-portion 28. The assembly 10 also includes a terminal 30 that defines a crimp-end 32 that is wrapped and crimped around the single-cable 18. The terminal 30 also defines a contact-end 34 that includes a plurality of fingers 36 that surround and make elastic-contact with the terminal-portion 28 of the socket-pin 22. As used herein, the term 'elastic-contact' means that the plurality of fingers 36 is configured to initially (as built state shown in Fig. 4A) establish an opening 38 that is smaller than the terminal-portion 28 of the socket-pin 22. However, when the socket-pin 22 is inserted into the opening 38 as shown in Fig. 4B, the plurality of fingers 36 are deflected radially outward, but maintain elastic pressure against the outside surface of the terminal-portion 28. Both the socket-pin 22 and the terminal 30 are formed of metal suitable for conducting electricity, and forming a reliable electrical contact between the plurality of fingers 36 and the outside surface of the terminal-portion 28. It is contemplated that the metal formulation for each part may be different (e.g. beryllium copper for the terminal 30, hard copper for the socket-pin 22) so that, for example, the material used for the terminal 30 is especially well suited to maintain the aforementioned elastic-contact. It is contemplated that the terminal 30 and/or the socket-pin 22 may be plated to improve or make more reliable the electrical contact therebetween.

[0009] Fig. 4A, Fig. 4B, and Fig. 4C cooperate to illustrate non-limiting details of the socket-pin 22 and the terminal 30. It is contemplated that the plurality of fingers 36 should include at least three fingers so the socket-pin 22 is centered in the opening 38 established by the plurality of fingers 36. It is recognized that additional points of contact will reduce the overall contact resistance between the socket-pin 22 and the terminal 30, so preferably the plurality of fingers 36 includes at least five fingers. For the size of the socket-pin 22 contemplated for this application (e.g. outside diameter of the terminal-portion 28 equal to about 6mm) it is contemplated that the optimum number of fingers is eight fingers to balance the number of fingers with the elastic force applied by each finger to maintain contact with the socket-pin 22. That is, it is expected that as the number of fingers increases the force each finger applies to the terminal-portion 28 will decrease which could make the electrical contact less reliable.

[0010] The crimp-end 32 of the terminal 30 defines a contact-surface 40 that makes contact with the single-cable 18 when the crimp-end 32 is wrapped and crimped around the single-cable 18. The contact-surface 40 may advantageously include or define a plurality of grooves 42 as part of the contact-surface 40. The plurality of grooves 42 serve to make a better contact with the single-cable 18 because the edges of the grooves incrementally deform the surface of the single-cable 18 and thereby make a better gripping contact with the single-cable 18.

[0011] Referring now to Fig. 4C, the assembly may include a contact-spring 44 as a means to make a high-current capacity contact between the socket-pin 22 and the power-pin 26. The contact-spring 44 may include an alternating pattern of a first spring arm 46 and a second spring arm 48 that are generally configured to provide additional points of contact and thereby improve contact performance.

[0012] Fig. 5A illustrates a non-limiting example of a retainer 50 that may be used to retain or attach various parts such a seal 52 to a housing 54 of the assembly 10. The retainer 50 may include or define a terminal-cavity 56 into which a high-voltage-interlock 58 (HVIL 58; see Fig. 5B) is inserted.

[0013] Fig. 5B illustrates non-limiting details of the HVIL 58 which includes two interlock-terminals 60A, 60B used to make contact with two interlock-pins 66 (hidden from view in Fig. 1) of the mating-connector 14. The application requires that the assembly 10 be almost fully seated in the mating-connector 14 before power is provided to the power-pin 26. The two interlock-terminals 60A, 60B are shorted together to provide a means to sense via the two interlock-pins 66 that the assembly 10 is in place. Previously, the shorting together of the two interlock-terminals 60A, 60B was done by soldering a shorting-wire between the two interlock-terminals 60A, 60B. However, it was realized the carrier-strip 62, which is normally removed when the two interlock-terminals 60A, 60B are manufactured, already provided this shorting function. The two interlock-terminals 60A, 60B are advantageously shorted together by a carrier-strip 62 connected to a strip-end 64 of the two interlock-terminals 60A, 60B opposite to two terminal-ends 68 of the two interlock-terminals 60A, 60B, where the two terminal-ends 68 make contact with the two interlock-pins 66. Those in the terminal manufacturing arts will recognize that the carrier-strip 62 is already present when the two interlock-terminals 60A, 60B are formed. Normally, the carrier-strip 62 is removed once the terminals are formed. However, since the application requires that the two interlock-terminals 60A, 60B are shorted together, the normal step of removing the carrier-strip 62 was eliminated from the process, and efficiency was improved.

[0014] When the two interlock-terminals 60A, 60B are formed, the index distance between the two interlock-terminals 60A, 60B is greater than desired. That is, the carrier-strip is too long. To overcome this problem, the carrier-strip 62 includes a folded-portion 70 that brings the two interlock-terminals 60A, 60B closer together than would the case for the carrier-strip 62 without the folded-portion 70.

[0015] Fig. 2 and Fig. 6 cooperate to illustrate non-limiting features of a ferrule-arrangement 74 that electrically couples the conductive-shield 16 of the single-cable 18 to a connector-shield 76 of the assembly 10. An outer-ferrule 78 (see also Fig. 6) of the ferrule-arrangement 74 defines a plurality of dimples 80 that make contact with the conductive-shield 76 when the assembly 10 is assembled. The plurality of dimples 80 are arranged in a first-row 82 and a second-row 84. The first-row 82 is characterized by a first-setback-distance 86 (e.g. 3mm) from a leading-edge 88 of the outer-ferrule 78. The second-row 84 is characterized by a second-setback-distance 90 (e.g. 6mm) from the leading-edge 88 that is greater than the first-setback-distance 86. By arranging the plurality of dimples 80 into two rows, the insertion force necessary to urge the outer-ferrule 78 over the connector-shield 76 is reduced when compared to configurations where four or more dimple are in a single row.

[0016] Accordingly, a multi-way power-connection assembly (the assembly 10 is provided. The assembly 10 provides an economical means to make a high-power connection with shielding and a high-voltage-interlock safety feature.

[0017] While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow.

Claims

1. A multi-way power-connection assembly (10) used to simultaneously connect multiple power-cables (12) to a mating-connector (14), each of the multiple power-cables (12) having a conductive-shield (16) overlying and insulated from a single-cable (18) used to conduct power, said assembly (10) comprising:

a socket-pin (22) that defines a socket-portion (24) used to make contact with a power-pin (26) of a mating-connector (14), and defines a terminal-portion (28);

a terminal (30) that defines a crimp-end (32) that is wrapped and crimped around a single-cable (18) and, defines a contact-end (34) that includes a plurality of fingers (36) that surround and make elastic-contact with the terminal-portion (28) of the socket-pin (22).

2. The assembly (10) in accordance with claim 1, wherein the plurality of fingers (36) includes at least five fingers (36).

3. The assembly (10) in accordance with claim 1 or 2, wherein the plurality of fingers (36) consists of eight fingers (36).

4. The assembly (10) in accordance any one of the preceding claims, wherein the crimp-end (32) of the terminal (30) defines a contact-surface (40) that makes contact with the single-cable (18) when the crimp-end (32) is wrapped and crimped around the single-cable (18), and the contact-surface (40) includes a plurality of grooves (42).

5. The assembly (10) in accordance any one of the preceding claims, wherein the assembly (10) includes two interlock-terminals (60A) used to make contact with two interlock-pins (66) of the mating-connector (14), wherein the two interlock-terminals (60A) are shorted together by a carrier-strip (62) connected to a strip-end (64) of the two interlock-terminals (60A) opposite to two terminal-ends (68) of the two interlock-terminals (60A) that make contact with the two interlock-pins (66).

6. The assembly (10) in accordance with claim 5, wherein the carrier-strip (62) includes a folded-portion (70) that brings the two interlock-terminals (60A) closer together than would the carrier-strip (62) without the folded-portion (70).

7. The assembly (10) in accordance any one of the preceding claims, wherein the assembly (10) includes a ferrule-arrangement (74) that electrically couples a conductive-shield (16) of the single-cable (18) to a connector-shield (76) of the assembly (10), and an outer-ferrule (78) of the ferrule-arrangement (74) defines a plurality of dimples (80) that make contact with the conductive-shield (16) when the assembly (10) is assembled, wherein the plurality of dimples (80) are arranged in a first-row (82) and a second-row (84), said first-row (82) characterized by a first-setback-distance (86) from a leading-edge (88) of the outer-ferrule (78), said second-row (84) characterized by a second-setback-distance (90) from the leading-edge (88) greater than the first-setback-distance (86).

Drawing