Amp LLC

The Whitaker Corporation

Advanced Semiconductor Materials America, Inc.

Advanced Simiconductor Materials/america

John K Daly

Earl R Kreinberg

Dean A Puerner

Glenn E Bennett

John E Lucius

Frederick H Rider

William B Fritz

Marty E Adcock

Robert K Grebe

Songchin S Lu

Kenneth F Folk

David S Szczesny

Ernest L Beinhaur

John G Hatfield

Paul S Vinson

Frank H Bermier, Jr

Malvin D Terry

A tappable conductive bus bar (11, 11') has a longitudinal slotted recess (17, 19) receiving at least one louvered spring strip (22, 23). At least one tab (26) is received through a gap (21) in the bus bar (11) to engage the louvered spring strip (22, 23). The bus bar (11) supplies current, with minimum wiring and parts, to one or more tabs (26), and the spacing between adjacent tabs (26) is not critical. Thus, the bus bar (11) is completely tappable.

Tappable bus bar

A right-angle header (10) includes a main housing (50) and a post locating member (200) securable thereto along a rear face thereof and including an array of post-receiving passageways (222,224,236,238) extending vertically therethrough to a mounting face (30), including post-locating portions at least at the mounting face. Contacts (100,130,140,160) include contact sections (118,120,142) exposed for mating across the mating face, body sections (102,132,144) including a right-angle bend, and post sections (110,110',148) which extend through the apertures of the post locating member (200) and beyond the mounting face for insertion into through-holes of a circuit board (40) upon mounting the header (10) thereto. The post-locating portions of passageways (222,224,242) are referenced to a structure (270) of the post locating member defining a datum, instead of to the passageways (52,54,56) of the main housing and are dimensioned to assure that all post sections (110,110',148) will be positioned to enter even off-center through-holes (36,38) and permit float therewithin of the post sections for incremental lateral adjustment to pass through the through-holes.

Right-angle board-mountable electrical connector with precision terminal

A post locating section (200) of a header (10) includes an array of post-receiving apertures (222,224,242) extending to a mounting face (30). Post sections (110,110',148) of header contacts (100,130,140,160) extend through the apertures of the post locating section (200) and beyond the mounting face for insertion into through-holes of a circuit board (40) upon mounting the header (10) thereto. The apertures (222,224,242) are referenced to a structure (270) of the post locating section defining a datum and are optimally dimensioned. The method of dimensioning the apertures includes assessing the manufacturing tolerance limits of the drilled circuit board through-hole diameters and locations, and of the dimension of the post sections, and determining the maximum permissible displacement of the post sections which will still permit entry of the tip sections (112,112',150) into the through-holes (36,38), and bounding the limits of the permissible displacement with the aperture side walls in a manner permitting float of displaced post sections during insertion through the through-holes.

Method of calculating optimum post apertures of a board-mountable

An initially integral terminal useful for terminating to flat conductor cable includes upper and lower plate sections coextending from a hinge to define a cable-receiving region therebetween, with first and second portions of both plate sections defining opposed cooperative arrays of termination means for terminating to said flat cable upon said upper and lower plate sections being pressed toward each other and into the flat cable. Upstanding opposed side wall sections join the first and second portions which are otherwise separated by an aperture proximate the center of the flat cable, enabling easy severing of the side walls at the aperture to define separate electrical terminations after application of the assembly to the flat cable. One or two contact sections can extend from a free edge of one of the upper and lower plate sections for connection to another article, defining a mid-cable tap for either single- or dual-connector cable respectively.

Mid-cable electrical termination

An electrical connector assembly includes a metal shell and a plurality of dielectric housings each housing a terminated end of each of a pair of flat cables of the type for transmission of electrical power at substantial current and voltage levels. Each mating terminal pair includes at least one having a contact section having an array of spring arm contact sections deflected by portions of the other when mated. Each termination is proximate a portion of a shell for heat dissipation. One of the shells is adapted for mounting to a bulkhead at a cutout, and the connectors are environmentally sealed to be appropriate for bulkhead mounting. Each connector includes a strain relief assembly suitable for use with flat cables of substantial rigidity and defines a cable exit, all after said terminated cables and housings therearound are assembled into the shell. A jackscrew system is used for facilitating connector mating.

Strain relief assembly for flat cable connector

Electrical connector for flat power cable

A tap or splice connector especially useful for a pair of dual conductor flat power cables includes two pairs of upper and lower structures which are applied to the stacked in-line cables side-by-side and then enclosed in a housing. The upper and lower structures each have a transverse array of cable-engaging wave-shaped bosses alternating with wave-receiving relief recesses when pressed together, so that the waves press strips of both cables in upper and lower arrays into the opposing recesses thus exposing conductor edges of the strips for electrical connection. Outer surfaces of the structures are then staked to urge the metal thereof laterally and tightly against the conductor edges adjacent thereto. The cables may first be prepared by punching medial slots thereinto at the interconnection site; the structures when applied are spaced from each other; and the housing covers include axial wall sections which extend between the side-by-side structures and through the cable slots, assuring isolation of the circuits. The structures preferably are self-locking upon being staked to secure the upper and lower structures to each other and to the cables. The housing covers may have opposed integral resilient cable-clamping sections to compensate for cable thickness differences.

Electrical connector and method of interconnecting flat power cables

Upper and lower connecting structures for use with flat power cable by being applied to major surfaces thereof, include arrays of cable-engaging bosses alternating with boss-receiving relief recesses; when pressed together the structures at least press conductor strips out of the cable plane and into opposing recesses of the opposing structures, exposing conductor strip edges for electrical connection and defining an array of interdigitated joints. The upper and lower structures are mechanically locked together by forming pockets in the side walls of the relief recesses of each structure to be disposed beside forwardmost portions of the cable-engaging bosses of the opposing structure upon application to the cable, and then deeply staking each of the interdigitated joints to split axially the forwardmost portion of the cable-engaging bosses and force the split portions laterally into the pockets, so that a portion of each structure is locked behind an associated portion of the other structure. The method and structures can be used for terminating an end portion of a cable for connection to another electrical article, or for forming a tap or splice connection between two flat cables.

Locking means for electrical interconnecting structures

A transition adapter for terminating flat power cable includes a stamped and formed member having opposed plate sections between which an end or an edge portion of the cable is receivable to be terminated where the plate sections have opposing cooperating terminating regions comprised of a plurality of alternating wave shapes and relief recesses, with each wave shape aligned with a recess of the opposing terminating region so that when the plate sections are urged together under sufficient force, the wave crests deflect integral strips of conductor cut of the plane of the cable, exposing sheared conductor edges for electrical connection therewith. Softer metal insert members are secured to and along outer surfaces of the plate sections and are then staked to deform the metal against the sheared conductor edges to engage and form gas-tight electrical connections of substantial surface area therewith. The terminating method can also include staking the wave joints to split them and force the split wave portions laterally, creating strong spring members against which the insert members can be staked for an improved electrical connection.

Electrical termination and method of terminating flat power cable

A transition adapter for terminating flat power cable includes at least a stamped and formed member having opposed plate sections between which an end or an edge portion of the cable is receivable to be terminated. The plate sections have opposing cooperating terminating regions comprised of a plurality of alternating wave shapes and relief recesses, with each wave shape aligned with a recess of the opposing terminating region. When the plate sections are urged together under sufficient force, shearing edges along each side of each wave shape shear the cable conductor by cooperating with shearing edges of the adjacent wave shape of the opposing terminating region, scissors-fashion. Crests of the wave shapes deflecting the sheared cable portions into the opposing relief recesses, forming a series of interlocking wave joints across the intermeshing terminating regions and terminating the cable between the plate sections. The wave crests deflect integral strips of conductor out of the plane of the cable, exposing sheared conductor edges for electrical connection therewith such as with solder. Softer metal insert members may be secured to and along outer surfaces of the plate sections to engage and form gas-tight electrical connections with substantial surface areas of the sheared conductor edges.

Electrical terminal for wave crimp termination of flat power cable

A pair of transition adapter terminals especially useful for terminating respective conductors of a dual conductor flat power cable, include respective contact sections at forward ends thereof. Cable-receiving slots across rearward ends thereof extend between pairs of integral bight straps or hinge sections joining upper and lower terminal plate sections. The slots receive respective tab-shaped portions of flat power cable insertably thereinto which are then disposed between the opposed slightly spaced upper and lower plate sections. The plate sections include opposing arrays of shearing waves shapes alternating with relief recesses transversely across, with each wave shape opposed from a respective relief recess. When the plate sections are pressed together, the opposing arrays of wave shapes shear the insulation and the conductor of the tab-shaped cable portion therebetween and simultaneously extrude the sheared conductor strips into the opposed relief recesses, exposing sheared conductor edges for enabling electrical connections therewith. The cable is prepared by cutting an axial slot along the centerline preferably dimensioned so that the exposed inwardly facing conductor edges are bitten into by the adjacent bight straps upon pressing together the plate sections.

Electrical terminals and method for terminating flat power cable

Two flat cables are interconnected to comprise a tap connection or a splice connection by stacking them and pressing together against them an assembly of upper and lower interconnecting structures which include opposing regions of alternating shearing wave shapes and relief recesses. The wave shapes shear the conductors of the cables and extrude the thus-sheared conductor strips into the opposing relief recesses so that newly sheared conductor edges are moved adjacent electrical engagement surfaces defined by vertical edges of the adjacent wave shapes. Dual conductor cables have their respective conductors interconnected by using a pair of assemblies of upper and lower interconnecting structures, each assembly having shearing wave shapes and relief recesses disposed transversely across only the half of the cables within which the appropriate conductors are disposed. The upper and lower structures can include lateral flanges which are riveted together after termination to the cables to lock the upper and lower structures together. A pair of housing members can be latched together to house the assemblies of interconnecting structures terminated to the cables.

A monolithic transition adapter terminated to a flat power cable has one or two plate sections extending forwardly from the termination which conclude in an array of first and second alternating spring contact arms deflectable downwardly and upwardly respectively. The spring arms are formed to include free ends having arcuate contact sections convex in opposing directions comprising a lead-in to receive thereinto a blade-like contact member from forwardly thereof, and facilitating the deflection by the mating contact of the spring arms in the respective opposing directions. A monolithic contact member matable with the transition adapter includes a planar body portion having a forward blade contact and a plurality of terminal sections rearwardly thereof such as for interconnecting with a printed circuit board. In one such contact member the blade contact shares providing for an assured lead-in for mating by including a plurality of blade sections in an array of alternating first and second blades angled to define alternating downward and upward ramps to engage respective free ends of the transition adapter's spring arms and initiate the deflection of the spring arms in appropriate opposing directions for mating; this enables the vertical distance between the free ends of the deflected spring contact arms after mating to be minimized, reducing the vertical profile of the mated interface.

Electrical terminals for flat power cable

A transition adapter for terminating flat power cable includes a stamped and formed member having opposed plate sections between which an end or an edge portion of the cable is receivable to be terminated where the plate sections have opposing cooperating terminating regions comprised of a plurality of alternating wave shapes and relief recesses, with each wave shape aligned with a recess of the opposing terminating region so that when the plate sections are urged together under sufficient force, the wave crests deflect integral strips of conductor out of the plane of the cable, exposing sheared conductor edges for electrical connection therewith. Softer metal insert members are secured to and along outer surfaces of the plate sections and are then staked to deform the metal against the shared conductor edges to engage and form gas-tight electrical connections of substantial surface area therewith. The terminating method can also include staking the wave joints to split them and force the split wave portions laterally, creating strong spring members against which the insert members can be staked for an improved electrical connection.

Method of staking a wave crimp for flat power cable termination

A power distribution system utilizes flat power cable in combination with a plurality of adapter members for the distribution of power within electronics systems. The adapter members allow flat power cable to be interconnected to conventional crimpable contacts and thereafter routed through conventional electrical connectors. The adapters also allow interconnection between flat cable and power busses or between flat cables and printed circuit boards. The adapters can also allow the interconnection of tabs and receptacles to flat power cable. The adapters are crimpable to the flat cable by means of hand tools which provides for a versatile means of distributing power.

Growing community of inventors

Scottsdale, AZ, United States of America

John K Daly