WO2017077025A1 - Vehicle earth point connector - Google Patents

Vehicle earth point connector Download PDF

Info

Publication number
WO2017077025A1
WO2017077025A1 PCT/EP2016/076650 EP2016076650W WO2017077025A1 WO 2017077025 A1 WO2017077025 A1 WO 2017077025A1 EP 2016076650 W EP2016076650 W EP 2016076650W WO 2017077025 A1 WO2017077025 A1 WO 2017077025A1
Authority
WO
WIPO (PCT)
Prior art keywords
terminal
connector
vehicle
arm
wires
Prior art date
Application number
PCT/EP2016/076650
Other languages
French (fr)
Inventor
Daniel Dimitrov
Original Assignee
Jaguar Land Rover Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jaguar Land Rover Limited filed Critical Jaguar Land Rover Limited
Priority to DE112016005079.8T priority Critical patent/DE112016005079T5/en
Publication of WO2017077025A1 publication Critical patent/WO2017077025A1/en

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/64—Connections between or with conductive parts having primarily a non-electric function, e.g. frame, casing, rail
    • H01R4/646—Connections between or with conductive parts having primarily a non-electric function, e.g. frame, casing, rail for cables or flexible cylindrical bodies
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/652—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding   with earth pin, blade or socket
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/16—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length only at particular parts of the work
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/03—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations
    • H01R11/05—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations the connecting locations having different types of direct connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/04—Pins or blades for co-operation with sockets
    • H01R13/05—Resilient pins or blades
    • H01R13/055—Resilient pins or blades co-operating with sockets having a rectangular transverse section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/64—Connections between or with conductive parts having primarily a non-electric function, e.g. frame, casing, rail
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
    • H01R13/629—Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure electrical locking indicators, manufacturing tolerances
    • H01R13/631—Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure electrical locking indicators, manufacturing tolerances for engagement only
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2101/00—One pole
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles

Definitions

  • This present disclosure relates to a vehicle earth point connector and particularly, but not exclusively, to a vehicle earth point connector for coupling one or more wires in a vehicle to an earth point on a body of a vehicle. Aspects of the invention relate to a connector and to a vehicle battery system and a vehicle incorporating the connector.
  • vehicle batteries often have one terminal (typically the negative terminal) coupled to the vehicle body through a cable running between the terminal and the body.
  • the cable is typically connected to the vehicle body using nut and bolt or stud type connections.
  • a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle comprising: a terminal having means for receiving one or more fasteners that mechanically attach the terminal to the body of the vehicle; and means for mechanical and electrical attachment to the one or more wires wherein the terminal defines a conductive path from the one or more wires to the body of the vehicle.
  • the terminal includes a body, the receiving means comprises a first arm extending from the body and configured to receive a first fastener of the one or more fasteners and the attachment means comprises a second arm extending from the body and configured for mechanical and electrical attachment to the one or more wires.
  • the one or more wires may include a wire coupled to a terminal of a battery of the vehicle.
  • the terminal may comprise a unitary structure.
  • the terminal may include a terminal body and the receiving means comprises a first arm extending from the terminal body and configured to receive a first fastener of the one or more fasteners and the attachment means comprises a second arm extending from the terminal body and configured for mechanical and electrical attachment to the one or more wires.
  • the terminal body may define a first planar surface disposed in a first plane and said first arm defines a second planar surface disposed in a second plane spaced from the first plane.
  • the second arm may define a third planar surface disposed in a third plane spaced from the first and second planes.
  • the second arm is configured to bend back towards the terminal body such that an end of the second arm is spaced from and faces the terminal body.
  • the terminal body may define a first planar surface disposed in a first plane and the second arm may define a second planar surface disposed in a second plane intersecting the first plane.
  • the attachment means may comprise a third arm extending from the terminal body and configured to receive a second fastener of the one or more fasteners.
  • the terminal body may define a first planar surface disposed in a first plane
  • the first arm may define a second planar surface disposed in a second plane spaced from the first plane
  • the third arm may define a third planar surface disposed in the second plane.
  • the connector may comprise a busbar fastened to said second arm and defining a plurality of contacts, each of the contacts configured to engage one of the one or more wires.
  • the one or more fasteners may comprise a rivet.
  • the one or more fasteners comprise a self-piercing rivet.
  • a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle comprising: a terminal configured for mechanical attachment to the body of the vehicle and for mechanical and electrical attachment to the one or more wires, the terminal defining a conductive path configured to conduct current from the one or more wires to the body of the vehicle; and, a housing molded about the terminal, the housing configured for coupling to a terminal connector disposed at an end of the one or more wires to thereby provide a sealed connection for the one or more wires and the terminal.
  • the one or more wires includes a wire coupled to a terminal of a battery of the vehicle.
  • the terminal may comprise a unitary structure.
  • the terminal may include a terminal body; a first arm extending from the terminal body and configured to receive a first fastener that mechanically attaches the first arm of the terminal to the body of the vehicle; and a second arm extending from the terminal body and configured for mechanical and electrical attachment to the one or more wires, the terminal defining a conductive path between the first and second arms configured to conduct current from the one or more wires to the body of the vehicle.
  • the housing may define a cavity configured to house an outer end of the second arm and an aperture through which an outer end of the first arm extends outwardly of the housing.
  • the second arm may be configured to bend back towards the terminal body such that an end of the second arm is spaced from and faces the terminal body.
  • the terminal may include a third arm extending from the terminal body and configured to receive a second fastener that mechanically attaches the third arm of the terminal to the body of the vehicle.
  • the connector may comprise a busbar coupled to said second arm and defining a plurality of contacts, each of the contacts configured to engage one of the one or more wires.
  • a vehicle battery assembly comprising: a battery having positive and negative terminals; a battery cable connected at one end to one of the terminals of the battery and having one or more wires; and, a connector as described herein.
  • a vehicle comprising the vehicle battery assembly described herein.
  • a method for attaching an earth point connector to a body of a vehicle includes temporarily sealing a cavity in a housing of the connector, the housing disposed about a terminal and configured for coupling to a terminal connector disposed at an end of one or more wires in the vehicle, the terminal having a terminal body and first and second arms extending from the terminal body and defining a conductive path between the first and second arms, the first arm extending outward from the housing and configured for mechanical attachment to the body of the vehicle, the second arm disposed within the cavity of the housing and configured for mechanical and electrical attachment to the one or more wires.
  • the method further includes mechanically attaching the first arm of the terminal of the connector to the body of the vehicle, applying paint to exposed surfaces of the connector and unsealing the cavity in the housing to expose the second arm of the terminal.
  • connection to the earth point connector may be disconnected and reconnected many times without damage to the connection.
  • connection will remain strong and maintain a current pathway despite vehicle vibration.
  • connection is less likely to suffer damage during manufacture or assembly and therefore more likely to maintain a current pathway.
  • connection is less exposed to environmental elements and therefore less likely to undergo oxidation.
  • Figure 1 is a schematic view of a vehicle incorporating a battery system according to one embodiment of the invention
  • Figure 2 is a perspective view of a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle according to one embodiment of the invention
  • Figure 3 is a perspective view of a portion of the connector of Figure 2; and Figure 4 is a perspective view of one embodiment of a connector terminal configured to couple one or more wires to the connector of Figures 2-3.
  • Figure 5 is a cross-sectional view of the connector terminal of Figure 4.
  • Figure 6 is a perspective view of an a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle according to another embodiment of the invention
  • Figure 7 is a perspective view of a portion of the connector of Figure 6;
  • Figure 8 is a perspective view of an a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle according to another embodiment of the invention.
  • Figure 9 is a perspective view of a portion of the connector of Figure 8; and Figure 10 is a flowchart illustrating a method for attaching an earth point connector to a body of a vehicle according to one embodiment of the invention.
  • the connector described herein is used to couple one or more wires in a vehicle to an earth point on a body of the vehicle with a structure that achieves one or more of the following advantages: the ability to disconnect and reconnect the wires from the vehicle body many times without damage to the connection; maintenance of a low resistance current pathway despite vehicle vibration and servicing; and reduced exposure to environmental elements within the vehicle.
  • FIG. 1 illustrates one embodiment of a vehicle 10 incorporating a battery system 12 in accordance with one embodiment of the invention.
  • vehicle 10 incorporating a battery system 12 in accordance with one embodiment of the invention.
  • HEVs hybrid electric vehicles
  • EREVs extended-range electrical vehicles
  • BEVs battery electric vehicles
  • SUVs sports utility vehicles
  • the battery system 12 may include a battery 14, a battery cable 16 having a terminal connector 18 at one end and a connector 20 for coupling one or more wires in the cable 16 to an earth point on the body 22 of the vehicle 10.
  • the battery 14 converts chemical energy into electrical energy and provides that electrical energy to power vehicle systems including electric motors, engine ignition systems, lights, vehicle infotainment systems and other systems.
  • the battery 14 may also stabilize the voltage that is generated by a generator in the vehicle 10 from the conversion of mechanical energy output by a vehicle engine.
  • the battery 14 may comprise a lead-acid, lithium-ion or similar battery.
  • the battery 14 is rechargeable through, for example, the generator on the vehicle 10 or a power source external to the vehicle 10.
  • the battery includes positive and negative terminals 24, 26.
  • One of the terminals-typically the positive terminal 24- is coupled to a power distribution system comprising, for example, junction boxes, wire harnesses, terminals and connectors.
  • the other terminal— typically the negative terminal 26— is connected to the body 22 of the vehicle 10 to provide a path to earth ground.
  • the cable 16 provides an electrical path from one of the terminals 24, 26 to the connector 20 and the body 22.
  • the cable 16 includes one or more conductive wires wrapped in insulation (typically PVC or cross-linked).
  • One end of the cable 16 may include a conventional connector for connecting to a terminal 24, 26 of the battery 14.
  • cable 16 includes a terminal connector 18 (describe in greater detail hereinbelow) at an opposite end configured to connect to the connector 20.
  • the connector 20 provides a means for coupling one or more wires in the cable 16 to an earth point on the body 22 of the vehicle 10.
  • the connector 20 may include a terminal 28 and a housing 30.
  • the terminal 28 provides a conductive path from the wires in the cable 16 to the body 22 of the vehicle 10.
  • the terminal 28 may include a terminal body 32, means, such as arms 34, 36, for receiving one or more fasteners that mechanically attach the terminal 28 to the body 22 of the vehicle 10 and means, such as arm 38, for mechanical and electrical attachment to the wires in the cable 16.
  • the terminal 28 may comprise a unitary or one piece structure. A unitary structure may enable more efficient manufacture of the terminal 28 and the connector 20 and minimizes resistance in the conductive path. It should be understood, however, that the terminal 28 could be formed as a multi-piece structure.
  • the terminal body 32 provides structural support for the arms 34, 36, 38 and orients the arms 34, 36, 38.
  • the terminal body 32 has a substantially rectilinear shape (e.g., a square or rectangular shape) with top and bottom planar surfaces 40, 42 disposed in parallel planes and four sides extending between the planar surfaces 40, 42. It will be appreciated that the shape of the terminal body 32 may vary, however.
  • the arms 34, 36 provide a means for attaching the terminal 28 to the body 22 of the vehicle 10.
  • the arms 34, 36 extend from opposite sides of the terminal body 32.
  • Each of the arms 34, 36 includes a portion 44, 46, respectively, having a substantially rectilinear shape with top and bottom planar surfaces 48, 50 and 52, 54, respectively.
  • the edges of the portion 44, 46 furthest from the terminal body 32 may be rounded as illustrated.
  • Each of the arms 34, 36 further includes a portion 56, 58, respectively, that is substantially S-shaped in cross-section and that extends between the terminal body 32 and a corresponding portion 44, 46 such that (i) the top planar surface 40 of the terminal body 32 and the top planar surfaces 48, 52 of the portions 44, 46 of the arms 34, 36 are disposed in separate planes that are spaced from, and parallel to, one another and (ii) the bottom planar surface 42 of the terminal body 32 and the bottom planar surfaces 50, 54 of the portions 44, 46 of the arms 34, 36 are disposed in separate planes that are spaced from, and parallel to, one another.
  • the terminal 28 provides additional structural support for the connector 20 when assembled to the housing 30 (when the housing is over moulded).
  • the bottom planar surface 42 of the terminal body 32 and the top planar surfaces 48, 52 of the portions 44, 46 of the arms 34, 36 are also disposed in separate planes that are spaced from, and parallel to, one another. It will be appreciated, however, that the surface 42 could alternatively be in the same plane as the surfaces 48, 52.
  • the arms 34, 36 are configured to receive fasteners used to couple the connector 20 to the body 22 of the vehicle 10.
  • the fasteners may comprise bolts, screws, rivets, welds or other conventional fasteners.
  • the fasteners may comprise self-piercing rivets, for example.
  • Self-piercing rivets provide the advantage of coupling the connector 20 to the body 22 without producing swarf or the like which would commonly be formed when using other types of fasteners.
  • the presence of swarf in or around the coupling between the connector 20 and the body 22 may affect the effectiveness of the grounding.
  • the arms 34, 36 may include apertures (not shown) configured to receive fasteners such as bolts or screws. Once the arms 34, 36 are affixed to the body 22 of the vehicle 10 using the fasteners, conventional body painting will assist in further sealing the arms 34, 36 of the terminal 28 from the environment.
  • the arm 38 provides a means for mechanical and electrical attachment to the one or more wires in the cable 16.
  • the arm 38 extends from one side of the terminal body 32 between the opposed sides from which the arms 34, 36 extend.
  • the arm 38 includes a portion 60 having a substantially rectilinear shape with top and bottom planar surfaces 62, 64.
  • the portion 60 may taper to a bevelled edge 66 to facilitate insertion of the arm 38 into a corresponding receptacle in the terminal connector 18.
  • the arm 38 further includes a portion 68 that is substantially C-shaped in cross-section and that extends between the terminal body 32 and the portion 60 such that (i) the arm 38 bends back towards the terminal body 32 so that the end of the arm 38 is spaced from and faces the terminal body 32 and (ii) the top and bottom planar surfaces 62, 64 are disposed in separate planes that are spaced from, and parallel to, the top and bottom planar surfaces 40, 42 of the terminal body 32.
  • the portion 68 of arm 38 initially curves away from the terminal body 32 in a direction opposite to the curve of the portions 56, 58 away from terminal body 32 such that the top and bottom surfaces 62, 64 of the arm 38 are disposed on an opposite side of the planes containing the top and bottom surfaces 40, 42 of the terminal body 32 relative to the top and bottom surfaces 48, 50 and 52, 54 of the arms 34, 36.
  • the housing 30 provides a means for connecting the connector 20 with the terminal connector 18 of the cable 16 and for providing a sealed connection between the terminal 28 and the wires of the cable 16.
  • the housing 30 also provides structural support to the terminal 28 and orients the terminal 28.
  • the housing 30 is moulded about the terminal 28 to form the assembled connector 20.
  • the housing 30 includes a body 70 that defines apertures through which the arms 34, 36 of terminal 28 extend to permit attachment of the arms 34, 36 to the body 22 of the vehicle 10.
  • the body 70 further defines a cavity 72 configured to house the arm 38 of the terminal 28 and permit mechanical and electrical connection of the terminal 28 to the wires of the battery cable 16.
  • the housing 30 is configured for coupling to the terminal connector 18 of the battery cable 16 and, upon connection to the terminal connector 18 provides a sealed connection for the arm 38 of the terminal 28 to the wires in the cable 16 in order to insulate the terminal 28 and connection and prevent them from damage due to exposure to external objects or elements.
  • the body 70 of the housing 30 may therefore define a number of features configured to engage corresponding features on the terminal connector 18 including a lip 74 surrounding an opening to the cavity 72 and rows of teeth 76 on either side of the body 70 for purposes discussed below. It will be appreciated that the shape and dimensions of the housing 30 may vary depending on the shape and dimensions of the terminal 28 and the terminal connector 18.
  • the terminal connector 18 may take on a variety of forms (with resulting modifications to the housing 30 of the connector 20) sufficient to couple the terminal connector 18 to the connector 20 and facilitate the mechanical and electrical attachment of wires (such as those from the cable 16) to the terminal 28.
  • the terminal connector 18 includes a housing 78, a contact carrier 80, a retainer cap 82, and means, such as lever 84, for locking the terminal connector 18 to the connector 20.
  • the housing 78 provides structural support and orients the other components of the terminal connector 18.
  • the housing 78 includes a body 86 that defines a bore 88 extending through the body 86.
  • the bore 88 is sized at one end to receive one end of the contact carrier 80 and at the other end to receive one end of the battery cable 16.
  • the body 86 may include a lip 90 at one end configured to house a lip seal 92 therein and to receive the lip 74 on the housing 30 in order to seal the connection between the terminal connector 18 and the connector 20.
  • the contact carrier 80 mechanically and electrically couples the wires from the battery cable 16 to the terminal 28 of the connector 20.
  • the carrier 80 is configured to receive both one end of the battery cable 16 and the terminal 28 of the connector 20.
  • One end of the carrier 80 is disposed within the bore 88 of the housing 78 and the remainder of the carrier 80 projects from the bore 88.
  • the retainer cap 82 is configured to retain an end of the battery cable 16 within the bore 88 of the housing 78.
  • the cap 82 includes a ring-shaped body 94 that defines a central aperture configured to receive an end of the battery cable 16 and a skirt 96 extending from the body 94 and defining a plurality of locking features configured to engage corresponding features on the outer surface of the body 86 of the housing 78 in order to secure the retainer cap 82, and the battery cable 16, relative to the housing 78.
  • the lever 84 provides a means for locking and unlocking the terminal connector 18 to the connector 20.
  • the lever 84 is mounted to opposite sides of the housing 78 and is configured to pivot about an axis 98 extending through the housing 78 between an unlocked position and a locked position (shown in Figure 4).
  • the lever 84 defines two rows of teeth 100 configured to engage the teeth 76 on the housing 30 in order to couple and lock the terminal connector 18 and the connector 20. It will be appreciated that other means for locking the terminal connector 18 to the connector 20 may be employed including, for example, a slide lock.
  • the connector 102 may again include a terminal 104 and a housing 106.
  • the terminal 104 provides a conductive path from the wires in the cable 16 to the body 22 of the vehicle 10.
  • the terminal 104 may include a terminal body 108, means, such as arms 1 10, 1 12, for receiving one or more fasteners that mechanically attach the terminal 104 to the body 22 of the vehicle 10 and means, such as arm 1 14 for mechanical and electrical attachment to the wires in cable 16.
  • the terminal 104 may comprise a unitary or one piece structure.
  • a unitary structure may enable more efficient manufacture of the terminal 104 and the connector 102 and minimizes resistance in the conductive path. It should be understood, however, that the terminal 104 could be formed as a multi-piece structure.
  • the terminal body 108 provides structural support for the arms 1 10, 1 12, 1 14 and orients the arms 1 10, 1 12, 1 14.
  • the terminal body 108 has a substantially rectilinear shape (e.g., a square or rectangular shape) with top and bottom planar surfaces 1 16, 1 18 disposed in parallel planes and four sides extending between the planar surfaces 1 16, 1 18. It will be appreciated that the shape of the terminal body 108 may vary, however.
  • the arms 1 10, 1 12 provide a means for attaching the terminal 104 to the body 22 of the vehicle 10.
  • the arms 1 10, 1 12 extend from opposite sides of the terminal body 108.
  • Each of the arms 1 10, 1 12 includes a portion 120, 122, respectively, having a substantially rectilinear shape with top and bottom planar surfaces 124, 126 and 128, 130, respectively.
  • the edges of the portion 120, 122 furthest from the terminal body 108 may be rounded as illustrated.
  • Each of the arms 1 10, 1 12 further includes a portion 132, 134, respectively, that is substantially S-shaped in cross-section and that extends between the terminal body 108 and a corresponding portion 120, 122 such that (i) the top planar surface 116 of the terminal body 108 and the top planar surfaces 124, 128 of the portions 120, 122 of the arms 1 10, 1 12 are disposed in separate planes that are spaced from, and parallel to, one another and (ii) the bottom planar surface 1 18 of the terminal body 108 and the bottom planar surfaces 126, 130 of the portions 120, 122 of the arms 1 10, 1 12 are disposed in separate planes that are spaced from, and parallel to, one another.
  • the terminal 104 provides additional structural support for the connector 102 when assembled to the housing 106.
  • the bottom planar surface 1 18 of the terminal body 108 and the top planar surfaces 124, 128 of the portions 120, 122 of the arms 1 10, 1 12 are also disposed in separate planes that are spaced from, and parallel to, one another. It will be appreciated, however, that the surface 1 18 could alternatively be in the same plane as the surfaces 124, 128.
  • the arms 1 10, 1 12 are configured to receive fasteners used to couple the connector 102 to the body 22 of the vehicle 10.
  • the fasteners may comprise bolts, screws, rivets, welds or other conventional fasteners.
  • the fasteners may comprise self-piercing rivets, for example.
  • the arms 1 10, 1 12 may include apertures (not shown) configured to receive fasteners such as bolts or screws. Once the arms 1 10, 1 12 are affixed to the body 22 of the vehicle 10 using the fasteners, conventional body painting will assist in further sealing the arms 1 10, 1 12 of the terminal from the environment.
  • the arm 1 14 provides a means for mechanical and electrical attachment to the one or more wires in the cable 16.
  • the arm 1 14 extends from one side of the terminal body 108 between the opposed sides from which the arms 1 10, 1 12 extend.
  • the arm 1 14 includes a portion 136 having a substantially rectilinear shape with front and back planar surfaces 138, 140.
  • the arm 1 14 further includes a portion 142 that curves between the portion 136 of the arm 1 14 and the terminal body 108 such that the planar surfaces 138, 140 of the arm 1 14 are disposed within planes that intersect planes containing the planar surfaces 1 16, 1 18 of the terminal body 108 and the planar surfaces 124, 126 and 128, 130 of the arms 120, 122, respectively.
  • the portion 142 has an arc length of about ninety degrees such that the planes containing the surfaces 138, 140 of the arm 1 14 are perpendicular to the planes containing the planar surfaces 1 16, 1 18 of the terminal body 108 and the planar surfaces 124, 126 and 128, 130 of the arms 120, 122, respectively.
  • the shape of the arm 1 14 may vary to configure the arm 1 14 for mechanical and electrical coupling to the wires of the cable 16 through the terminal connector 18.
  • the housing 106 provides a means for connecting the connector 102 with the terminal connector 18 of the cable 16 and for providing a sealed connection between terminal 104 and the wires of the cable 16.
  • the housing 106 also provides structural support to the terminal 104 and orients the terminal 104.
  • the housing 106 is moulded about the terminal 104 to form the assembled connector 102.
  • the housing 106 includes a body 144 that defines apertures through which the arms 1 10, 1 12 of the terminal 104 extend to permit attachment of the arms 1 10, 1 12 to the body 22 of the vehicle 10.
  • the body 144 further defines a cavity 146 configured to house the arm 1 14 of the terminal 104 and permit mechanical and electrical connection of the terminal 104 to the wires of the battery cable 16.
  • the housing 106 is configured for coupling to the terminal connector 18 of the battery cable 16 and, upon connection to the terminal connector 18 provides a sealed connection for the arm 1 14 of the terminal 104 to the wires in the cable 16 in order to insulate the terminal 104 and connection and prevent them from damage due to exposure to external objects or elements.
  • the body 144 of the housing 106 may therefore define a number of features configured to engage corresponding features on the terminal connector 18 including a lip 148 surrounding an opening to the cavity 146 and rows of teeth 150 on either side of body 144 to engage corresponding teeth on a locking lever of a terminal connector as described hereinabove. It will be appreciated that the shape and dimensions of the housing 106 may vary depending on the shape and dimensions of the terminal 104 and the terminal connector 18.
  • a connector 152 for coupling one or more wires in the cable 16 to earth ground through the body 22 of the vehicle 10.
  • the connector 152 is substantially similar to connector 102 and may include a terminal 104 and housing 106 as described hereinabove.
  • the connector 152 further includes a busbar 154.
  • the busbar 154 is configured to couple a plurality of wires from the cable 16 or another source to the arm 1 14 of the terminal 104.
  • the busbar 154 may be fastened to the arm 1 14 using welds or other conventional fastening mechanisms capable of conducting current between the busbar 154 and the terminal 104.
  • the busbar 154 defines a plurality of contacts 156 each of which may be configured to engage one or more wires through conventional female terminal connectors formed at the end of each wire. Referring to Figure 9, the busbar 154 may define two spaced rows of contacts 156. It will be appreciated, however, that the shape of the busbar 154 and the number of contacts 156 may vary depending on the application.
  • the method may begin with the process 158 of temporarily sealing the cavity 72 or 146 in the housing 30 or 106 of the connector 20, 102, 152.
  • the cavity 72 or 146 may be sealed using a waterproof seal or cup that adheres to or otherwise cooperates with the lip 74 or 148 to prevent ingress of foreign elements or objects into the cavity 72 or 146. It will be understood that a variety of seals may be used.
  • the method may continue with the process 160 of mechanically attaching the arms 34, 36 or 1 10, 1 12 of the terminal 28 or 104 of the connector 20, 102 or 152 to the body 22 of the vehicle 10.
  • the arms 34, 36 or 1 10, 1 12 may be attached to the body 22 of the vehicle 10 using a variety of fasteners including bolts, screws, rivets, welds or other conventional fasteners.
  • the fasteners may comprise self- piercing rivets, for example.
  • Self-piercing rivets provide the advantage of coupling the connector 20 to the body 22 without producing swarf or the like which would commonly be formed when using other types of fasteners.
  • the presence of swarf in or around the coupling between the connector 20 and the body 22 may affect the effectiveness of the grounding.
  • the method may continue with the process 162 of applying paint to exposed surfaces of the connector 20, 102 or 152.
  • the painting process 162 assist in further sealing arms 34, 36 or 1 10, 1 12 from the environment.
  • the method may continue with the process 164 of unsealing the cavity 72 or 146 in the housing 30 or 106 to expose the arm 38 or 1 14 of the terminal 28 or 104.
  • the waterproof seal or cup may be decoupled from the lip 74 or 148 thereby exposing the arm 38 or 1 14 and permitting attachment of wires to the arm 38 or 1 14 upon connection of a terminal connector 18 to the connector 20, 102, or 152. It will be appreciated in view of the above that at least one benefit or advantage of at least some embodiments or implementations of the present invention, among potentially others, is that the wires from the battery cable or another electrical system can be repeatedly and easily connected and disconnected to the connector without damaging the connection .
  • connectors employ terminals having a shape (e.g. planar) that reduces or eliminates the risk of rotation during connection or disconnection and thereby reduces or eliminates the need to provide anti-rotation mechanisms.
  • the connectors provide for a sealed connection between the terminal and wires preventing oxidation or other damage from environmental conditions or foreign objects and thereby reducing long term maintenance requirements.
  • Another benefit or advantages is that the connector is less likely to be damaged or to loosen as a result of initial assembly of the connection, servicing the connection or vibration during operation of the vehicle and is therefore able to maintain a low resistance current pathway from the wires to ground.
  • the terms “for example,” “e.g.,” “for instance,” “such as,” and “like,” and the verbs “comprising,” “having,” “including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that that the listing is not to be considered as excluding other, additional components or items.

Abstract

A connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle is provided. The connector includes a terminal having means for receiving one or more fasteners that mechanically attach the terminal to the body of the vehicle. The receiving means may comprise one or more arms extending from a body of the terminal that are configured to receive fasteners that mechanically attach the arms of the terminal to the body of the vehicle. The terminal also has means for mechanical and electrical attachment to the one or more wires. The attachment means may comprise another arm extending from the body that is configured for mechanical and electrical attachment to the one or more wires. The terminal defines a conductive path from the one or more wires to the body of the vehicle.

Description

VEHICLE EARTH POINT CONNECTOR
TECHNICAL FIELD
This present disclosure relates to a vehicle earth point connector and particularly, but not exclusively, to a vehicle earth point connector for coupling one or more wires in a vehicle to an earth point on a body of a vehicle. Aspects of the invention relate to a connector and to a vehicle battery system and a vehicle incorporating the connector.
BACKGROUND
Electrical circuits within a vehicle are frequently coupled to earth points on a body of the vehicle. For example, vehicle batteries often have one terminal (typically the negative terminal) coupled to the vehicle body through a cable running between the terminal and the body. The cable is typically connected to the vehicle body using nut and bolt or stud type connections.
While nut and bolt or stud type connections are generally effective, this type of connection has several potential drawbacks. In some vehicles, the battery or other electrical circuit must be disconnected at the ground connection to the vehicle body rather than the negative terminal of the battery. The typical nut and bolt connection, however, is not designed for frequent disconnection and reconnection and is subject to damage from such actions. Nut and bolt or connections may also become loose due to vibration within the vehicle and, as a result, form a high resistance current pathway from the battery or other circuit to the vehicle body. Similarly, cross threading of the nuts and bolts during manufacture or service or applying too little torque during vehicle manufacture or service can also lead to a high resistance current pathway. Conversely, applying too much torque can lead to damage to a bolt (stud) or nut and intermittent breaks in the current pathway. Nut and bolt connections are also frequently exposed to environmental elements within or outside the vehicle and at risk of oxidation and failure.
Accordingly, it is an aim of the present invention to address, for example, one or more of the disadvantages identified above. SUMMARY OF THE INVENTION
According to an aspect of the invention for which protection is sought, there is provided a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle, comprising: a terminal having means for receiving one or more fasteners that mechanically attach the terminal to the body of the vehicle; and means for mechanical and electrical attachment to the one or more wires wherein the terminal defines a conductive path from the one or more wires to the body of the vehicle. In one embodiment, the terminal includes a body, the receiving means comprises a first arm extending from the body and configured to receive a first fastener of the one or more fasteners and the attachment means comprises a second arm extending from the body and configured for mechanical and electrical attachment to the one or more wires.
Optionally, the one or more wires may include a wire coupled to a terminal of a battery of the vehicle.
In certain embodiments the terminal may comprise a unitary structure. Optionally, the terminal may include a terminal body and the receiving means comprises a first arm extending from the terminal body and configured to receive a first fastener of the one or more fasteners and the attachment means comprises a second arm extending from the terminal body and configured for mechanical and electrical attachment to the one or more wires. In certain embodiments the terminal body may define a first planar surface disposed in a first plane and said first arm defines a second planar surface disposed in a second plane spaced from the first plane.
Optionally, the second arm may define a third planar surface disposed in a third plane spaced from the first and second planes. In certain embodiments the second arm is configured to bend back towards the terminal body such that an end of the second arm is spaced from and faces the terminal body.
The terminal body may define a first planar surface disposed in a first plane and the second arm may define a second planar surface disposed in a second plane intersecting the first plane. The attachment means may comprise a third arm extending from the terminal body and configured to receive a second fastener of the one or more fasteners. Optionally, the terminal body may define a first planar surface disposed in a first plane, the first arm may define a second planar surface disposed in a second plane spaced from the first plane and the third arm may define a third planar surface disposed in the second plane.
The connector may comprise a busbar fastened to said second arm and defining a plurality of contacts, each of the contacts configured to engage one of the one or more wires.
Optionally, the one or more fasteners may comprise a rivet. In some embodiments the one or more fasteners comprise a self-piercing rivet.
According to another aspect of the invention for which protection is sought, there is provided a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle, comprising: a terminal configured for mechanical attachment to the body of the vehicle and for mechanical and electrical attachment to the one or more wires, the terminal defining a conductive path configured to conduct current from the one or more wires to the body of the vehicle; and, a housing molded about the terminal, the housing configured for coupling to a terminal connector disposed at an end of the one or more wires to thereby provide a sealed connection for the one or more wires and the terminal.
In certain embodiments the one or more wires includes a wire coupled to a terminal of a battery of the vehicle.
Optionally, the terminal may comprise a unitary structure.
In certain embodiments the terminal may include a terminal body; a first arm extending from the terminal body and configured to receive a first fastener that mechanically attaches the first arm of the terminal to the body of the vehicle; and a second arm extending from the terminal body and configured for mechanical and electrical attachment to the one or more wires, the terminal defining a conductive path between the first and second arms configured to conduct current from the one or more wires to the body of the vehicle. Optionally, the housing may define a cavity configured to house an outer end of the second arm and an aperture through which an outer end of the first arm extends outwardly of the housing.
The second arm may be configured to bend back towards the terminal body such that an end of the second arm is spaced from and faces the terminal body. Optionally, the terminal may include a third arm extending from the terminal body and configured to receive a second fastener that mechanically attaches the third arm of the terminal to the body of the vehicle.
In certain embodiments the connector may comprise a busbar coupled to said second arm and defining a plurality of contacts, each of the contacts configured to engage one of the one or more wires. According to yet another aspect of the invention for which protection is sought, there is provided a vehicle battery assembly, comprising: a battery having positive and negative terminals; a battery cable connected at one end to one of the terminals of the battery and having one or more wires; and, a connector as described herein. According to yet another aspect of the invention for which protection is sought, there is provided a vehicle comprising the vehicle battery assembly described herein.
According to yet another aspect of the invention for which protection is sought, there is provided a method for attaching an earth point connector to a body of a vehicle. The method includes temporarily sealing a cavity in a housing of the connector, the housing disposed about a terminal and configured for coupling to a terminal connector disposed at an end of one or more wires in the vehicle, the terminal having a terminal body and first and second arms extending from the terminal body and defining a conductive path between the first and second arms, the first arm extending outward from the housing and configured for mechanical attachment to the body of the vehicle, the second arm disposed within the cavity of the housing and configured for mechanical and electrical attachment to the one or more wires. The method further includes mechanically attaching the first arm of the terminal of the connector to the body of the vehicle, applying paint to exposed surfaces of the connector and unsealing the cavity in the housing to expose the second arm of the terminal.
Optional features of the various aspects of the invention are set out below in the dependent claims.
At least some embodiments of the present invention have the advantage that the connection to the earth point connector may be disconnected and reconnected many times without damage to the connection. At least some embodiments of the present invention have the advantage that the connection will remain strong and maintain a current pathway despite vehicle vibration. At least some embodiments of the present invention have the advantage that the connection is less likely to suffer damage during manufacture or assembly and therefore more likely to maintain a current pathway. At least some embodiments of the present invention have the advantage that the connection is less exposed to environmental elements and therefore less likely to undergo oxidation.
Within the scope of this application it is expressly intended that the various aspects, embodiments, examples, and alternatives set out in the preceding paragraphs, in the claims, and/or in the following description or drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such embodiments and/or features are incompatible. The applicant reserves the right to change any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.
BRIEF DESCRIPTION OF THE DRAWINGS
One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein like designations denote like elements, and in which: Figure 1 is a schematic view of a vehicle incorporating a battery system according to one embodiment of the invention;
Figure 2 is a perspective view of a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle according to one embodiment of the invention;
Figure 3 is a perspective view of a portion of the connector of Figure 2; and Figure 4 is a perspective view of one embodiment of a connector terminal configured to couple one or more wires to the connector of Figures 2-3.
Figure 5 is a cross-sectional view of the connector terminal of Figure 4.
Figure 6 is a perspective view of an a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle according to another embodiment of the invention; Figure 7 is a perspective view of a portion of the connector of Figure 6;
Figure 8 is a perspective view of an a connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle according to another embodiment of the invention;
Figure 9 is a perspective view of a portion of the connector of Figure 8; and Figure 10 is a flowchart illustrating a method for attaching an earth point connector to a body of a vehicle according to one embodiment of the invention.
DETAILED DESCRIPTION
The connector described herein is used to couple one or more wires in a vehicle to an earth point on a body of the vehicle with a structure that achieves one or more of the following advantages: the ability to disconnect and reconnect the wires from the vehicle body many times without damage to the connection; maintenance of a low resistance current pathway despite vehicle vibration and servicing; and reduced exposure to environmental elements within the vehicle.
Referring now to the drawings wherein like reference numbers are used to identify identical components in the various views, Figure 1 illustrates one embodiment of a vehicle 10 incorporating a battery system 12 in accordance with one embodiment of the invention. Although the following description is provided in the context of the particular vehicle illustrated in Figure 1 , it will be appreciated that this vehicle is merely an example and that other vehicles may certainly be used instead. For instance, in various embodiments, the battery system and related components described herein may be used with any type of vehicle including traditional vehicles, hybrid electric vehicles (HEVs), extended-range electrical vehicles (EREVs), battery electric vehicles (BEVs), passenger cars, sports utility vehicles (SUVs), cross-over vehicles, and trucks, to cite a few possibilities. Further, although the following description is provided in the context of providing an earth point connection for wires in the battery system 12, it will be appreciated that the embodiments of the invention described herein could be used to couple wires from various electrical systems within the vehicle 10 to earth points on the body of the vehicle 10. According to the illustrated embodiment, the battery system 12 may include a battery 14, a battery cable 16 having a terminal connector 18 at one end and a connector 20 for coupling one or more wires in the cable 16 to an earth point on the body 22 of the vehicle 10.
The battery 14 converts chemical energy into electrical energy and provides that electrical energy to power vehicle systems including electric motors, engine ignition systems, lights, vehicle infotainment systems and other systems. The battery 14 may also stabilize the voltage that is generated by a generator in the vehicle 10 from the conversion of mechanical energy output by a vehicle engine. The battery 14 may comprise a lead-acid, lithium-ion or similar battery. The battery 14 is rechargeable through, for example, the generator on the vehicle 10 or a power source external to the vehicle 10. The battery includes positive and negative terminals 24, 26. One of the terminals-typically the positive terminal 24- is coupled to a power distribution system comprising, for example, junction boxes, wire harnesses, terminals and connectors. The other terminal— typically the negative terminal 26— is connected to the body 22 of the vehicle 10 to provide a path to earth ground.
The cable 16 provides an electrical path from one of the terminals 24, 26 to the connector 20 and the body 22. The cable 16 includes one or more conductive wires wrapped in insulation (typically PVC or cross-linked). One end of the cable 16 may include a conventional connector for connecting to a terminal 24, 26 of the battery 14. In accordance with certain embodiments of the invention, cable 16 includes a terminal connector 18 (describe in greater detail hereinbelow) at an opposite end configured to connect to the connector 20. Referring to Figures 2-3, the connector 20 provides a means for coupling one or more wires in the cable 16 to an earth point on the body 22 of the vehicle 10. The connector 20 may include a terminal 28 and a housing 30.
The terminal 28 provides a conductive path from the wires in the cable 16 to the body 22 of the vehicle 10. The terminal 28 may include a terminal body 32, means, such as arms 34, 36, for receiving one or more fasteners that mechanically attach the terminal 28 to the body 22 of the vehicle 10 and means, such as arm 38, for mechanical and electrical attachment to the wires in the cable 16. In accordance with one aspect of certain embodiments of the invention, the terminal 28 may comprise a unitary or one piece structure. A unitary structure may enable more efficient manufacture of the terminal 28 and the connector 20 and minimizes resistance in the conductive path. It should be understood, however, that the terminal 28 could be formed as a multi-piece structure.
The terminal body 32 provides structural support for the arms 34, 36, 38 and orients the arms 34, 36, 38. In the illustrated embodiment, the terminal body 32 has a substantially rectilinear shape (e.g., a square or rectangular shape) with top and bottom planar surfaces 40, 42 disposed in parallel planes and four sides extending between the planar surfaces 40, 42. It will be appreciated that the shape of the terminal body 32 may vary, however.
The arms 34, 36 provide a means for attaching the terminal 28 to the body 22 of the vehicle 10. The arms 34, 36 extend from opposite sides of the terminal body 32. Each of the arms 34, 36 includes a portion 44, 46, respectively, having a substantially rectilinear shape with top and bottom planar surfaces 48, 50 and 52, 54, respectively. The edges of the portion 44, 46 furthest from the terminal body 32 may be rounded as illustrated. Each of the arms 34, 36 further includes a portion 56, 58, respectively, that is substantially S-shaped in cross-section and that extends between the terminal body 32 and a corresponding portion 44, 46 such that (i) the top planar surface 40 of the terminal body 32 and the top planar surfaces 48, 52 of the portions 44, 46 of the arms 34, 36 are disposed in separate planes that are spaced from, and parallel to, one another and (ii) the bottom planar surface 42 of the terminal body 32 and the bottom planar surfaces 50, 54 of the portions 44, 46 of the arms 34, 36 are disposed in separate planes that are spaced from, and parallel to, one another. In this manner, the terminal 28 provides additional structural support for the connector 20 when assembled to the housing 30 (when the housing is over moulded). In the illustrated embodiment, the bottom planar surface 42 of the terminal body 32 and the top planar surfaces 48, 52 of the portions 44, 46 of the arms 34, 36 are also disposed in separate planes that are spaced from, and parallel to, one another. It will be appreciated, however, that the surface 42 could alternatively be in the same plane as the surfaces 48, 52. The arms 34, 36 are configured to receive fasteners used to couple the connector 20 to the body 22 of the vehicle 10. The fasteners may comprise bolts, screws, rivets, welds or other conventional fasteners. The fasteners may comprise self-piercing rivets, for example. Self-piercing rivets provide the advantage of coupling the connector 20 to the body 22 without producing swarf or the like which would commonly be formed when using other types of fasteners. The presence of swarf in or around the coupling between the connector 20 and the body 22 may affect the effectiveness of the grounding. The arms 34, 36 may include apertures (not shown) configured to receive fasteners such as bolts or screws. Once the arms 34, 36 are affixed to the body 22 of the vehicle 10 using the fasteners, conventional body painting will assist in further sealing the arms 34, 36 of the terminal 28 from the environment.
The arm 38 provides a means for mechanical and electrical attachment to the one or more wires in the cable 16. The arm 38 extends from one side of the terminal body 32 between the opposed sides from which the arms 34, 36 extend. The arm 38 includes a portion 60 having a substantially rectilinear shape with top and bottom planar surfaces 62, 64. The portion 60 may taper to a bevelled edge 66 to facilitate insertion of the arm 38 into a corresponding receptacle in the terminal connector 18. The arm 38 further includes a portion 68 that is substantially C-shaped in cross-section and that extends between the terminal body 32 and the portion 60 such that (i) the arm 38 bends back towards the terminal body 32 so that the end of the arm 38 is spaced from and faces the terminal body 32 and (ii) the top and bottom planar surfaces 62, 64 are disposed in separate planes that are spaced from, and parallel to, the top and bottom planar surfaces 40, 42 of the terminal body 32. The portion 68 of arm 38 initially curves away from the terminal body 32 in a direction opposite to the curve of the portions 56, 58 away from terminal body 32 such that the top and bottom surfaces 62, 64 of the arm 38 are disposed on an opposite side of the planes containing the top and bottom surfaces 40, 42 of the terminal body 32 relative to the top and bottom surfaces 48, 50 and 52, 54 of the arms 34, 36. Although a particular shape for the arm 38 has been illustrated, it will be appreciated that the shape of the arm 38 may vary to configure the arm 38 for mechanical and electrical coupling to the wires of the cable 16 through the terminal connector 18. The housing 30 provides a means for connecting the connector 20 with the terminal connector 18 of the cable 16 and for providing a sealed connection between the terminal 28 and the wires of the cable 16. The housing 30 also provides structural support to the terminal 28 and orients the terminal 28. The housing 30 is moulded about the terminal 28 to form the assembled connector 20. The housing 30 includes a body 70 that defines apertures through which the arms 34, 36 of terminal 28 extend to permit attachment of the arms 34, 36 to the body 22 of the vehicle 10. The body 70 further defines a cavity 72 configured to house the arm 38 of the terminal 28 and permit mechanical and electrical connection of the terminal 28 to the wires of the battery cable 16. The housing 30 is configured for coupling to the terminal connector 18 of the battery cable 16 and, upon connection to the terminal connector 18 provides a sealed connection for the arm 38 of the terminal 28 to the wires in the cable 16 in order to insulate the terminal 28 and connection and prevent them from damage due to exposure to external objects or elements. The body 70 of the housing 30 may therefore define a number of features configured to engage corresponding features on the terminal connector 18 including a lip 74 surrounding an opening to the cavity 72 and rows of teeth 76 on either side of the body 70 for purposes discussed below. It will be appreciated that the shape and dimensions of the housing 30 may vary depending on the shape and dimensions of the terminal 28 and the terminal connector 18.
Referring to Figure 4-5, one embodiment of a terminal connector 18 will be described. Although a particular terminal connector 18 is illustrated, it should be understood that the terminal connector 18 may take on a variety of forms (with resulting modifications to the housing 30 of the connector 20) sufficient to couple the terminal connector 18 to the connector 20 and facilitate the mechanical and electrical attachment of wires (such as those from the cable 16) to the terminal 28. In the illustrated embodiment, the terminal connector 18 includes a housing 78, a contact carrier 80, a retainer cap 82, and means, such as lever 84, for locking the terminal connector 18 to the connector 20.
The housing 78 provides structural support and orients the other components of the terminal connector 18. The housing 78 includes a body 86 that defines a bore 88 extending through the body 86. The bore 88 is sized at one end to receive one end of the contact carrier 80 and at the other end to receive one end of the battery cable 16. The body 86 may include a lip 90 at one end configured to house a lip seal 92 therein and to receive the lip 74 on the housing 30 in order to seal the connection between the terminal connector 18 and the connector 20.
The contact carrier 80 mechanically and electrically couples the wires from the battery cable 16 to the terminal 28 of the connector 20. The carrier 80 is configured to receive both one end of the battery cable 16 and the terminal 28 of the connector 20. One end of the carrier 80 is disposed within the bore 88 of the housing 78 and the remainder of the carrier 80 projects from the bore 88.
The retainer cap 82 is configured to retain an end of the battery cable 16 within the bore 88 of the housing 78. The cap 82 includes a ring-shaped body 94 that defines a central aperture configured to receive an end of the battery cable 16 and a skirt 96 extending from the body 94 and defining a plurality of locking features configured to engage corresponding features on the outer surface of the body 86 of the housing 78 in order to secure the retainer cap 82, and the battery cable 16, relative to the housing 78.
The lever 84 provides a means for locking and unlocking the terminal connector 18 to the connector 20. In the illustrated embodiment, the lever 84 is mounted to opposite sides of the housing 78 and is configured to pivot about an axis 98 extending through the housing 78 between an unlocked position and a locked position (shown in Figure 4). The lever 84 defines two rows of teeth 100 configured to engage the teeth 76 on the housing 30 in order to couple and lock the terminal connector 18 and the connector 20. It will be appreciated that other means for locking the terminal connector 18 to the connector 20 may be employed including, for example, a slide lock.
Referring now to Figures 6-7, another embodiment of a connector 102 is provided for coupling one or more wires in the cable 16 to an earth point on the body 22 of the vehicle 10. The connector 102 may again include a terminal 104 and a housing 106. The terminal 104 provides a conductive path from the wires in the cable 16 to the body 22 of the vehicle 10. The terminal 104 may include a terminal body 108, means, such as arms 1 10, 1 12, for receiving one or more fasteners that mechanically attach the terminal 104 to the body 22 of the vehicle 10 and means, such as arm 1 14 for mechanical and electrical attachment to the wires in cable 16. In accordance with one aspect of certain embodiments of the invention, the terminal 104 may comprise a unitary or one piece structure. A unitary structure may enable more efficient manufacture of the terminal 104 and the connector 102 and minimizes resistance in the conductive path. It should be understood, however, that the terminal 104 could be formed as a multi-piece structure. The terminal body 108 provides structural support for the arms 1 10, 1 12, 1 14 and orients the arms 1 10, 1 12, 1 14. In the illustrated embodiment, the terminal body 108 has a substantially rectilinear shape (e.g., a square or rectangular shape) with top and bottom planar surfaces 1 16, 1 18 disposed in parallel planes and four sides extending between the planar surfaces 1 16, 1 18. It will be appreciated that the shape of the terminal body 108 may vary, however.
The arms 1 10, 1 12 provide a means for attaching the terminal 104 to the body 22 of the vehicle 10. The arms 1 10, 1 12 extend from opposite sides of the terminal body 108. Each of the arms 1 10, 1 12 includes a portion 120, 122, respectively, having a substantially rectilinear shape with top and bottom planar surfaces 124, 126 and 128, 130, respectively. The edges of the portion 120, 122 furthest from the terminal body 108 may be rounded as illustrated. Each of the arms 1 10, 1 12 further includes a portion 132, 134, respectively, that is substantially S-shaped in cross-section and that extends between the terminal body 108 and a corresponding portion 120, 122 such that (i) the top planar surface 116 of the terminal body 108 and the top planar surfaces 124, 128 of the portions 120, 122 of the arms 1 10, 1 12 are disposed in separate planes that are spaced from, and parallel to, one another and (ii) the bottom planar surface 1 18 of the terminal body 108 and the bottom planar surfaces 126, 130 of the portions 120, 122 of the arms 1 10, 1 12 are disposed in separate planes that are spaced from, and parallel to, one another. In this manner, the terminal 104 provides additional structural support for the connector 102 when assembled to the housing 106. In the illustrated embodiment, the bottom planar surface 1 18 of the terminal body 108 and the top planar surfaces 124, 128 of the portions 120, 122 of the arms 1 10, 1 12 are also disposed in separate planes that are spaced from, and parallel to, one another. It will be appreciated, however, that the surface 1 18 could alternatively be in the same plane as the surfaces 124, 128. The arms 1 10, 1 12 are configured to receive fasteners used to couple the connector 102 to the body 22 of the vehicle 10. The fasteners may comprise bolts, screws, rivets, welds or other conventional fasteners. The fasteners may comprise self-piercing rivets, for example. Self-piercing rivets provide the advantage of coupling the connector 102 to the body 22 without producing swarf or the like which would commonly be formed when using other types of fasteners. The presence of swarf in or around the coupling between the connector 102 and the body 22 may affect the effectiveness of the grounding. The arms 1 10, 1 12 may include apertures (not shown) configured to receive fasteners such as bolts or screws. Once the arms 1 10, 1 12 are affixed to the body 22 of the vehicle 10 using the fasteners, conventional body painting will assist in further sealing the arms 1 10, 1 12 of the terminal from the environment. The arm 1 14 provides a means for mechanical and electrical attachment to the one or more wires in the cable 16. The arm 1 14 extends from one side of the terminal body 108 between the opposed sides from which the arms 1 10, 1 12 extend. The arm 1 14 includes a portion 136 having a substantially rectilinear shape with front and back planar surfaces 138, 140. The arm 1 14 further includes a portion 142 that curves between the portion 136 of the arm 1 14 and the terminal body 108 such that the planar surfaces 138, 140 of the arm 1 14 are disposed within planes that intersect planes containing the planar surfaces 1 16, 1 18 of the terminal body 108 and the planar surfaces 124, 126 and 128, 130 of the arms 120, 122, respectively. In the illustrated embodiment, the portion 142 has an arc length of about ninety degrees such that the planes containing the surfaces 138, 140 of the arm 1 14 are perpendicular to the planes containing the planar surfaces 1 16, 1 18 of the terminal body 108 and the planar surfaces 124, 126 and 128, 130 of the arms 120, 122, respectively. Although a particular shape for the arm 1 14 has been illustrated, it will be appreciated that the shape of the arm 1 14 may vary to configure the arm 1 14 for mechanical and electrical coupling to the wires of the cable 16 through the terminal connector 18.
The housing 106 provides a means for connecting the connector 102 with the terminal connector 18 of the cable 16 and for providing a sealed connection between terminal 104 and the wires of the cable 16. The housing 106 also provides structural support to the terminal 104 and orients the terminal 104. The housing 106 is moulded about the terminal 104 to form the assembled connector 102. The housing 106 includes a body 144 that defines apertures through which the arms 1 10, 1 12 of the terminal 104 extend to permit attachment of the arms 1 10, 1 12 to the body 22 of the vehicle 10. The body 144 further defines a cavity 146 configured to house the arm 1 14 of the terminal 104 and permit mechanical and electrical connection of the terminal 104 to the wires of the battery cable 16. The housing 106 is configured for coupling to the terminal connector 18 of the battery cable 16 and, upon connection to the terminal connector 18 provides a sealed connection for the arm 1 14 of the terminal 104 to the wires in the cable 16 in order to insulate the terminal 104 and connection and prevent them from damage due to exposure to external objects or elements. The body 144 of the housing 106 may therefore define a number of features configured to engage corresponding features on the terminal connector 18 including a lip 148 surrounding an opening to the cavity 146 and rows of teeth 150 on either side of body 144 to engage corresponding teeth on a locking lever of a terminal connector as described hereinabove. It will be appreciated that the shape and dimensions of the housing 106 may vary depending on the shape and dimensions of the terminal 104 and the terminal connector 18. Referring now to Figure 8, another embodiment of a connector 152 is provided for coupling one or more wires in the cable 16 to earth ground through the body 22 of the vehicle 10. The connector 152 is substantially similar to connector 102 and may include a terminal 104 and housing 106 as described hereinabove. The connector 152, however, further includes a busbar 154. The busbar 154 is configured to couple a plurality of wires from the cable 16 or another source to the arm 1 14 of the terminal 104. The busbar 154 may be fastened to the arm 1 14 using welds or other conventional fastening mechanisms capable of conducting current between the busbar 154 and the terminal 104. The busbar 154 defines a plurality of contacts 156 each of which may be configured to engage one or more wires through conventional female terminal connectors formed at the end of each wire. Referring to Figure 9, the busbar 154 may define two spaced rows of contacts 156. It will be appreciated, however, that the shape of the busbar 154 and the number of contacts 156 may vary depending on the application.
Referring now to Figure 10, a method for attaching an earth point connector, such as any of connectors 20, 102, 152, to the body 22 of vehicle 10 will be described. The method may begin with the process 158 of temporarily sealing the cavity 72 or 146 in the housing 30 or 106 of the connector 20, 102, 152. The cavity 72 or 146 may be sealed using a waterproof seal or cup that adheres to or otherwise cooperates with the lip 74 or 148 to prevent ingress of foreign elements or objects into the cavity 72 or 146. It will be understood that a variety of seals may be used. The method may continue with the process 160 of mechanically attaching the arms 34, 36 or 1 10, 1 12 of the terminal 28 or 104 of the connector 20, 102 or 152 to the body 22 of the vehicle 10. As noted hereinabove, the arms 34, 36 or 1 10, 1 12 may be attached to the body 22 of the vehicle 10 using a variety of fasteners including bolts, screws, rivets, welds or other conventional fasteners. The fasteners may comprise self- piercing rivets, for example. Self-piercing rivets provide the advantage of coupling the connector 20 to the body 22 without producing swarf or the like which would commonly be formed when using other types of fasteners. The presence of swarf in or around the coupling between the connector 20 and the body 22 may affect the effectiveness of the grounding. The method may continue with the process 162 of applying paint to exposed surfaces of the connector 20, 102 or 152. The painting process 162 assist in further sealing arms 34, 36 or 1 10, 1 12 from the environment. The method may continue with the process 164 of unsealing the cavity 72 or 146 in the housing 30 or 106 to expose the arm 38 or 1 14 of the terminal 28 or 104. The waterproof seal or cup may be decoupled from the lip 74 or 148 thereby exposing the arm 38 or 1 14 and permitting attachment of wires to the arm 38 or 1 14 upon connection of a terminal connector 18 to the connector 20, 102, or 152. It will be appreciated in view of the above that at least one benefit or advantage of at least some embodiments or implementations of the present invention, among potentially others, is that the wires from the battery cable or another electrical system can be repeatedly and easily connected and disconnected to the connector without damaging the connection . As a result, specific tools are no longer required to connect and disconnect the wires, replacement parts (e.g. bolts) do not need to be stored, there is less maintenance due to damaged connections, wires can be grounded individually without crimping, splicing or otherwise bundling the wires, and it is easier to repair individual damaged wires through the use of pre-term inated leads. Another benefit or advantage is that at least some of the connectors employ terminals having a shape (e.g. planar) that reduces or eliminates the risk of rotation during connection or disconnection and thereby reduces or eliminates the need to provide anti-rotation mechanisms. Another benefit or advantages is that the connectors provide for a sealed connection between the terminal and wires preventing oxidation or other damage from environmental conditions or foreign objects and thereby reducing long term maintenance requirements. Another benefit or advantages is that the connector is less likely to be damaged or to loosen as a result of initial assembly of the connection, servicing the connection or vibration during operation of the vehicle and is therefore able to maintain a low resistance current pathway from the wires to ground.
It will be understood that the embodiments described above are given by way of example only and are not intended to limit the invention, the scope of which is defined in the appended claims. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. For example, the specific combination and order of steps is just one possibility, as the present method may include a combination of steps that has fewer, greater or different steps than that shown here. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims. Additionally, features, characteristics, or aspects described in conjunction with one embodiment are to be understood to be applicable to any other embodiment described herein unless incompatible therewith.
As used in this specification and claims, the terms "for example," "e.g.," "for instance," "such as," and "like," and the verbs "comprising," "having," "including," and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that that the listing is not to be considered as excluding other, additional components or items. Further, the terms "comprise" and "contain" and variations thereof, for example "comprising" and "comprises", mean "including but not limited to", and are not intended to (and do not) exclude other possibilities not expressly provided for herein. Moreover the singular encompasses the plural unless the context otherwise requires: in particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.

Claims

1 . A connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle, comprising:
a terminal having
means for receiving one or more fasteners that mechanically attach the terminal to the body of the vehicle; and
means for mechanical and electrical attachment to the one or more wires wherein the terminal defines a conductive path from the one or more wires to the body of the vehicle.
2. The connector of claim 1 wherein the one or more wires includes a wire coupled to a terminal of a battery of the vehicle.
3. The connector of any of claims 1 to 2 wherein the terminal is a unitary structure.
4. The connector of any of claims 1 to 3 wherein the terminal includes a terminal body and wherein the receiving means comprises a first arm extending from the terminal body and configured to receive a first fastener of the one or more fasteners and the attachment means comprises a second arm extending from the terminal body and configured for mechanical and electrical attachment to the one or more wires.
5. The connector of claim 4 wherein the terminal body defines a first planar surface disposed in a first plane and said first arm defines a second planar surface disposed in a second plane spaced from the first plane.
6. The connector of claim 5 wherein the second arm defines a third planar surface disposed in a third plane spaced from the first and second planes.
7. The connector of any of claims 4 to 6 wherein the second arm bends back towards the terminal body such that an end of the second arm is spaced from and faces the terminal body.
8. The connector of claim 4 wherein the terminal body defines a first planar surface disposed in a first plane and the second arm defines a second planar surface disposed in a second plane intersecting the first plane.
9. The connector of any of claims 4 to 8 wherein the attachment means comprises a third arm extending from the terminal body and configured to receive a second fastener of the one or more fasteners.
10. The connector of claim 9 wherein the terminal body defines a first planar surface disposed in a first plane, the first arm defines a second planar surface disposed in a second plane spaced from the first plane and the third arm defines a third planar surface disposed in the second plane.
1 1 . The connector of any of claims 4 to 10 comprising a busbar fastened to said second arm and defining a plurality of contacts, each of the contacts configured to engage one of the one or more wires.
12. The connector of any preceding claim wherein the one or more fasteners comprise a self-piercing rivet.
13. A connector for coupling one or more wires in a vehicle to an earth point on a body of the vehicle, comprising:
a terminal configured for mechanical attachment to the body of the vehicle and for mechanical and electrical attachment to the one or more wires, the terminal defining a conductive path configured to conduct current from the one or more wires to the body of the vehicle; and,
a housing disposed about the terminal, the housing configured for coupling to a terminal connector disposed at an end of the one or more wires to thereby provide a sealed connection for the one or more wires and the terminal.
14. The connector of claim 13 wherein the one or more wires includes a wire coupled to a terminal of a battery of the vehicle.
15. The connector of any of claims 13 to 14 wherein the terminal is a unitary structure.
16. The connector of any of claims 13 to 15 wherein the terminal includes
a terminal body;
a first arm extending from the terminal body and configured to receive a first fastener that mechanically attaches the first arm of the terminal to the body of the vehicle; and a second arm extending from the terminal body and configured for mechanical and electrical attachment to the one or more wires, the terminal defining a conductive path between the first and second arms configured to conduct current from the one or more wires to the body of the vehicle.
17. The connector of claim 16 wherein the housing defines a cavity configured to house an outer end of the second arm and an aperture through which an outer end of the first arm extends outwardly of the housing.
18. The connector of any of claims 16 to 17 wherein the second arm bends back towards the terminal body such that an end of the second arm is spaced from and faces the terminal body.
19. The connector of any of claims 16 to 18 wherein the terminal includes a third arm extending from the terminal body and configured to receive a second fastener that mechanically attaches the third arm of the terminal to the body of the vehicle.
20. The connector of any of claims 16 to 19 comprising a busbar coupled to said second arm and defining a plurality of contacts, each of the contacts configured to engage one of the one or more wires.
21 . A vehicle battery assembly, comprising:
a battery having positive and negative terminals;
a battery cable connected at one end to one of the positive and negative terminals of the battery and having one or more wires; and,
a connector as set forth in any of claim 1 through 20.
22. A vehicle, comprising a connector of any of claims 1 to 20 or a vehicle battery assembly of claim 21.
23. A method for attaching an earth point connector to a body of a vehicle, comprising: temporarily sealing a cavity in a housing of the connector, the housing disposed about a terminal and configured for coupling to a terminal connector disposed at an end of one or more wires in the vehicle, the terminal having a terminal body and first and second arms extending from the terminal body and defining a conductive path between the first and second arms, the first arm extending outward from the housing and configured for mechanical attachment to the body of the vehicle, the second arm disposed within the cavity of the housing and configured for mechanical and electrical attachment to the one or more wires;
mechanically attaching the first arm of the terminal of the connector to the body of the vehicle;
applying paint to exposed surfaces of the connector; and,
unsealing the cavity in the housing to expose the second arm of the terminal.
PCT/EP2016/076650 2015-11-05 2016-11-04 Vehicle earth point connector WO2017077025A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE112016005079.8T DE112016005079T5 (en) 2015-11-05 2016-11-04 VEHICLE MASS POINT PLUG

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1519532.4 2015-11-05
GBGB1519532.4A GB201519532D0 (en) 2015-11-05 2015-11-05 Vehicle earth point connector

Publications (1)

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WO2017077025A1 true WO2017077025A1 (en) 2017-05-11

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DE112016005079T5 (en) 2018-08-30
GB201519532D0 (en) 2015-12-23
GB2544412B (en) 2020-09-09

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