Electrical connector for very thin sheet metal member

June 23, 1964

E. A. WEIMER, JR

3,138,658

ELECTRICAL CONNECTOR FOR VERY THIN SHEET Filed Sept. 27, 1961

METAL MEMBER

Sheets-Sheet 1

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June 23, 1964

ELECTRICAL

E. A. WEIMER, JR 3,138,658

CONNECTOR FOR VERY THIN SHEET METAL MEMBER

Filed Sept. 27, 1961

Sheets-Sheet 2

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United States Patent Office „ , ^{3138 658}

Patented June 23, 1964

3,138,658

ELECTRICAL CONNECTOR FOR VERY THIN SHEET METAL MEMBER

Edgar A. Weimer, Jr., Harrisburg, Pa., assignor to AMP Incorporated, Harrisburg, Pa.

Filed Sept. 27,1961, Ser. No. 141,166

Claims. (Cl. 174—94)

This application constitutes a continuation-in-part of my previous application, Serial No. 857,158, filed December 3, 1959, now abandoned.

The extensive use of conductive foil or very thin sheet metal members (e.g., aluminum) as an electrical conductor for electronic and miniature components is complicated by the fact that it is difficult to join the foil to other electrical conductors. Because of the fragile nature of the foil, securing the foil to a wire or component tends to either tear the foil or to make an imperfect connection. It is an object of this invention to provide an electrical connector capable of being secured to conductive foil, or the like, which provides an electrical connection, is easily applied and has high tensile strength and excellent properties of electrical conductivity.

It is also an object of this invention to provide an electrical connecting device adapted to be secured to aluminum foil by wrapping it around the foil and pressing it into the foil.

It is also an object of this invention to provide an electrical connecting device adapted to be secured to aluminum foil by wrapping or folding it over the foil and clamping it thereto so that tangs on one area of the device pierce the foil. The opposing end of the device operates as an anvil to deform the tangs after they have pierced the foil.

Other objects and attainments of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings in which there is shown and described an illustrative embodiment of the invention; it is to be understood, however, that this embodiment is not intended to be exhaustive nor limiting of the invention but is given for purposes of illustration in order that others skilled in the art may fully understand the invention and the principles thereof and the manner of applying it in practical use so that they may modify it in various forms, each as may be best suited to the conditions of a particular use.

In the drawings:

FIGURE 1 illustrates a blank electrical connector shown in perspective and made according to the teaching of this invention;

FIGURE 2 is a view similar to FIGURE 1 illustrating the connector applied to a length of foil intermediately the end of the foil;

FIGURE 3 is a view illustrating an electrical connector as applied to the end of the piece of conductive foil and illustrating its being connected to an electrical wire;

FIGURE 4 is a view similar to FIGURE 3 showing the connector in its partially-opened position;

FIGURE 5 is a view of another embodiment similar to FIGURE 3 showing the connector, wire and foil in plan view;

FIGURE 6 is a view taken through plane 6—6 of FIGURE 5;

FIGURE 7 is another species of connector embodying the principles of this invention;

FIGURES 8 and 9 illustrate various ways in which conductors may be joined to the connector;

FIGURE 10 is a cross-sectional view of another species of connector embodying the principles of this invention; and

FIGURE 11 is a view of the device of FIGURE 10 applied to foil.

As shown in FIGURE 1, the connector includes a blade portion 10 and a ferrule-forming portion 12 at one end 5 of the blade. The ferrule-forming portion is secured to the blade portion by a narrow, neck-like member 14. The blade portion may be considered to comprise two areas, each area having a plurality of pyramidal tangs or ears 16 formed about perforations 18. The outer sur10 faces of the tangs are substantially parallel to the axis of the aperture. The areas containing the tangs are separated by a medial portion which is imperforate. As shown in FIGURE 2, the blade is bent around the foil 20 in the imperforate area.

As shown in the drawings, the ferrule-forming portion 12 may be fashioned into a ferrule and brazed along the seam, or otherwise fashioned into a ferrule member. This ferrule will accommodate an electrical wire and may be crimped thereto to form an excellent electrical con20 nection. The blade portion may be folded over a piece of conductive foil 20, as shown in FIGURE 2, and pressed onto it to form a “sandwich-like” structure, with the foil disposed intermediately of the folded blade. Pressing the blade onto the foil causes the tangs to pierce the foil and 25 are then deformed to secure the foil to the connector.

The tangs are disposed so that none of the tangs tend to rupture the foil. The aggregate number of tangs builds up a strong connection between the blade and the foil.

As shown in FIGURES 3 and 4, the ferrule-forming 30 portion may be disposed laterally to the blade portion so that the axis of the wire coincides with the axis of the foil. Again the connector is secured to the foil and the wire in the same manner.

As shown in FIGURES 5 through 7, the relationship 35 of the tangs determines the condition of the connection between the foil and the connector. In FIGURES 5 and 6, the upper tangs fit into the lower perforation and vice versa, so that the tangs puncture through the foil and the outer section of the tangs sandwich the foil therebe40 tween. In FIGURE 7, the bottom portion of the blade does not contain any perforation but rather acts as an anvil so that, after the portion with the tangs pierces the foil, the lower section acts as an anvil to deform the tangs. This closing action of the tangs, as well as the piercing 45 action, binds the foil to the connector.

The device illustrated in FIGURE 8 is adapted to be joined to a conductor by means other than the ferrule-forming portion 12 shown in FIGURES 1-4. In FIGURE 8, a pair of tabs 130, 132 emanate from the 50 blade 110, and a bolt 134 extends through aligned openings (not shown) in the tabs 130, 132. A standard ringtongue connector 136, crimped onto a conductor 138, may be employed to complete the electrical circuit.

FIGURE 9 is similar to FIGURE 8, except that a pair 55 of ferrule-forming members 240 and 242 are integral with the tab 232 extending from the connector 210. This illustrates how multiple lead wires may be secured to one connector. The tab 230 may also have ferrule-forming portions secured thereto. FIGURES 8 and 9 illustrate 60 the connector secured to the end of the foil and the conductors extending at right angles; however, it is apparent that they could be secured to the side of the foil, if so desired.

The embodiment described in FIGURE 10 is similar ₆5 to FIGURE 7. The connector 310, in addition to having tangs 316, also has dimpled portions 322. The outer surface of each tang is substantially parallel to the axis of the aperture. Each dimple 322 is opposed to the one of the tangs 316 and is concave toward the tang. As 70 each tang is pressed onto the foil 320 to perforate it the curved surface of the dimple 322 forces it in a direction whereby it will firmly grasp the foil 320 (note FIG3,138,658

URE 11). A recessed portion 323 surrounds each dimple to insure penetration of the tangs prior to their being deformed.

It is apparent from the description that the action between the tangs and the foil, when the blade is flattened over against the foil and pressed down, causes the foil and the connector to become securely engaged without rupturing the foil. The ferrule-forming portion may be secured to a lead wire to make the connection. The effect is a good electrical connection between a conductor and an aluminum foil conductor.

Changes in construction will occur to those skilled in the art and various apparently different modifications and embodiments may be made without departing from the scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective against the prior art.