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  Electrical connector terminal and method of producing sameUSPTO Application #: 20060216970Title: Electrical connector terminal and method of producing same Abstract: A blade terminal for a surface mount electrical connector is provided. A first elongate member of a terminal body cooperates with a housing of the electrical connector to secure the terminal body to the connector housing. A second elongate member of the terminal body includes a curved portion having a hole therethrough. The curved portion includes a convex surface that facilitates automated assembly operations, and the aperture helps to overcome surface tension in liquid solder, thereby promoting a secure electrical connection. (end of abstract)
Agent: Brooks Kushman P.C. / Lear Corporation - Southfield, MI, US Inventor: Slobadan Pavlovic USPTO Applicaton #: 20060216970 - Class: 439083000 (USPTO) Related Patent Categories: Electrical Connectors, Preformed Panel Circuit Arrangement, E.g., Pcb, Icm, Dip, Chip, Wafer, Etc., Distinct Contact Secured To Panel Circuit, Contact Soldered To Panel Circuit The Patent Description & Claims data below is from USPTO Patent Application 20060216970. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to an electrical connector terminal, and a method of producing such a terminal. [0003] 2. Background Art [0004] As the use of electronic devices becomes increasingly prevalent, there is a need to provide an ever increasing number of electronic components on printed circuit boards (PC boards). In the past, it was not uncommon for an electronic component to have wire leads that were inserted into holes in the PC board. With this "through-hole" technology, the wire leads from the electronic component extended completely through the PC board. This made it difficult, if not impossible, to use both sides of the PC board for different circuits. [0005] In many cases today, through-hole connections on PC boards have been replaced with surface mount technology (SMT). With SMT components, blade terminals have replaced the wire leads which formerly extended through the PC boards. These terminals are connected to a surface of one side of the PC board, usually by soldering. This leaves the opposite side of the PC board available for constructing a different circuit using the same or different SMT components. [0006] Because electronic components are often very light weight, it is not uncommon for the surface tension present in the liquid solder to push the SMT component up and away from the PC board; this is sometimes called the "Manhattan effect". When this happens, the resulting connection between the SMT component and the PC board can be weak. Even if some of the solder does adhere to a terminal on the SMT connector, the solder may pull back from the terminal when it cools. Moreover, even if some of the solder remains in contact with a terminal, the connection can be broken during use, particularly if the PC board is located in an area subject to vibration--e.g., in an electrical box in a vehicle. [0007] Therefore, it would be desirable to provide a terminal for an SMT connector that overcame some or all of the surface tension of the liquid solder when it was being connected to a PC board. SUMMARY OF THE INVENTION [0008] The present invention provides a terminal for an SMT connector having a geometric configuration that helps to ensure a strong connection to a PC board despite surface tension in a liquid solder used to connect it. [0009] The invention also provides a blade terminal for a surface mount electrical connector which includes a terminal body including a first portion configured to cooperate with a housing of the electrical connector for securing the terminal body to the connector housing. The terminal body further includes a second portion in electrical communication with the first portion. The second portion includes an aperture therethrough configured to receive an electrically conductive material therein. This facilitates an electrical connection between the second portion and a surface of an electrical board. [0010] The invention further provides a header connector for an electrical box in a vehicle. The electrical box includes an electrical board. The connector includes a connector housing configured to receive an in-line connector attached to a wiring harness for electrically connecting the electrical box to the wiring harness. The connector also includes a blade terminal including first and second elongate members in electrical communication with each other. The first elongate member is configured to cooperate with the connector housing for securing the first elongate member to the connector housing. The second elongate member includes an aperture therethrough for receiving at least partially melted solder therein. This facilitates an electrical connection between the second elongate member and a surface of the electrical board. [0011] The invention also provides a method for producing a blade terminal for a surface mount electrical connector. The method includes forming a first elongate member capable of cooperating with a housing of the electrical connector for securing the first elongate member to the connector housing. A second elongate member is formed, and is configured for electrical connection to the first elongate member. An aperture is formed through the second elongate member for receiving an electrically conductive material therein. This facilitates an electrical connection between the second elongate member and a surface of an electrical board. BRIEF DESCRIPTION OF THE DRAWINGS [0012] FIG. 1 is a perspective view of an electrical connector including blade terminals in accordance with the present invention; [0013] FIG. 2A is a front plan view of a power distribution box for a vehicle that includes the electrical connector shown in FIG. 1; [0014] FIG. 2B is a perspective view of an in-line connector configured to mate with the connector shown in FIG. 2A; [0015] FIG. 3 is a perspective view of the underside of the connector shown in FIG. 1; [0016] FIG. 4 is a perspective view of a blade terminal used in the connector shown in FIG. 1; [0017] FIG. 5 is a side plan view of the blade terminal shown in FIG. 4, connected to a portion of a PC board; and [0018] FIG. 5A is a detail view of a portion of the connection between the terminal and PC board shown in FIG. 5. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) [0019] FIG. 1 shows an SMT connector 10 in accordance with one embodiment of the present invention. In particular, the connector 10 shown in FIG. 1 is a header connector that can used in an electrical box 12--see FIG. 2B--such as might be used in a vehicle. The electrical box 12 could, for example, be a power distribution box, or a junction box. As shown in FIG. 2A, the electrical box 12 includes a number of electronic components 14, 16, 18, 20, 22 which are attached to a PC board 24. If, for example, the electrical box 12 is a power distribution box in a vehicle, an in-line connector 26--see FIG. 2B--can be used to connect the header connector 10 to various systems within the vehicle via a wiring harness 28. [0020] Returning to FIG. 1, it is shown that the header connector 10 includes a connector housing 30 and a number of electrical terminals 32, 34, 36. FIG. 3 shows the underside of the connector 10 including portions of the various electrical terminals that will connect to a PC board, such as the PC board 24 shown in FIG. 2A. As shown in FIG. 3, each of the terminals 32 (two on each side of the connector 10) and the terminals 34 (five on each side of the connector 10) are blade terminals configured to facilitate surface mounting of the connector 10 to a PC board, such as the PC board 24. Conversely, the terminals 36 (two on each end of the connector 10) are through-hole terminals which are configured to be located within holes in a PC board, such as the PC board 24. A connector, such as the connector 10, may or may not include through-hole terminals, such as the terminals 36. The through-hole terminals can be beneficial, however, in that they can be used to help position a connector on a PC board. Moreover, if only a small number of through-hole terminals are used, this still leaves most of the opposite side of a PC board available for use in the creation of another circuit. Continue reading... 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