Blind, shank expanding electrical terminal structure

Claim 1

A blind shank expanding threaded electrical grounding terminal structure: 1. a sheet of material having an electrically conductive center and covered on its first and second sides with generally nonconductive layers, said sheet of material having a cylindrical aperture therein extending through said electrically conductive center and said generally non-conductive layers whereby said electrically conductive center is exposed in the region defined by the periphery of said cylindrical aperture; 2. an integrally formed elongated shank co-axially centered in said cylindrical aperture, said elongated shank including: a. a head located on one end, said head adapted to cause a collar to be formed in a radially expandable sleeve on the second side of said sheet of material in bearing engagement with the non-conductive layer located on said second side; b. a sleeve expanding region located adjacent to said head, said sleeve expanding region adapted to radially press a radially expandable sleeve into low resistance electrical contact with the portion of said electrically conductive center exposed in the region defined by the periphery of said cylindrical aperture; and, c. a threaded portion extending axially outwardly from said sleeve expanding region on the opposite side thereof from said head; 3. a radially expandable sleeve mounted about said elongated shank and extending through said sheet of material so as to generally surround said sleeve expanding region, said radially expandable sleeve being in low resistance electrical contact with the portion of said electrically conductive center exposed in the region defined by the periphery of said cylindrical aperture and in low resistance electrical contact with said sleeve expanding region of said elongated shank, said radially expandable sleeve including: a. a pre-formed collar located in bearing, but non-electrical, engagement with the non-conductive layer located on the first side of said sheet of mateRial; and, b. a cylindrical region integral with said collar, said cylindrical region surrounding said sleeve expanding region of said elongated shank and radially pressed by said sleeve expanding region into low resistance electrical contact with the portion of said electrically conductive center exposed in the region defined by the periphery of said cylindrical aperture; and, c. an outwardly rolled collar portion located in bearing, but non-electrical, engagement with the non-conductive layer located on the second side of said sheet of material, said outwardly rolled collar portion being formed by the head of said elongated shank pressing said sleeve outward in the region thereof lying outside of the cylindrical aperture on said second side; 4. an electrical contact, connected to an electrical conductor at least partially surrounding the part of said threaded portion of said elongated shank located adjacent to said preformed collar on the side thereof remote from the side of said pre-formed collar in bearing engagement with said sheet of material; and, 5. a nut threaded onto said threaded portion so as to press said electrical contact into low resistance electrical contact with said pre-formed collar.

Claim 22

A method of creating a threaded electrical terminal in a sheet of material having an electrically conductive center and covered on both sides with generally non-conductive layers, said method comprising the steps of: forming a cylindrical aperture in said sheet, said cylindrical aperture formed so as to pass through said sheet and expose said electrically conductive center in the region defined by the periphery of said cylindrical aperture; inserting into said cylindrical aperture a blind shank expanding electrical terminal, said blind shank expanding electrical terminal comprising an elongated shank threaded at one end, and a radially expandable cylindrical sleeve surrounding the other end of said shank, said shank and said sleeve formed such that axial movement of said shank with respect to said sleeve along their common axis in a predetermined direction causes said radially expandable sleeve to expand radially outwardly, said sleeve being formed of a metallic material that is electrically compatible with the electrically conductive center of said sheet of material, said sleeve having an outer diameter sized such that it is surrounded by, but spaced slightly from, said cylindrical aperture when centered in said cylindrical aperture prior to said axial movement, said sleeve including a collar having a diameter greater than the outer diameter of said sleeve surrounding the end of said sleeve nearest said threaded end of said shank, said blind shank expanding electrical terminal being inserted into said cylindrical aperture to a position such that said collar rests against one side of said sheet of material; and, causing said radially expandable sleeve to radially expand outwardly into low resistance electrical contact with said electrically conductive center of said sheet of material in the region where the cylindrical periphery of said cylindrical aperture and the adjacent peripheral surface of said sleeve meet by axially moving said elongated shank in said predetErmined direction with respect to said radially expandable sleeve.

Claim 23

A method of creating a threaded electrical terminal in a sheet of material having an electrically conductive center and covered on both sides with generally non-conductive layers, said method comprising the steps of: forming a cylindrical aperture in said sheet, said cylindrical aperture formed so as to pass through said sheet and expose said electrically conductive center in the region defined by the periphery of said cylindrical aperture; inserting into said cylindrical aperture a blind shank expanding electrical terminal, said blind shank expanding electrical terminal comprising an elongated shank threaded at one end, and a radially expandable cylindrical sleeve surrounding the other end of said shank, said shank and said sleeve formed such that axial movement of said shank with respect to said sleeve along their common axis in a predetermined direction causes said radially expandable sleeve to expand radially outwardly, said sleeve being formed of a metallic material that is electrically compatible with the electrically conductive center of said sheet of material, said sleeve having an outer diameter sized such that it is surrounded by, but spaced slightly from, said cylindrical aperture when centered in said cylindrical aperture prior to said axial movement, said sleeve including a collar having a diameter greater than the outer diameter of said sleeve surrounding the end of said sleeve nearest said threaded end of said shank, said blind shank expanding electrical terminal being inserted into said cylindrical aperture to a position such that said collar rests against one side of said sheet of material; and, causing said radially expandable sleeve to radially expand outwardly into low resistance electrical contact with said electrically conductive center of said sheet of material in the region where the cylindrical periphery of said cylindrical aperture and the adjacent peripheral surface of said sleeve meet by axially moving said elongated shank in said predetErmined direction with respect to said radially expandable sleeve.

Claim 26

A method of creating a threaded electrical terminal in a body of material having an electrically conductive center and covered on one side with a generally non-conductive layer, said method comprising the steps of: forming a cylindrical aperture in said body, said cylindrical aperture formed so as to pass through said generally non-conductive layer and terminate in said body so as to expose said electrically conductive center in the region defined by the periphery of said cylindrical aperture; inserting into said cylindrical aperture a blind shank expanding electrical terminal, said blind shank expanding electrical terminal comprising an elongated shank threaded at one end, and a radially expandable cylindrical sleeve surrounding the other end of said shank, said shank and said sleeve formed such that axial movement of said shank with respect to said sleeve along their common axis in a predetermined direction causes said radially expandable sleeve to expand radially outwardly, said sleeve being formed of a metallic material that is electrically compatible with the electrically conductive center of said body of material, said sleeve having an outer diameter sized such that it is surrounded by, but spaced slightly from, said cylindrical aperture when centered in said cylindrical aperture prior to said axial movement, said sleeve including a collar having a diameter greater that the outer diameter of said sleeve surrounding the end of said sleeve nearest said threaded end of said shank, said blind shank expanding electrical terminal being inserted into said cylindrical aperture to a position such that said collar rests against said generally non-conductive layer; and, causing said radially expandable sleeve to radially expand outwardly into low resistance electrical contact with said electrically conductive center of said body of material in the region where the cylindrical periphery of said cylindrical aperture and the adjacent peripheral surface of said sleeve meet by axially moving said elongated shank in said predetermined direction with respect to said radially expandable sleeve.

Claim 27

A method of creating a threaded electrical terminal in a body of material having an electrically conductive center and covered on one side with a generally non-conductive layer, said method comprising the steps of: forming a cylindrical aperture in said body, said cylindrical aperture formed so as to pass through said generally non-conductive layer and terminate in said body so as to expose said electrically conductive center in the region defined by the periphery of said cylindrical aperture; inserting into said cylindrical aperture a blind shank expanding electrical terminal, said blind shank expanding electrical terminal comprising an elongated shank threaded at one end, and a radially expandable cylindrical sleeve surrounding the other end of said shank, said shank and said sleeve formed such that axial movement of said shank with respect to said sleeve along their common axis in a predetermined direction causes said radially expandable sleeve to expand radially outwardly, said sleeve being formed of a metallic material that is electrically compatible with the electrically conductive center of said body of material, said sleeve having an outer diameter sized such that it is surrounded by, but spaced slightly from, said cylindrical aperture when centered in said cylindrical aperture prior to said axial movement, said sleeve including a collar having a diameter greater that the outer diameter of said sleeve surrounding the end of said sleeve nearest said threaded end of said shank, said blind shank expanding electrical terminal being inserted into said cylindrical aperture to a position such that said collar rests against said generally non-conductive layer; and, causing said radially expandable sleeve to radially expand outwardly into low resistance electrical contact with said electrically conductive center of said body of material in the region where the cylindrical periphery of said cylindrical aperture and the adjacent peripheral surface of said sleeve meet by axially moving said elongated shank in said predetermined direction with respect to said radially expandable sleeve.