Brazed ground terminal for non-ferrous vehicle components

#This disclosure relates to the concept of brazing ground terminals for aluminum and other non-ferrous parts of a vehicle.

#Vehicle bodies may be manufactured with non-ferrous metals such as aluminum or magnesium. Many electrical vehicle components are connected to ground through the vehicle body. Attaching ground connectors to steel vehicle bodies is accomplished by simply welding the connectors to the steel bodies by resistance welding.

#Ground wires for aluminum vehicle bodies are connected to expensive weld studs or weld nuts that are welded by resistance welding to the vehicle body. Welding weld studs or weld nuts to aluminum alloys may result in burn through at the location of the welds due to the difficulty in welding to aluminum. Welds of aluminum studs or nuts to aluminum parts results in welds that have reduced tensile and shear strength.

#FIG. 1 is an exploded perspective view of a grounding connector clinched to a vehicle body and secured by a braze deposit that is shown with a wire having connection terminal and a screw.

#FIG. 2 is a perspective view of a grounding connector nut having braze material feet that are adapted to be melted to secure the nut to the vehicle body.

#FIG. 3 is a perspective view of a grounding connector nut having channels formed in the nut into which braze material is melted to flow between the nut and the vehicle body.

#The illustrated embodiments are disclosed with reference to the drawings. However, it is to be understood that the disclosed embodiments are intended to be merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts.

#Referring to FIG. 1, a ground connector 10 is shown attached to a vehicle body 12. The ground connector 10 includes a nut 16 that is connected by a clinch joint 18 to the vehicle body 12. A deposit of braze material 20 is melted to flow between the nut 16 and the vehicle body 12. The braze material 20 permanently connects the nut 16 to the vehicle body 12. The nut 16 includes a fastener receiving opening 22 that may be a non-threaded opening if a self-tapping screw 24 is used to connect a wire 28 having a terminal connector 30 to the nut 16. Alternatively, a threaded opening may be used with a conventional screw. Use of the self-tapping screw 24 and braze material 20 provide a good electrical connection between the wire 28 and the vehicle body 12.

#The clinch joint 18 is formed by a clinching process. Clinching features (not shown) may be provided on the nut 16 to facilitate the clinching process.