Electrical connector

Abstract

An electrical connector includes an insulating base and a pair of contacts mounted within the base and fastened together by a fastener. Each conductive contact includes a flat body portion, a plurality of resilient fingers extending from a first end of the body portion, and a connector extending from the body portion to couple the conductive contact to the base. A first flexure region between the fastener and a first end of the plurality of resilient fingers permits the plurality of resilient fingers to flex laterally to receive the conductive member within the receiving space. A second flexure region between the first end of the plurality of resilient fingers and a second end of the body portion permits the body portion and the plurality of resilient fingers to flex laterally when the conductive member is received within the receiving space but the conductive member is not properly aligned with the receiving space.

Description

[0001] Related Applications

[0002] This application claims the benefit of U.S. Provisional Application No. 62 / 950,939, filed Dec. 20, 2019, which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present invention is directed to a busbar connection system and an electrical system including such a busbar connection system. Background Art

[0004] Busbar connection systems are particularly commonly employed in power distribution systems to distribute power from a power source to a large number of electrical devices. Such a power distribution system typically includes at least two conductive contacts spaced apart from one another at a predetermined distance for connection to a large number of electrical devices. Each electrical device includes at least two pluggable connectors for connecting to one of the conductive contacts respectively. The plurality of pluggable connectors of each electrical device are spaced apart from one another at the predetermined distance of the two conductive contacts of the power system. In applications requiring more power, several conductive contacts are ganged together to allow for more power transmission.

[0005] Due to manufacturing tolerances, the distance between the conductive contacts can have a deviation that exceeds the typical variation of known standard busbar systems. Their electrical connectors have to be prepared and installed with high precision, which results in high manufacturing costs. Some people would appreciate an improved structure that allows for greater manufacturing tolerances and thus lower costs. Summary of the Invention

[0006] Accordingly, the present disclosure provides an improved busbar assembly that can employ a pair of conductive contacts that are less precisely manufactured but provide reliable electrical connections.

[0007] An electrical connector includes an insulating base and a pair of contacts mounted within the base and fastened together by a fastener. Each conductive contact includes a flat body portion, a plurality of resilient fingers extending from a first end of the body portion, and a connector extending from the body portion to couple the conductive contact to the base. A first flexure region between the fastener and the first ends of the plurality of resilient fingers allows the plurality of resilient fingers to flex laterally to receive the conductive member within the receiving space. A second flexure region between the first ends of the plurality of resilient fingers and a second end of the body portion allows the body portion and the plurality of resilient fingers to flex laterally when the conductive member is received within the receiving space but the conductive member is not properly aligned with the receiving space. Brief Description of the Drawings

[0008] The present disclosure is illustrated by way of example and not limitation in the accompanying drawings, in which like reference numerals represent like components, and in which:

[0009] Figure 1 A perspective view of an electrical system is shown, the electrical system including an embodiment of an electrical connector, an electrical component, and a conductive member;

[0010] Figure 2 Shows Figure 1 A perspective view of the electrical connector shown;

[0011] Figure 3 Shows Figure 2 An exploded perspective view of the electrical connector shown;

[0012] Figure 4 And Figure 5 Shows Figure 2 A top plan view of two conductive contacts of the electrical connector shown;

[0013] Figure 6 And Figure 7 An enlarged partial cross-sectional view showing an embodiment of a clamp and two conductive contacts;

[0014] Figure 8 Shows two conductive contacts of an electrical connector that can be disposed in the Figure 1 Electrical connector shown in an exploded top plan view;

[0015] Figure 9 Shows Figure 8 A cross-sectional view of two conductive contacts shown and in an assembled state;

[0016] Figure 10 Shows two conductive contacts of an electrical connector that can be disposed in the Figure 1 Electrical connector shown in an exploded perspective view;

[0017] Figure 11 And Figure 12 Shows Figure 10 A side view of the conductive contact;

[0018] Figure 13 Shows two conductive contacts of an electrical connector that can be disposed in the Figure 1 Electrical connector shown in an exploded perspective view;

[0019] Figure 14 Shows Figure 8 A cross-sectional view of two conductive contacts shown and in an assembled state;

[0020] Figure 15 Shows Figure 13 AndFigure 14 Exploded view of a fastener;

[0021] Figure 16 showing Figure 2 Rear view of the shown electrical connector;

[0022] Figure 17 showing Figure 2 Cross-sectional view of the shown electrical connector;

[0023] Figure 18 showing a schematic diagram;

[0024] Figure 19 showing a perspective view of another embodiment of an electrical connector, which can be used with Figure 1 the shown electrical component and a conductive member;

[0025] Figure 20 showing Figure 19 Exploded perspective view of the shown electrical connector;

[0026] Figure 21 showing Figure 19 Side view of the fastened two conductive contacts of the shown electrical connector;

[0027] Figure 22 and Figure 23 showing Figure 21 Side view of the conductive contact;

[0028] Figure 24 showing Figure 19 Cross-sectional view of the shown electrical connector shown in perspective;

[0029] Figure 25 showing Figure 19 Bottom view of the shown electrical connector;

[0030] Figure 26 showing Figure 19 Cross-sectional view of the shown electrical connector;

[0031] Figure 27 showing a perspective view of another embodiment of an electrical connector, which can be used with Figure 1 the shown electrical component and a conductive member;

[0032] Figure 28 and Figure 29 showing Figure 27 Side view of the conductive contact of the shown electrical connector;

[0033] Figure 30 showing Figure 27 Bottom view of the shown electrical connector; and

[0034] Figure 31 and Figure 32 shows Figure 27 a cross-sectional view of the electrical connector shown. DETAILED DESCRIPTION

[0035] The accompanying drawings show embodiments of the present disclosure, and it will be understood that the disclosed embodiments are merely examples and that the present disclosure may be implemented in various forms. Accordingly, the specific details disclosed herein should not be construed as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to implement the present disclosure in various ways.

[0036] An electrical system 20 includes an electrical connector 22, 222, 422, an electrical component 24 such as a circuit board configured to have the electrical connector 22, 222, 422 mounted thereon, and a conductive member 26 configured to communicatively engage the electrical connector 22, 222, 422. In one embodiment, the conductive member 26 is a bus and the electrical connectors 22, 222, 422 are configured to transmit power therethrough. In one embodiment, the conductive member 26 is another electrical connector such as the electrical connector 422. Other embodiments may also be contemplated, where the conductive member 26 is a circuit board of an electronic device or a mating connector. In addition to power, signals can also be transmitted through the electrical connectors 22, 222, 422.

[0037] In one embodiment, the conductive member 26 has an elongated, generally rectangular-shaped body portion 28 configured to be clamped by the electrical connectors 22 on two sides 30, 32 and defining a docking edge 34. For example, the two sides 30, 32 have surfaces that coincide with planes extending parallel to each other along the longitudinal axis and the transverse axis, respectively.

[0038] The electrical connectors 22, 222, 422 include first and second conductive contacts 36a, 36b, 236a, 236b, 436a, 436b, an insulating base 38, 238, 438 for mounting the conductive contacts 36a, 36b, 236a, 236b, 436a, 436b, and a fastener 40 for connecting the conductive contacts 36a, 36b, 236a, 236b, 436a, 436b together. In one embodiment, the conductive contacts 36a, 36b, 236a, 236b, 436a, 436b are configured to transmit power therethrough. In another embodiment, the conductive contacts 36a, 36b, 236a, 236b, 436a, 436b are configured to transmit electrical signals therethrough. Figures 1 to 16 The embodiment shown shows a right-angle connector, while Figures 19 to 32 the embodiment shown shows a vertical connector.

[0039] Attention Figures 1 to 16 An embodiment of the electrical connector 22 shown. As shown in this embodiment, the electrical connector 22 and the electrical component 24 are relatively oriented with respect to a longitudinal axis, a vertical (or upright) axis, and a transverse (or horizontal) axis that are mutually perpendicular. This layout is typically referred to as a "right angle" system, and other embodiments may be arranged at another intermediate angle.

[0040] As Figures 3 to 5 Shown, each conductive contact 36a, 36b has a connecting portion formed by a generally rectangular flat body portion 42a, 42b and a plurality of elastic fingers 44a, 44b extending from the flat body portions 42a, 42b, and each conductive contact 36a, 36b also has a mounting portion 46a, 46b extending from the flat body portions 42a, 42b and a mounting flange 48a, 48b extending from the mounting portions 46a, 46b. The mounting portions 46a, 46b are fixed to the base 38. The mounting flanges 48a, 48b are fixed to the electrical component 24. When the flat body portions 42a, 42b and the elastic fingers 44a, 44b are fastened together by the fasteners 40 described herein, the flat body portions 42a, 42b and the elastic fingers 44a, 44b form a freestanding beam within the base 38. For clarity purposes, the components of the conductive contact 36a are described herein, and the similar components of the conductive contact 36b are denoted by the same reference numerals except for the appended "b" instead of "a".

[0041] The flat body portion 42a has a front end 50a, an opposite rear end 52a, and a top edge 54a and a bottom edge 56a that extend between the front end 50a and the rear end 52a and define a first side 58a and a second side 60a. A longitudinal axis 62a is defined by the flat body portion 42a from the front end 50a to the rear end 52a. The sides 58a, 60a coincide with respective planes that extend parallel to each other along the longitudinal axis and the transverse axis. An upper tab 64a extends upward from the top edge 54a, and a lower tab 66a extends downward from the bottom edge 56a. Each tab 64a, 66a is coplanar with the flat body portion 42a and is close to but spaced from the rear end 52a of the flat body portion 42a.

[0042] A plurality of resilient fingers 44a extend from a front end 50a of a flat body portion 42a. As shown, the plurality of resilient fingers 44a include: a rear wall 68a that extends from the front end 50a of the flat body portion 42a at an angle relative to a longitudinal axis 62a; and a row of spaced-apart contact beams 70a that extend from a front end of the rear wall 68a. Each contact beam 70a generally forms a shallow U-shape having a curved or V-shaped base 72a and inclined portions 74a, 76a that extend from the base 72a. The inclined portion 74a extends between the base 72a and the rear wall 68a. The inclined portion 76a forms a front end 75a of the conductive contact 36a.

[0043] The mounting portion 46a has: a first portion 78a that extends perpendicularly from a rear end 52a of the flat body portion 42a; and a second portion 80a that extends perpendicularly from the first portion 78a and overlaps a side surface 60a of the flat body portion 42a. The second portion 80a is flat and extends parallel to the longitudinal axis 62a and parallel to the flat body portion 42a. The first portion 78a may be U-shaped. The second portion 80a has a portion 82a that extends downward from the first portion 78a and extends parallel to the longitudinal axis 62a. The second portion 80a has a engaging portion that engages with the base 38 to prevent the mounting portion 46a from moving relative to the base 38. A first engaging portion may be provided by a protrusion 84a that extends outward from an outer side surface of the second portion 80a. The protrusion 84a may be formed as a barb and, as shown, has: an inclined front surface that is inclined relative to a plane defined by the second portion 80a; and a rear surface that is perpendicular to the second portion 80a. A second engaging portion may be provided by a flange 86a that extends upward from a top end of the second portion 80a. As shown, the flange 86a has: a first flange portion that extends upward from the second portion 80a; and a second flange portion that extends outward from the first flange portion and is perpendicular to the first flange portion.

[0044] The mounting flange 48a extends from the portion 82a of the mounting portion 46a and is perpendicular to the second portion 80a and the flat body portion 42a. An opening 88a is provided through the mounting flange 48a.

[0045] The conductive contacts 36a, 36b are fastened together by a fastener 40 to form a fastened pair before being inserted into the base 38. In the fastened pair, the sides 58a, 58b of the conductive contacts 36a, 36b face each other, so that the flat body portions 42a, 42b are parallel to each other, the rear walls 68a, 68b of the resilient fingers 44a, 44b are inclined outwardly relative to each other, the first portions 78a, 78b extend outwardly relative to each other, and the mounting flanges 48a, 48b extend outwardly relative to each other. The flat body portions 42a, 42b are joined together by the fastener 40 to prevent relative movement between the flat body portions 42a, 42b. The flat body portions 42a, 42b are cantilevered from the first portions 78a, 78b, and the flat body portions 42a, 42b define a flexure beam. As shown, the fastener 40 is approximately located at the middle of the length of the beam formed by the flat body portions 42a, 42b and the resilient fingers 44a, 44b. When mating, the fastener 40 effectively changes the bending or flexure of the conductive contacts 36a, 36b. The flexure arms are substantially shortened, and the fastener 40 provides a fixed point for the flexure beam. The fastener 40 is disposed close to but spaced from the front ends 50a, 50b of the flat body portions 42a, 42b. In the fastened pair, the resilient fingers 44a, 44b define a receiving space 90 for the conductive member 26 in front of the fastener 40, and the fastener 40 controls the size of the receiving space 90. The bases 72a, 72b of the contact beams 70a, 70b define a width that is smaller than a width of the conductive member 26 therebetween, so that when the conductive member 26 is inserted between the resilient fingers 44a, 44b, the resilient fingers 44a, 44b flex outwardly to allow the conductive member 26 to enter the receiving space 90 but maintain electrical contact with the conductive member 26.

[0046] In one embodiment, as Figure 6 shown, the fastener 40 is provided by at least one rivet 92 having a body portion 94 that extends through openings 96a, 96b in the flat body portions 42a, 42b. The rivet 92 has heads 98, 100 formed at each end of the body portion 94. One head 98 abuts against the side 60a of the flat body portion 42a, while the other head 100 abuts against the side 60b of the flat body portion 42b. In one embodiment, as Figure 7As shown, the fastener 40 is set by at least one screw 102. The screw 102 has a single head 104 and a body portion 106 that projects from the head 104 and engages openings 96a, 96b in the flat body portions 42a, 42b. As shown, two rivets 92 or screws 102 are provided and are vertically aligned with each other. However, a single rivet 92 or screw 102 or more than two rivets 92 or screws 102 can be provided. Alternatively, the rivets 92 or screws 102 can be horizontally aligned. The sides 58a, 58b of the flat body portions 42a, 42b abut each other in this embodiment. However, when screws 102 are used, the flat body portions 42a, 42b can be separated from each other.

[0047] In one embodiment, as Figure 8 and Figure 9 shown, the fastener 40 is set by at least one projection 108. The projection 108 extends from the flat body portion 42a and sits within an opening 110 formed in another flat body portion 42b. The projection 108 and the opening 110 can be press-fitted together to maintain the connection of the flat body portions 42a, 42b. Alternatively, the projection 108 and the wall forming the opening 110 can be adhesively bonded or welded together. In one embodiment, the opening 110 is formed as a three-sided recess 112. As shown, two projections 108 / openings 110 are provided and are vertically aligned with each other. However, one projection 108 / opening 110 or more than two projections 108 / openings 110 can be provided. In one embodiment, the flat body portion 42a has one projection 108 and one opening 110, while the other body portion 42b has a corresponding opening 110 and a corresponding projection 108 for docking with the projection 108 and opening 110 of the flat body portion 42a. As shown, the sides 58a, 58b of the flat body portions 42a, 42b abut each other in this embodiment. However, the sides 58a, 58b of the flat body portions 42a, 42b can be spaced apart relative to each other.

[0048] In one embodiment, as Figures 10 to 12 shown, the fastener 40 is set by a C-shaped fastener 114. The fastener 114 has a base 118 and a pair of legs 120, 122 that extend from the base 118. The base 118 rests against the side 60a. The leg 120 extends through openings 124a, 124b in the flat body portions 42a, 42b. The leg 122 extends through openings 126a, 126b in the flat body portions 42a, 42b, and the ends of the legs 120, 122 are bent to rest against the side 60b of the flat body portion 42b. As shown, a single fastener 114 is provided. However, more than one fastener 114 can be provided. The sides 58a, 58b of the flat body portions 42a, 42b abut each other in this embodiment.

[0049] In one embodiment, as Figures 13 to 15 shown, the fastener 40 is provided by at least one fastener 128 having: a body portion 130 that extends through openings 132a, 132b, 134a, 134b in the flat body portions 42a, 42b; heads 136, 138 formed at each end of the body portion 130; and a collar portion 140 that extends from the body portion 130 between the heads 136, 138 and is located between the flat body portions 42a, 42b. The head 136 abuts against the side 60a of the flat body portion 42a, and the head 138 abuts against the side 60b of the flat body portion 42b. The flat body portions 42a, 42b are held in a spaced-apart relationship by the collar portion 140. If the fastener 128 is formed of a conductive material, the conductive contacts 36a, 36b are electrically connected together. If the fastener 128 is formed of a non-conductive material, the conductive contacts 36a, 36b are electrically isolated from each other. As shown, two fasteners 128 are provided and are vertically aligned with each other. However, a single fastener 128 or more than two fasteners 128 may be provided.

[0050] Any other suitable fastener may also be employed. In some embodiments, an urging element (not shown) may be employed in place of the fastener 40. The urging element allows some relative movement between the conductive contacts 36a, 36b while maintaining a clamping effect.

[0051] As Figure 3 , Figure 16 and Figure 17 shown, the base 38 has a top wall 142, a bottom wall 144, and two side walls 146, 148 extending between the top wall 142 and the bottom wall 144, which define a cavity 150 extending from a mating end or front end 152 of the base 38 to a mounting end or rear end 154 of the base 38. A longitudinal axis extends along the base 38 from the mating end 152 to the mounting end 154. The front and rear ends of the cavity 150 are open to define a front opening 158 and a rear opening 160. The top wall 142 and the bottom wall 144 each have an elongated slot 156 (shown only for the top wall 142) that extends from the mating end 152 toward the mounting end 154 and communicates with the cavity 150 and the front opening 158. In the illustrated embodiment, the front opening 158 and the slot 156 are sized to receive the conductive member 26 therein when the mating edge 34 of the conductive member 26 travels in a mating direction M1 into the front opening 158 and the slot 156. The mating direction M1 extends generally parallel to the longitudinal axis of the base 38.

[0052] As Figure 16 and Figure 17As shown, the base 38 includes joints that engage with the joints of the conductive contacts 36a, 36b of the fastening pair. The connection of these joints prevents the mounting portions 46a, 46b from moving relative to the base 38, while the fastened flat body portions 42a, 42b can move in a generally transverse direction relative to the base 38. The base 38 has a first joint in the form of a protrusion 162 and a protrusion 164. The protrusion 162 extends inwardly from an inner side surface of the side wall 146 and engages with the protrusion 84a on the second portion 80a of the conductive contact 36a. The protrusion 164 extends inwardly from an inner side surface of the side wall 148 and engages with the protrusion 84b on the second portion 80b of the conductive contact 36b. The protrusions 162, 164 on each side wall 146, 148 may be formed in a barb shape, the barb having: an inclined rear surface that is inclined relative to the plane defined by the respective side walls 146, 148; and a front surface that is perpendicular to the respective side walls 146, 148. As shown, the rear surface and the front surface are spaced apart from each other by a surface parallel to the respective side walls 146, 148. The base 38 has a second joint, which is provided by: a first wall 166 that extends inwardly from the side wall 146 and into the cavity 150, is close to but spaced from the top wall 142, and extends longitudinally; a first front wall 168 at a front end of the first wall 166; and a second wall 170 that extends inwardly from the side wall 148 and into the cavity 150, is close to but spaced from the top wall 142, and extends longitudinally; and a second front wall 172 at a front end of the second wall 170. The walls 166, 168 form a first channel 174 for receiving the flange 86a of the conductive contact 36a, and the walls 170, 172 form a second channel 176 for receiving the flange 86b of the conductive contact 36b.

[0053] The base further includes spaced slots 178, 180 that pass through the bottom wall 144 of the base 38, extend longitudinally from the mounting end 154 toward the docking end 152, and communicate with the cavity 150. The slots 178, 180 receive portions 82a, 82b of the mounting portions 46a, 46b that pass through them. The slots 178, 180 have a transverse dimension that prevents the second portions 80a, 80b from moving laterally relative to the base 38.

[0054] The base 38 further includes a plurality of surfaces on the top wall 142 that form an elongated recess 182 extending longitudinally from the mounting end 154 toward the docking end 152 and a plurality of surfaces on the bottom wall 144 that form an elongated recess 184 extending longitudinally from the mounting end 154 toward the docking end 152. The upper tabs 64a, 64b are received in the recess 182, and the lower tabs 66a, 66b are received in the recess 184. The recess 182 has a width that is slightly wider than the combined width of the tabs 64a, 64b, and the recess 184 has a width that is slightly wider than the combined width of the tabs 66a, 66b.

[0055] The fastened electrical contact members 36a, 36b are first inserted into the base 38 by inserting the resilient fingers 44a, 44b through the mounting ends 154 of the base 38. The flanges 86a, 86b slide along the channels 174, 176, the tabs 64a, 64b slide along the recesses 182, the tabs 66a, 66b slide along the recesses 184, the portions 82a of the mounting portions 46a slide along the slots 178 and extend downward from the bottom wall 144 of the base 38, and the portions 82b of the mounting portions 46b slide along the slots 180 and extend downward from the bottom wall 144 of the base 38. The inclined surfaces of the protrusions 84a, 84b on the electrical contact members 36a, 36b contact the inclined surfaces of the protrusions 162, 164 on the base 38, and as the insertion continues, the protrusions 84a, 84b move past the protrusions 162, 164. Once past, the flat surfaces of the protrusions 84a, 84b, 162, 164 abut against each other, and the front ends of the flanges 86a, 86b abut against the front walls 168, 172. The fastened electrical contact members 36a, 36b are thereby prevented from being easily removed from the base 38. With the fastened electrical contact members 36a, 36b located within the base 38, the mounting portions 46a, 46b are rigidly affixed to the base 38, and the flat body portions 42a, 42b are cantilevered from the first portions 78a, 78b. The fastened electrical contact members 36a, 36b face each other inversely.

[0056] To form the electrical system 20, the electrical connector 22 is electrically connected to the electrical component 24 by securing the mounting flanges 48a, 48b to the electrical component 24, for example by extending screws 186 through the openings 88a, 88b in the mounting flanges 48a, 48b and into the electrical component 24. Thereafter, the conductive member 26 is inserted through the docking end 152 of the base 38 and into the receiving space 90 to engage the contact beams 70a, 70b on each side 30, 32 of the conductive member 26 to form an electrical connection between the conductive member 26 and the contact beams 70a, 70b.

[0057] The electrical system 20 defines a first flexure region Z1 and a second flexure region Z2, see Figure 17。The first flexure region Z1 extends between the fastener 40 and the front ends 75a, 75b of the resilient fingers 44a, 44b. The second flexure region Z2 extends between the front ends 75a, 75b of the resilient fingers 44a, 44b and the rear ends 52a, 52b of the fastened flat body portions 42a, 42b. When the conductive member 26 engages with the contact beams 70a, 70b, the contact beams 70a, 70b flex in the first flexure region Z1. The contact beams 70a, 70b provide a stable normal force acting on the conductive member 26. When the conductive member 26 is received within the receiving space 90 but the conductive member 26 is not directly aligned with the receiving space 90, the second flexure region Z2 allows a certain degree of misalignment between the electrical connector 22 and the conductive member 26. If misaligned, the free standing beams formed by the fastened flat body portions 42a, 42b and the resilient fingers 44a, 44b will laterally flex within the base 38 in the second flexure region Z2 and relative to the mounting portions 46a, 46b and the electrical component 24 about the longitudinal axes 62a, 62b. The widths of the recesses 182, 184 limit the amount of movement of the flat body portions 42a, 42b and the resilient fingers 44a, 44b within the second flexure region Z2 because the tabs 64a, 64b, 66a, 66b sit within the recesses 182, 184. This is schematically shown as Figure 18 shown. In this layout and as shown in the figure, the normal force presented on the conductive member 26 remains constant because the fastened electrical contacts 36a, 36b and the resilient fingers 44a, 44b move laterally. As shown, the dimensions of the receiving space 90 remain constant during the lateral flexure of the fastened electrical contacts 36a, 36b and the resilient fingers 44a, 44b, and thus the force presented on the conductive member 26 will remain the same. If the two electrical contacts were to float independently of each other, the two electrical contacts would present a higher elastic force.

[0058] A pair of fastened electrical contacts 36a, 36b is shown, but multiple pairs of fastened electrical contacts 36a, 36b can also be considered.

[0059] Attention Figures 19 to 26 to the illustrated embodiment of the electrical connector 222. The electrical connector 222 and the electrical component 24 are relatively aligned with respect to axes including a longitudinal axis, a vertical (or upright) axis, and a horizontal (or transverse) axis. This layout is typically referred to as a "vertical" system.

[0060] Each of the conductive contact members 236a, 236b has a connecting portion formed by a generally rectangular flat body portion 242a, 242b and a plurality of elastic fingers 244a, 244b extending from the flat body portions 242a, 242b. Each of the conductive contact members 236a, 236b further has a mounting portion 246a, 246b extending from a bottom end of the flat body portions 242a, 242b and a mounting flange 248a, 248b extending from the flat body portions 242a, 242b. The mounting portions 246a, 246b are fixed to the base 238. The mounting flanges 248a, 248b are fixed to the electrical component 24. When the flat body portions 242a, 242b and the elastic fingers 244a, 244b are fastened together by the fastener 40 described herein, the flat body portions 242a, 242b and the elastic fingers 244a, 244b form a free standing beam relative to the mounting flanges 248a, 248b with respect to the base 238. For clarity purposes, the components of the conductive contact member 236a are described herein, and the similar components of the conductive contact member 236b are denoted by the same reference numerals except that the accompanying "b" replaces "a".

[0061] As Figures 21 to 23 shown, the flat body portion 242a has a top end 250a, an opposite bottom end 252a, and side edges 254a, 256a extending between the top end 250a and the bottom end 252a and defining a first side surface 258a and a second side surface 260a. A longitudinal axis 262a is defined by the flat body portion 242a from the top end 250a to the bottom end 252a. The side surfaces 258a, 260a coincide with respective planes extending parallel to each other along the longitudinal axis and the transverse axis. A first side tab 264a extends outwardly from the side edge 254a, and a second side tab 266a extends outwardly from the side edge 256a. Each tab 264a, 266a is coplanar with a portion of the flat body portion 242a.

[0062] The plurality of elastic fingers 244a extend from the top end 250a of the flat body portion 242a and are formed in the same manner as the plurality of elastic fingers 44a, 44b. Thus, it will not be repeated here specifically.

[0063] The mounting portion 246a has a first portion 278a extending vertically from each side edge 254a, 256a of the flat body portion 242a, and a second portion 280a which is flat, extending vertically from the first portion 278a and overlapping with the side 260a of the flat body portion 242a and parallel to the flat body portion 42a. The second portion 280a extends parallel to the longitudinal axis 262a. The first portion 278a may be U-shaped. The second portion 280a has an engagement portion that engages with the base 238 to prevent the mounting portion 246a from moving relative to the base 238. The engagement portion may be provided by a protrusion 284a extending upwardly from each second portion 280a and coplanar with the second portion 280a. The protrusion 284a may be formed as an elongated arm having a hook-shaped end. The tab 264a is proximate to but spaced from an upper end of the first portion 278a.

[0064] The mounting flange 248a extends from the bottom end 252a of the flat body portion 242a and is perpendicular to the bottom end 252a of the flat body portion 242a. The mounting flange 248a is located below a lower end of the second portion 280a. An opening 288a is provided through the mounting flange 248a.

[0065] The conductive contacts 236a, 236b are fastened together by fasteners 40 (which may be Figures 6 to 15 40 or any other suitable fastener) to form a fastened pair before insertion into the base 238. In the fastened pair, the sides 258a, 258b of the conductive contacts 236a, 236b face each other, so that the flat body portions 242a, 242b are parallel to each other, the rear walls 268a, 268b of the resilient fingers 244a, 244b are inclined outwardly relative to each other, the first portions 278a, 278b extend outwardly relative to each other, and the mounting flanges 248a, 248b extend outwardly relative to each other. The flat body portions 242a, 242b are connected together by the fastener 40 to prevent relative movement between the flat body portions 242a, 242b. The planar body portions 242a, 242b and mounting portions 246a, 246b are cantilevered from the mounting flanges 248a, 248b, and the planar body portions 242a, 242b define a curved beam. When mated, the fastener 40 effectively changes the bend or flexure of the conductive contacts 236a, 236b. The curved arms are substantially shortened, and the fastener 40 provides a fixing point for the curved beam. The fastener 40 is disposed proximate to but spaced apart from the top ends 250a, 250b8b of the planar body portions 242a, 242b.

[0066] like Figure 20 , Figure 24 and Figure 25As shown, the base 238 has a side wall 342, an opposite side wall 344, and side walls 346, 348 extending between side wall 342 and side wall 344, which define a cavity 350 extending from a mating end or top end 352 of the base 238 to a mounting end or bottom end 354 of the base 238. A longitudinal axis extends along the base 238 from the mating end 352 to the mounting end 354. The front and rear ends of the cavity 350 are open to define a top opening 358 and a bottom opening 360. Each of the side walls 342, 344 has an elongated slot 356 that extends from the mating end 352 toward the mounting end 354 and communicates with the cavity 350 and the top opening 358. In the illustrated embodiment, the top opening 358 and the slot 356 are sized to receive the conductive member 26 therein when the mating edge 34 of the conductive member 26 travels in a mating direction into the top opening 358 and the slot 356. The mating direction extends generally parallel to the longitudinal axis of the base 238.

[0067] The base 238 includes a joint portion that engages with the joint portions of the fastening pair of conductive contacts 236a, 236b. This connection of the joint portions prevents the flat body portions 242a, 242b and the mounting portions 246a, 246b from moving relative to the base 238. The base 238 has a joint portion in the form of a protrusion 362 that extends inwardly from an inner side surface of the side wall 346 and engages with a protrusion 284 on a second portion 280a of the respective conductive contact 236a, and a protrusion (not shown) that extends inwardly from an inner side surface of the side wall 348 and engages with a protrusion 284b on a second portion 280b of the respective conductive contact 236b. The protrusions 362, 364 on each of the side walls 346, 348 may be formed as barbs having an inclined surface inclined relative to the plane defined by the respective side walls 346, 348 and a flat surface perpendicular to the respective side walls 346, 348.

[0068] The base 238 further includes a plurality of surfaces on the side wall 342 that form an elongated recess 382 extending longitudinally from the mounting end 354 toward the mating end 352, and a plurality of surfaces on the side wall 344 that form an elongated recess 384 extending longitudinally from the mounting end 354 toward the mating end 352. The tabs 264a, 264b are received in the recess 382, and the tabs 266a, 266b are received in the recess 384. The recess 382 has a width slightly wider than the combined width of the tabs 264a, 264b, and the recess 384 has a width slightly wider than the combined width of the tabs 266a, 266b.

[0069] The fastened electrical contact members 236a, 236b are inserted into the base 238 by first inserting the resilient fingers 244a, 244b through the mounting end 354 of the base 238. The outer surfaces of the protrusions 284a and the second portions 280a slide along an inner surface of the side wall 346, the outer surfaces of the protrusions 284b and the second portions 280b slide along an inner surface of the side wall 348, the tabs 264a, 264b slide along the recess 382, and the tabs 266a, 266b slide along the recess 384. The hooked ends of the protrusions 284a, 284b on the electrical contact members 236a, 236b engage the protrusions 362 on the base 238. The fastened electrical contact members 236a, 236b are thereby prevented from being easily removed from the base 238. With the fastened electrical contact members 236a, 236b positioned within the base 238, the mounting portions 246a, 246b are rigidly attached to the base 238. The fastened electrical contact members 236a, 236b face each other in an inverted manner.

[0070] To form an electrical system, the electrical connector 222 is electrically coupled to the electrical component 24 by fixing it to the electrical component 24 through the mounting flanges 248a, 248b, for example, by screws extending through the openings 288a, 288b of the mounting flanges 248a, 248b and into the electrical component 24. In the embodiment as Figure 26 shown, the bottom end of the base 238 is spaced from the mounting flanges 248a, 248b to form a space 388. Thereafter, the conductive member 26 is inserted through the docking end 352 of the base 238 and into the receiving space 290 to engage the contact beams 270a, 270b on each side 30, 32 of the conductive member 26 to form an electrical connection between the conductive member 26 and the contact beams 270a, 270b.

[0071] The electrical system defines a first flexure region Z1 and a second flexure region Z2, see Figure 26。The first flexure region Z1 extends between the fastener 40 and the front ends 275a, 275b of the resilient fingers 244a, 244b. The second flexure region Z2 extends between the front ends 275a, 275b of the resilient fingers 244a, 244b and the bottom ends 252a, 252b of the fastened flat body portions 242a, 242b. When the conductive member 26 engages the contact beams 270a, 270b, the contact beams 270a, 270b flex in the first flexure region Z1. The contact beams 270a, 270b provide a stable normal force acting on the conductive member 26. When the conductive member 26 is received within the receiving space 290 but the conductive member 26 is not properly aligned with the receiving space 290, the second flexure region Z2 allows a certain degree of misalignment between the electrical connector 222 and the conductive member 26. If misaligned, the free standing beams formed by the base 238, the fastened flat body portions 242a, 242b, and the resilient fingers 244a, 244b will flex laterally about the longitudinal axes 262a, 262b in the second flexure region Z2 relative to the mounting flanges 248a, 248b. In this configuration, the normal force presented on the conductive member 26 remains constant because the base 238, the fastened flat body portions 242a, 242b, and the resilient fingers 244a, 244b move laterally. As shown, the dimensions of the receiving space 290 remain constant during the lateral flexure of the base 238, the fastened electrical contacts 236a, 236b, and the resilient fingers 244a, 244, and thus the force will remain the same.

[0072] A pair of fastened electrical contacts 236a, 236b are shown, but multiple pairs of fastened electrical contacts 236a, 236b are also contemplated.

[0073] Attention Figures 27 to 32 The illustrated embodiment of the electrical connector 422. The electrical connector 422 and the electrical component 24 are relatively aligned with respect to a longitudinal axis, a vertical (or upright) axis, and a horizontal (or transverse) axis. This configuration is typically referred to as a "vertical" system.

[0074] Each of the conductive contacts 436a, 436b has a connecting portion having a flat body portion 442a, 442b of a generally rectangular shape and a plurality of elastic fingers 444a, 444b extending from the flat body portions 442a, 442b. Each of the conductive contacts 436a, 436b further has a mounting portion 446a, 446b extending from the flat body portions 442a, 442b and a mounting flange 448a, 448b extending from the flat body portions 442a, 442b. When the flat body portions 442a, 442b and the elastic fingers 444a, 444b are fastened together by the fastener 40 described herein, the flat body portions 442a, 442b and the elastic fingers 444a, 444b form a free-standing beam within the base 438. The conductive contacts 436a, 436b are formed in the same manner as the conductive contacts 236a, 236b except for the following differences. The mounting portions 446a, 446b are parallel to their respective flat body portions 442a, 442b, not perpendicular to their respective flat body portions 442a, 442b, and the mounting portions 446a, 446b do not include openings. Additionally, a tab 521a, 521b extends outwardly from a side edge of each mounting flange 448a, 448b and approaches a lower end of the mounting portion 446a, 446b. Accordingly, the details of the conductive contacts 436a, 436b are not repeated herein and like components are designated by like reference numerals but in the 400's in this embodiment.

[0075] The conductive contacts 436a, 436b are fastened together by a fastener 40 (which may be any one of the fasteners 40 shown Figures 6 to 15 or any other suitable fastener) to form a fastened pair before being inserted into the base 438 in the same manner as the conductive contacts 236a, 236b except that the mounting flanges 448a, 448b are parallel to each other. The flat body portions 442a, 442b are joined together by the fastener 40 to prevent relative movement between the flat body portions 442a, 442b. As shown, the fastener 40 is located at approximately the middle of the length of a beam formed by the flat body portions 442a, 442b and the elastic fingers 444a, 444b.

[0076] The base 438 has a side wall 542, an opposite side wall 544, and side walls 546, 548 extending between the side walls 542 and 544, which define a cavity 550 extending from a mating end or top end 552 of the base 438 to a mounting end or bottom end 554 of the base 438. A longitudinal axis extends along the base 438 from the mating end 552 to the mounting end 554. The front and rear ends of the cavity 550 are open to define a top opening 558 and a bottom opening 560. Each of the side walls 542, 544 has an elongated slot 556 that extends from the mating end 552 toward the mounting end 554 and communicates with the cavity 550 and the top opening 558. In the illustrated embodiment, the top opening 558 and the slot 556 are sized to receive the conductive member 26 therein when the mating edge 54 of the conductive member 26 travels in a mating direction into the top opening 558 and the slot 556. The mating direction extends generally parallel to the longitudinal axis of the base 438.

[0077] Similar to the base 238, the base 438 includes a mating portion (not shown) that mates with the protrusions 484a, 484b of the conductive contacts 436a, 436b of the fastening pair, similar to the protrusions 362. This connection of the mating portion prevents the mounting portions 446a, 446b from moving relative to the base 438. Similar to the base 238, the base 438 includes a plurality of surfaces on the side wall 542 that form an elongated recess 582 extending longitudinally from the mounting end 554 toward the mating end 552 and a plurality of surfaces on the side wall 544 that form an elongated recess 584 extending longitudinally from the mounting end 554 toward the mating end 552. The tabs 464a, 464b, 521a, 521b are received in the recess 582, while the tabs 466a, 466b, 523a, 523b are received in the recess 584. The recess 582 has a width slightly wider than the combined width of the tabs 464a, 464b, and the recess 584 has a width slightly wider than the combined width of the tabs 466a, 466b.

[0078] The base 438 further includes: a first mounting wing 525 that extends outward from the side wall 546 and is perpendicular to the longitudinal axis of the base 438; and a second mounting wing 527 that extends outward from the side wall 548 and is perpendicular to the longitudinal axis of the base 438. The mounting wings 525, 527 are horizontally aligned with each other.

[0079] The secured electrical contacts 436a, 436b are inserted into the base 438 by first inserting the resilient fingers 444a, 444b through the mounting end 554 of the base 438. The outer surfaces of the projections 484a and the second portions 480a slide along an inner surface of the sidewall 546, the outer surfaces of the projections 484b and the second portions 480b slide along an inner surface of the sidewall 548, the tabs 464a, 464b, 521a, 521b slide along the recess 582, and the tabs 466a, 466b, 523a, 523b slide along the recess 584. The hooked ends of the projections 484a, 484b on the electrical contacts 436a, 436b engage projections (not shown) on the base 438, and the secured electrical contacts 436a, 436b are thereby prevented from being easily removed from the base 438. With the secured electrical contacts 436a, 436b located within the base 438, the mounting portions 446a, 446b are rigidly attached to the base 438. The secured electrical contacts 436a, 436b face each other in an inverted manner.

[0080] To form the electrical system 420, the electrical connector 422 is electrically coupled to the electrical component 24 by securing the mounting wings 525, 527 to the electrical component 24, for example, by screws extending through the openings in the mounting wings 525, 527 and into the electrical component 24. The base 438 passes through an opening (not shown) in the electrical component 24. The electrical system 20 defines a first flexure region Z1 and a second flexure region Z2, see Figure 32。The first flexure region Z1 extends between the fastener 40 and the front ends 475a, 475b of the resilient fingers 444a, 444b. The second flexure region Z2 extends between the front ends 475a, 475b of the resilient fingers 444a, 444b and the bottom ends 452a, 452b of the fastened flat body portions 442a, 442b. Thereafter, the conductive member 26 (or the base 438 and the mounting flanges 448a, 448b of another electrical connector 422) is inserted through the docking end 552 of the base 438 and into the receiving space 490 to engage with the contact beams 470a, 470b on each side 30, 32 of the conductive member 26 to form an electrical connection between the conductive member 26 and the contact beams 470a, 470b. When the conductive member 26 (or the mounting flanges 448a, 448b) engages with the contact beams 470a, 470b, the contact beams 470a, 470b flex in the first flexure region Z1. The contact beams 470a, 470b provide a stable normal force acting on the conductive member 26. When the conductive member 26 (or the mounting flanges 448a, 448b of another electrical connector 422) is received in the receiving space 490 but the conductive member 26 (or the mounting flanges 448a, 448b of another electrical connector 422) is not properly aligned with the receiving space 490, the second flexure region Z2 allows a certain degree of misalignment between the electrical connector 422 and the conductive member 26 (or the mounting flanges 448a, 448b of another electrical connector 422). If misaligned, the free standing beams formed by the flat body portions 442a, 442b and the resilient fingers 444a, 444b will flex laterally in the second flexure region Z2 about the longitudinal axes 462a, 462b relative to the mounting flanges 448a, 448b and the base 438. In this layout, the normal force presented on the conductive member 26 (or the mounting flanges 448a, 448b of another electrical connector 422) remains constant because the fastened flat body portions 442a, 442b and the resilient fingers 444a, 444b move laterally relative to the mounting flanges 448a, 448b and the base 438. As shown, the dimensions of the receiving space 490 remain constant during the lateral flexure of the fastened electrical contact members 436a, 436b and the resilient fingers 444a, 444b, and thus the force will remain the same.

[0081] The widths of the recesses 582, 584 limit the amount of movement of the flat body portions 442a, 442b and the resilient fingers 444a, 444b in the second flexure region Z2 because the tabs 464a, 464b, 466a, 466b sit within the recesses 582, 584.

[0082] A pair of fastened electrical contact members 436a, 436b are shown, but multiple pairs of fastened electrical contact members 436a, 436b can also be considered.

[0083] The disclosure provided herein illustrates features by way of its preferred and exemplary embodiments. Upon reading this disclosure, many other embodiments, modifications, and variations within the scope and spirit of the appended claims will occur to those of ordinary skill in the art.

Claims

1. An electrical connector, comprising: an insulating base having a first end, a second end, and a cavity extending from the first end to the second end; a first conductive contact, comprising: a first flat body portion having a first end and an opposite second end, wherein a first longitudinal axis is defined between the first end and the second end of the first flat body portion; a plurality of first elastic fingers extending from the first end of the first flat body portion, the plurality of first elastic fingers being adjacent to the first end of the first flat body portion; and a first mounting portion extending from the first flat body portion, the first mounting portion including a first portion extending from the first flat body portion and perpendicular to the first flat body portion, and a second portion extending from the first portion and perpendicular to the first portion, the second portion being fixed to the base, the first flat body portion, the plurality of first elastic fingers, and the first mounting portion being located within the cavity of the base; a second conductive contact, comprising: a second flat body portion having a first end and an opposite second end, wherein a second longitudinal axis is defined between the first end and the second end of the second flat body portion; a plurality of second elastic fingers extending from the first end of the second flat body portion, the plurality of second elastic fingers being adjacent to the first end of the second flat body portion; and a second mounting portion extending from the plurality of second flat body portions, the second mounting portion including a first portion extending from the second flat body portion and perpendicular to the second flat body portion, and a second portion extending from the first portion of the second mounting portion and perpendicular to the first portion of the second mounting portion, the second portion of the second mounting portion being fixed to the base, the second flat body portion, the plurality of second elastic fingers, and the second mounting portion being located within the cavity of the base; and A fastener connects the first flat body portion and the second flat body portion together. The plurality of first elastic fingers and the plurality of second elastic fingers define a receiving space therebetween configured to receive a conductive member. A first flexure region is defined between the fastener and the first ends of the plurality of first elastic fingers and the plurality of second elastic fingers. In the first flexure region, the first elastic fingers and the second elastic fingers are configured to flex laterally within the cavity relative to their respective first longitudinal axis and second longitudinal axis to receive the conductive member within the receiving space. A second flexure region is defined between the first ends of the plurality of first elastic fingers and the plurality of second elastic fingers and the second ends of the first flat body portion and the second flat body portion. And in the second flexure region, the first flat body portion and the second flat body portion and the plurality of first elastic fingers and the plurality of second elastic fingers are configured to flex laterally within the cavity when the conductive member is received within the receiving space but the conductive member is not properly aligned with the receiving space.

2. The electrical connector according to claim 1, wherein, The first part is U-shaped.

3. The electrical connector according to claim 1, wherein, The fastener connects the first flat body portion and the second flat body portion together adjacent to the plurality of first elastic fingers and the plurality of second elastic fingers.

4. The electrical connector according to claim 1, wherein, The fastener is a rivet or a screw extending through the first flat body portion and the second flat body portion.

5. The electrical connector according to claim 1, wherein, The fastener is a protrusion extending from one of the first flat body portion and the second flat body portion and seated in an opening in the other of the first flat body portion and the second flat body portion.

6. The electrical connector according to claim 1, wherein, The fastener is a C-shaped fastener extending into the openings of the first flat body portion and the second flat body portion.

7. The electrical connector according to claim 1, wherein, The fastener is a fastener having: a body portion extending through openings in the first flat body portion and the second flat body portion; a head formed at each end of the body portion of the fastener; and a locking portion extending from the body portion of the fastener, the locking portion being located between the first flat body portion and the second flat body portion.

8. The electrical connector according to claim 7, wherein, The fastener is conductive.

9. The electrical connector according to claim 1, wherein, The first conductive contact further includes a first mounting flange extending from the first flat body portion, and the second conductive contact further includes a second mounting flange extending from the second flat body portion. The first mounting flange and the second mounting flange are configured to be connected to an electrical component.

10. The electrical connector according to claim 1, wherein, Each conductive contact further includes: a mounting flange extending from the second part of the mounting portion, the mounting flange being configured to be connected to an electrical component.

11. The electrical connector according to claim 1, wherein, The base further includes a pair of mounting flanges configured to be connected to an electrical component.

12. An electrical connector, comprising: an insulating base having a first end and a second end and a cavity extending from the first end to the second end, the cavity being defined by walls; A first conductive contact member includes a first connecting portion and a first mounting portion. The first connecting portion has a first flat body portion and a plurality of first elastic fingers. The first flat body portion has a first end and an opposite second end. A first longitudinal axis is defined between the first end and the second end of the first flat body portion. The plurality of first elastic fingers extend from the first end of the first flat body portion. The first mounting portion extends from the first flat body portion and is firmly fixed to the base in the cavity. The first mounting portion positions the first connecting portion in the cavity of the base and spaces it apart from the wall of the cavity. A second conductive contact member includes a second connecting portion and a second mounting portion. The second connecting portion has a second flat body portion and a plurality of second elastic fingers. The second flat body portion has a first end and an opposite second end. A second longitudinal axis is defined between the first end and the second end of the second flat body portion. The plurality of second elastic fingers extend from the first end of the second flat body portion. The second mounting portion extends from the second flat body portion and is firmly fixed to the base. The second mounting portion positions the second connecting portion in the cavity of the base and spaces it apart from the wall of the cavity. And A fastener is located between the first flat body portion and the second flat body portion and fixes the first flat body portion and the second flat body portion together. The fastener is spaced apart from the first mounting portion and the second mounting portion. The plurality of first elastic fingers and the plurality of second elastic fingers define a receiving space therebetween configured to receive a conductive member. Wherein, the first connecting portion and the second connecting portion fixed together stand freely in the cavity and are configured to flex laterally in the cavity relative to their respective first longitudinal axis and second longitudinal axis to receive the conductive member in the receiving space.

13. The electrical connector as claimed in claim 12, wherein, A first flexure region is defined between the fastener and the first ends of the plurality of first elastic fingers and the plurality of second elastic fingers; and a second flexure region is defined between the first ends of the plurality of first elastic fingers and the plurality of second elastic fingers and the second ends of the first flat body portion and the second flat body portion. Wherein, in the first flexure region, the plurality of first elastic fingers and the plurality of second elastic fingers are configured to flex in the cavity to receive the conductive member in the receiving space. Wherein, in the second flexure region, the first flat body portion and the second flat body portion and the plurality of first elastic fingers and the plurality of second elastic fingers are configured to flex in the cavity when the conductive member is received in the receiving space but the conductive member is not exactly aligned with the receiving space.

14. The electrical connector according to claim 13, wherein, Each of the first mounting portion and the second mounting portion has a flat portion spaced apart from its respective first flat body portion and second flat body portion.

15. An assembly includes the electrical connector as claimed in claim 1, and the electrical connector is coupled to a circuit board.

16. The assembly according to claim 15, wherein, In each of the conductive contacts, a first portion of the mounting portion extends from a second end of the flat body portion.

17. The assembly according to claim 15, wherein, The fastener includes one of a rivet, a screw, and a clip.

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