Two-piece right-angled male terminal for joint assembly of electric connector and electric connector thereof

Abstract

A right-angled male terminal of an electric connector is provided with a first pin and a second pin which are press-fitted together to form a split body in interference fit. One pin is provided with an unthreaded socket, and the other pin is provided with a butt joint protruding part. The butt joint protruding part of one contact pin is connected to one insertion opening of the other contact pin through interference fit, and the axial center lines of the two contact pins are perpendicular to each other. This structure optimizes straightness and the true location of the holes, provides electrical stability, and eliminates the problems caused by material extrusion and / or material expansion.

Description

[0001] Related Applications

[0002] This application claims priority to Indian Provisional Application No. 202241067885, filed on Nov. 25, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to a right-angle male terminal for a header assembly of an electrical connector. Background Art

[0004] Connectors, such as high-current wire-to-board / wire-to-bus connectors for high-power applications such as computers, data servers, bus applications, etc., employ a header assembly with right-angle terminals to provide a connection between a wire and a circuit board / bus. Electrical contact occurs between the male terminal and the substrate of the circuit board. In a surface-mount connection, a tail of the male terminal is soldered to a conductive contact pad on the surface of the circuit board. In a through-hole connection, the tail of the male terminal extends through a hole in the circuit board and is electrically connected by soldering to the conductive material in the hole. In a screw-mount assembly, a screw shank is screwed into the tail of the male terminal from a second side of the circuit board, and a washer, which may be a flat washer or a Belleville washer, is located between the circuit board and an enlarged head of the screw.

[0005] As shown in FIGS. 21 and 22, it is known to bend a solid, elongated, cylindrical rod to form a right-angle terminal 2. Before bending, the solid rod has opposite ends that define a centerline of the rod. The solid rod is bent in a region of the bent portion to form the right-angle terminal 2. In an ideal case, the solid rod is bent to an exact 90 degrees such that centerlines 4a, 6a of a wire connection portion 4 and a tail 6 of the resulting male terminal 2 are perpendicular to each other. The tail 6 may have an enlargement 8 near its end. The male terminal 2 is insert-molded into a header of a header assembly. The wire connection portion 4 is within the header while the tail 6 extends downward from the header for connection to a circuit board 16. During this process, when a rod of a larger diameter is bent or when a tail 6 of a shorter length is provided, due to the following considerations, electrical performance problems of the resulting connector may occur.

[0006] In a bent region, the material on one inner side (material extrusion region SA, see Figure 21) of the solid rod is extruded along the inner bending radius as a result of compression. The extruded material bulges from the cylindrical shape, as shown in Figure 23. Additionally, as a result of bending the solid rod, the material on one outer side (material expansion region EA, see Figure 21) expands along the outer bending radius as a result of tension. Due to the movement of the microstructure, cracks may appear on the outer side of the obtained terminal. All of these can affect the electrical performance of the obtained terminal.

[0007] Additionally, an important consideration for providing proper electrical contact in a surface mount connection is that a flat end 10 formed as part of the tail 6 sits flush against a flat surface 20 of the circuit board 16. This eliminates any air gaps that could affect the electrical performance. In the bending of the known solid rod, due to the springback that occurs during bending, the centerline 6a of the tail 6 and the flat surface 20 of the circuit board 16 often cannot be completely perpendicular to each other, so a point contact 12 is formed between the flat end 10 and the flat surface 20, thereby also creating an air gap 14. This can lead to poor electrical contact between the flat surface 10 of the tail 6 and the flat surface 20 of the circuit board 16, because the reduced surface contact may result in higher resistance and higher heat in current transmission. The same problem can also affect the electrical performance of a via connection, because the tail 6 may be inclined relative to the central axis 22a of the via 22, thereby impairing the electrical performance. 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.

[0009] Figure 1 An underside perspective view showing an electrical connector mounted on a circuit board according to a first embodiment;

[0010] Figure 2 An exploded perspective view of the electrical connector and the circuit board;

[0011] Figure 3 A side view showing the components forming the electrical connector and showing a two-piece right-angle male terminal mounted on the circuit board;

[0012] Figure 4 An exploded side view of the two-piece right-angle male terminal;

[0013] Figure 5 An end view of the two-piece right-angle male terminal;

[0014] Figure 6 A cross-sectional view of a connector assembly of the electrical connector including the two-piece right-angle male terminal and mounted on the circuit board;

[0015] Figure 7 A cross-sectional view showing a male terminal with a two-piece right angle installed therein and mounted on a circuit board;

[0016] Figure 8 A bottom perspective view showing an electrical connector according to a second embodiment mounted on a circuit board;

[0017] Figure 9 Showing the formation Figure 8 of the components of an electrical connector and a side view showing a two-piece right angle male terminal mounted on a circuit board;

[0018] Figure 10 Showing Figure 9 an exploded side view of a two-piece right angle male terminal one;

[0019] Figure 11 Showing Figure 9 an end view of a two-piece right angle male terminal;

[0020] Figure 12 Showing an electrical connector having a two-piece right angle male terminal therein and mounted on a circuit board Figure 8 a cross-sectional view of a joint assembly of;

[0021] Figure 13 A side view showing a two-piece right angle male terminal forming the components of an electrical connector according to a third embodiment;

[0022] Figure 14 Showing Figure 13 a perspective view of a pair of two-piece right angle male terminals;

[0023] Figure 15 Showing a joint assembly of an electrical connector having Figure 13 a two-piece right angle male terminal therein according to the third embodiment;

[0024] Figure 16 Showing Figure 15 an end view of the joint assembly;

[0025] Figure 17 A side view showing a two-piece right angle male terminal forming the components of an electrical connector according to a fourth embodiment;

[0026] Figure 18 Showing Figure 17 a perspective view of a pair of two-piece right angle male terminals;

[0027] Figure 19 Showing a joint assembly of an electrical connector having Figure 17A perspective view of a connector assembly including a two-piece right-angled male terminal;

[0028] Figure 20 Shows Figure 19 An end view of the connector assembly shown;

[0029] Figure 21 shows a cross-sectional view of a prior art male terminal shown disassembled from a circuit board;

[0030] Figure 22 shows an end view of a prior art male terminal shown mounted on a circuit board; and

[0031] Figure 23 shows an enlarged perspective view of a prior art male terminal and a portion thereof.

[0032] The accompanying drawings illustrate an embodiment of the present disclosure, and it should be understood that the disclosed embodiments are merely examples of the present disclosure, and the present disclosure may be embodied in various forms. Therefore, the specific details disclosed herein should not be construed as limiting, but only as a basis for the claims and as a representative basis for teaching those skilled in the art to use the present disclosure in various ways. Detailed Description

[0033] Although the present disclosure may be readily embodied in embodiments in different forms, the specific embodiments shown in the drawings and described in detail herein are to be understood, while understanding that the present disclosure is to be regarded as an example of the principles of the present disclosure and not intended to limit the present disclosure to that shown and described herein. Therefore, unless otherwise stated, the features disclosed herein may be combined to form additional combinations not shown for the purpose of brevity. It will further be recognized that in some embodiments, within the scope of the present disclosure, one or more components shown in the drawings may be eliminated and / or replaced with additional components.

[0034] The present disclosure is illustrated by way of example and not limited to the drawings, in which like reference numerals represent like components, and in the drawings, the drawings illustrate the features of multiple embodiments of a terminal of a connector assembly.

[0035] The present disclosure relates to a two-piece right-angled male terminal 100, 200, 300, 400 for use in a connector assembly 24 of an electrical connector 26, overcoming the problems that occur when bending a single solid rod to form a right-angled terminal in the prior art as shown in FIGS. 21 and 22. The male terminals 100, 200, 300, 400 are conductive. This design is particularly suitable for forming 3.4 mm terminals, 6 mm terminals, 8 mm terminals, 11 mm terminals, and 15 mm terminals.

[0036] The electrical connector 26 includes a header assembly 24 and a receptacle 28 that are detachably coupled together. The header assembly 24 includes a housing 30 that is coupled to the circuit board 16, for example, by fasteners 32. The male terminals 100, 200, 300, 400 are insert-molded into the housing 30 and open into a cavity 34 of the housing 30. The male terminals 100, 200, 300, 400 may be formed of a copper alloy. The receptacle 28 includes a housing 36 that has a plurality of channels therethrough. Conductive slots 38 having a plurality of flexible contact beams are located at the front ends within each channel, see Figure 7 . A wire connector 40 is seated within each channel behind the respective slot 38 and is electrically coupled to the respective slot 38. A wire 42 is electrically coupled to each wire connector 40.

[0037] When the header assembly 24 and the receptacle 28 are coupled together, the housing 36 of the receptacle 28 is seated within the cavity 34 of the header assembly 24. The male terminals 100, 200, 300, 400 enter their respective channels and engage the contact beams of the slots 38. As a result, the wire 42 is electrically coupled to the male terminals 100, 200, 300, 400.

[0038] Figures 2 to 7 A first embodiment of the male terminal 100 is shown and provided for a screw mounting assembly with the circuit board 16. Figures 7 to 12 A second embodiment of the male terminal 200 is shown and provided for a solder mounting assembly with the circuit board 16. Figures 13 to 16 A third embodiment of the male terminal 300 is shown and provided for a screw mounting assembly with the circuit board 16. Figures 17 to 20 A fourth embodiment of the male terminal 400 is shown and provided for a solder mounting assembly with the circuit board 16. In each embodiment, the male terminals 100, 200, 300, 400 are formed by a first pin 50, 500 and a second pin 102, 202, 302, 402 that are joined by an interference fit. By arranging a first pin 50, 500 to be joined to a split second pin 102, 202, 302, 402 to form the male terminals 100, 200, 300, 400, the flatness and the true position of the holes are optimized. Additionally, by arranging the first pin 50, 500 to be joined to the split second pin 102, 202, 302, 402 in the manner described herein to form the male terminals 100, 200, 300, 400, electrical stability is provided. Additionally, problems of material extrusion and / or material expansion caused by the bending methods of the prior art are eliminated. The use of the interference fit does not affect the electrical performance of the male terminals 100, 200, 300, 400.

[0039] In Figures 3 to 5 the male terminal 100 shown and Figures 9 to 11In the illustrated embodiment of the male terminal 200, the first pin 50 is formed of an elongated solid rod having opposite first and second ends 54, 56 that define an axial centerline 58 of the rod. The first pin 50 has a first portion 60 and a second portion 62 extending from one end of the first portion 60. Each of the portions 60, 62 may be cylindrical. The second portion 62 has a diameter greater than that of the first portion 60, such that a flat wall 64 is formed therebetween by the second portion 62. The second portion 62 has opposite flat wall portions 66, 68 extending from its second end 56 and along a portion of the second portion 62. Refer to Figure 6 and Figure 7 , a socket 70 is disposed through the second portion 62 and particularly through the flat wall portion 68 at a location adjacent to but spaced from the second end 56. A centerline 72 of the socket 70 intersects the centerline 58 of the first pin 50. The socket 70 is non-threaded and has an open lower end for receiving the second pin 102 and may have an opposite open end as shown. As shown, the socket 70 is cylindrical.

[0040] In Figures 3 to 5 the illustrated first embodiment of the male terminal 100, the second pin 102 is formed of an elongated solid rod having opposite first and second ends 104, 106 that define an axial centerline 108 therebetween. The second pin 102 has an upper first portion 110, a second portion 112 extending from a lower end of the first portion 110, a third portion 114 extending from a lower end of the second portion 112, and a fourth portion 116 extending from a lower end of the third portion 114. The first portion 110 has a profile that conforms to the profile of the socket 70. Each of the portions 110, 112, 114, 116 may be cylindrical. The second portion 112 has a diameter greater than that of the first portion 110, such that an upper flat wall 118 is formed therebetween by the second portion 112. The third portion 114 has a diameter greater than that of the fourth portion 116, such that a lower flat wall surface 120 is formed therebetween by the third portion 114. The third portion 114 defines an enlarged portion of the second pin 102. The third portion 114 may have a diameter greater than that of the second portion 112.

[0041] The first portion 110 of the second pin 102 forms a mating projection and is seated within the socket 70 of the first pin 50 after assembly. The axial centerline 72 of the socket 70 is aligned with the axial centerline 108 of the second pin 102. The socket 70 of the first pin 50 and the first portion 110 of the second pin 102 are dimensioned to ensure that the first portion 110 is press-fit tightly into the socket 70 to provide an interference fit, and the tolerances are tightly controlled to ensure that the centerlines 58, 108 of the pins 50, 102 are perpendicular to each other. The flat wall 118 of the second pin 102 engages the flat wall portion 68 of the first pin 50 and prevents the second pin 102 from further entering the socket 70. Although the socket 70 and the first portion 110 are shown and described as cylindrical, the socket 70 and the first portion 110 can have a polygonal cross-section along their length.

[0042] An internal blind hole 122 is provided in the second pin 102 and extends from the second end 106 of the second pin 102, through the fourth portion 116, the third portion 114 and into the second portion 112. The wall forming the blind hole 122 has an internal thread pattern provided thereon.

[0043] The connected first and second pins 50, 102 form a first embodiment of the male terminal 100, which is insert-molded into the housing 30 to form the connector assembly 24. One end 54 of the first pin 50 and a portion of the first portion 60 adjacent thereto extend into the cavity 34 and form a wire connection portion. A portion of the third portion 114 and the fourth portion 116 of the second pin 102 extend downwardly from the housing 30. The flat wall surface 120 of the third portion 114 is flush with the flat surface 20 of the circuit board 16 and lies in planar contact with the flat surface 20 of the circuit board 16, and the fourth portion 116 is located within the hole 22 passing through the circuit board 16. The axis 22a of the hole 22 is aligned with the centerline 108 of the second pin 102. The fourth portion 116 has a diameter smaller than the diameter of the hole 22. A screw 124 of a fastener 126, which can be a screw, is screwed into the blind hole 122 from a second side 128 of the circuit board 16, and a washer 130, which can be a flat washer or a Belleville washer, is located between the second side 128 of the circuit board 16 and an enlarged head 132 of the fastener 126. This provides optimal surface-to-surface contact between the flat wall surface 120 and the flat surface 20 of the circuit board 16.

[0044] In Figures 9 to 11In a second embodiment of the male terminal 200 shown, the second pin 202 is formed of an elongated solid rod having opposite first and second ends 204, 206 that define an axial centerline 208 therebetween. The second pin 202 has an upper first portion 210 and a lower second portion 212 that extends from a lower end of the first portion 210. The first portion 210 has a profile that conforms to the profile of the socket 70. Each of the portions 210, 212 may be cylindrical. The second portion 212 has a diameter greater than that of the first portion 210, such that an upper flat wall 218 is formed therebetween by the second portion 212.

[0045] Similar to the first embodiment of the male terminal 100, the first portion 210 forms a docking projection and seats within the socket 70 of the first pin 50 after assembly. The axial centerline 72 of the socket 70 is aligned with the axial centerline 208 of the second pin 202. The socket 70 of the first pin 50 and the first portion 210 of the second pin 202 are dimensioned to ensure that the first portion 210 is press-fit tightly into the socket 70 to provide an interference fit, and the tolerances are tightly controlled to ensure that the centerlines 58, 208 of the pins 50, 202 are perpendicular to each other. The flat wall 218 of the second pin 202 engages the flat wall portion 68 of the first pin 50 and prevents the second pin 202 from further entering the socket 70. Although the socket 70 and the first portion 210 are shown and described as cylindrical, the socket 70 and the first portion 210 can have a polygonal cross-section along their lengths.

[0046] The connected first and second pins 50, 202 form the second embodiment of the male terminal 200, which is insert-molded into the housing 30 to form the connector assembly 24. One end 54 of the first pin 50 and a portion of the first portion 60 adjacent thereto extend into the cavity 34 and form a wire connection portion. A portion of the second portion 212 of the second pin 202 extends downward from the housing 30. A lower portion of the second portion 212 forms a tail and is located within the hole 22 through the circuit board 16 and may extend below the second side 128 of the circuit board 16. The axis 22a of the hole 22 is aligned with the centerline 208 of the second pin 202. The diameters of the second portion 212 and the hole 22 are controlled such that an axis-to-axis alignment occurs between the second portion 212 and the hole 22. Thereafter, the second pin 202 is soldered to the circuit board 16.

[0047] When installing the connector assembly 24 on the circuit board 16, the two-piece male terminals 100, 200 assist in aligning the male terminals 100, 200 with the holes 22 on the circuit board 16, and assist in achieving the correct and true positioning of the male terminals 100, 200 relative to the circuit board 16, and establish an optimal electrical contact after the soldering process is completed.

[0048] In Figure 13 andFigure 14 In the embodiment of the male terminal 300 shown and Figure 17 and Figure 18 the male terminal 400 shown, the first pin 500 is formed by an elongated solid rod having opposite first and second ends 554, 556 that define an axial centerline 558 therebetween. The first pin 500 has a first portion 560, a second portion 562 extending from one end of the first portion 560, and a third portion 572 extending from one end of the second portion 562. Each of the portions 560, 562, 572 may be cylindrical. The second portion 562 has a diameter greater than that of the first portion 560, whereby a flat wall 564 is formed by the second portion 562 therebetween. The second portion 562 has a diameter greater than that of the third portion 572, whereby a flat wall 574 is formed by the second portion 562 therebetween.

[0049] In Figure 13 and Figure 14 the third embodiment of the male terminal 300 shown, the second pin 302 is formed by an elongated solid rod having opposite first and second ends 304, 306 that define an axial centerline 308 therebetween. The second pin 302 has an upper first portion 310, a second portion 312 extending from a lower end of the first portion 310, and a third portion 314 extending from a lower end of the first portion 310. Each of the portions 310, 312, 314 may be cylindrical. The second portion 312 has a diameter greater than that of the first portion 310, whereby an upper flat wall 318 is formed by the second portion 312 therebetween. The second portion 312 has a diameter greater than that of the third portion 314, whereby a lower flat wall surface 320 is formed by the second portion 312 therebetween. The second portion 312 defines an enlarged portion of the second pin 302.

[0050] The first portion 310 has opposite flat wall portions 334, 336 extending from its upper end 304 and along a portion of the first portion 310. A socket 338 passes through the first portion 310 and particularly through the flat wall portion 334 at a position close to but spaced from the upper end 304. A centerline of the socket 338 intersects the centerline 308 of the second pin 302. The socket 338 is non-threaded and has an open end to receive the first pin 500 and may have an opposite open end as shown. As shown, the socket 338 is cylindrical.

[0051] The third portion 572 of the first pin 500 has a contour that conforms to the contour of the socket 338 and forms a pair of docking protrusions that, upon assembly, sit within the socket 338 of the second pin 302. The axial centerline of the socket 338 is aligned with the axial centerline 558 of the first pin 500. The flat wall 574 of the second portion 562 abuts the flat wall portion 334 and prevents the third portion 572 from further entering the socket 338. The third portion 572 of the first pin 500 and the socket 338 of the second pin 302 are dimensioned to ensure that the third portion 572 is press-fit tightly into the socket 338 to provide an interference fit, and the tolerances are tightly controlled to ensure perpendicularity of the centerlines of the pins 500, 302 to each other. Although the socket 338 and the third portion 572 are shown and described as cylindrical, the socket 338 and the third portion 572 can have a polygonal cross-section along their length.

[0052] An internal blind hole (not shown) is provided in the second pin 302 and extends from the second end 306 of the second pin 302, through the third portion 314, and into the second portion 312. In one embodiment, the blind hole does not intersect the socket 338. The wall forming the blind hole has an internal thread pattern provided thereon.

[0053] The connected first and second pins 500, 302 form a third embodiment of the male terminal 300, insert molded into the housing 30 to form the connector assembly 24. One end 554 of the first pin 500 and a portion of the first part 560 adjacent thereto extend into the cavity 34 and form a wire connection portion. A portion of the second part 312 and the third part 314 of the second pin 302 extend downward from the housing 30. The flat wall surface 320 of the second part 312 is flush with the flat surface 20 of the circuit board 16 and lies flat on the flat surface 20 of the circuit board 16 in planar contact, and the third part 314 forms a tail and is located within the hole 22 through the circuit board 16. The axis 22a of the hole 22 is aligned with the centerline 308 of the second pin 302. The third part 314 has a diameter smaller than the diameter of the hole 22. The screw 124 of the fastener 126 is screwed into the blind hole of the second pin 302 from the second side 128 of the circuit board 16, and a washer 130, which can be a flat washer or a Belleville washer, is located between the second side 128 of the circuit board 16 and the enlarged head 132 of the fastener 126. This provides optimal surface-to-surface contact between the flat wall surface 320 and the flat surface 20 of the circuit board 16.

[0054] In Figure 17 and Figure 18In a fourth embodiment of the male terminal 400 shown, the second pin 402 is formed of an elongated solid rod having opposite first and second flat ends 404, 406 that define an axial centerline 408 therebetween. The second pin 402 has an upper first portion 410, a second portion 412 extending from a lower end of the first portion 410, and a third portion 414 extending from a lower end of the first portion 410. Each of the portions 410, 412, 414 may be cylindrical. The second portion 412 has a diameter greater than that of the first portion 410 such that an upper flat wall 418 is formed therebetween by the second portion 412. The second portion 412 has a diameter greater than that of the third portion 414 such that a lower flat wall surface 420 is formed therebetween by the second portion 412. The second portion 412 defines an enlargement of the second pin 402.

[0055] The first portion 410 has opposite flat wall portions 434, 436 extending from its upper first end 404 and along a portion of the first portion 410. A socket 438 is provided through the first portion 410 and particularly through the flat wall portion 434 at a location proximate but spaced from the first end 404. A centerline of the socket 438 intersects the centerline 408 of the second pin 402. The socket 438 is non-threaded and has an open end to receive the first pin 500 and may have an opposite open end as shown. The socket 438 may be cylindrical.

[0056] A third portion 572 of the first pin 500 forms a docking protrusion and seats within the socket 438 of the second pin 402 after assembly. The axial centerline of the socket 438 is aligned with the axial centerline 558 of the first pin 500. The flat wall 574 of the second portion 562 abuts against the flat wall portion 434 and prevents the third portion 572 from further entering into the socket 438. The third portion 572 of the first pin 500 and the socket 438 of the second pin 402 are dimensioned to ensure that the third portion 572 is press-fit tightly into the socket 438 to provide an interference fit, and the tolerances are closely controlled to ensure that the centerlines of the pins 500, 402 are perpendicular to each other. Although the socket 438 and the third portion 572 are shown and described as cylindrical, the socket 438 and the third portion 572 can have a polygonal cross-section along their lengths.

[0057] A fourth embodiment of the male terminal 400 formed by connecting the first and second pins 500, 402 is insert molded into the housing 30 to form the connector assembly 24. One end 554 of the first pin 500 and a part of the first portion 560 adjacent thereto extend into the cavity 34 to form a wire connection portion. A part of the second portion 412 and the third portion 414 of the second pin 402 extend downward from the housing 30. A lower portion of the third portion 412 forms a tail and is located within the hole 22 passing through the circuit board 16 and can extend below the second side 128 of the circuit board 16. The axis 22a of the hole 22 is aligned with the center line 408 of the second pin 402. The diameters of the third portion 414 and the hole 22 are controlled such that an axis-to-axis alignment occurs between the third portion 414 and the hole 22. Thereafter, the second pin 402 is soldered to the circuit board 16.

[0058] When the connector assembly 24 is mounted on the circuit board 16, the two-piece male terminals 300, 400 assist in aligning the male terminals 300, 400 with the holes 22 on the circuit board 16, and help achieve the correct and true positioning of the male terminals 300, 400 relative to the circuit board 16, and establish an optimal electrical contact after the soldering process is completed.

[0059] Although the two-piece male terminals 100, 200, 300, 400 are shown and described herein as being soldered or fastened to the circuit board 16, the two-piece male terminals 100, 200, 300, 400 can be surface-mounted on the circuit board 16.

[0060] The two-piece design of the male terminals 100, 200, 300, 400 of each embodiment achieves a 90-degree angle with precise tolerances and no deviation. Additionally, the high-precision tolerances enable the male terminals 100, 200, 300, 400 to be overmolded within the connector assembly 24.

[0061] In the context of describing the present invention (particularly in the context of the following claims), the use of the terms "indefinite article 'a' before a consonant sound", "indefinite article 'an' before a consonant sound", "the", "at least one", and similar references shall be construed to cover both the singular and the plural, unless otherwise specified herein or clearly contradicted by the context. The use of the term "at least one" followed by a list of one or more items (e.g., "at least one of A and B") shall be construed to mean either one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise specified herein or clearly contradicted by the context. Unless otherwise specified, the terms "comprising", "having", "including", and "containing" shall be construed as open-ended terms (i.e., meaning "including but not limited to"). Unless otherwise specified herein, the recitation of a range of values herein is merely intended to be a shorthand method of referring individually to each separate value falling within the range, and each separate value is incorporated into the specification as if it were individually recited herein. All processes described herein may be performed in any suitable order, unless otherwise specified herein or clearly contradicted by the context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein is merely intended to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0062] Preferred embodiments of the present invention are described herein, including the best mode known to the inventors for practicing the present invention. Variations of these preferred embodiments may become apparent to those of ordinary skill in the art upon reading the above description. The inventors expect those skilled in the art to appropriately employ such variations, and the inventors also intend for the present invention to be practiced in other ways than specifically described herein. Accordingly, the present invention includes all modifications and equivalents of the subject matter recited in the appended claims as permitted by applicable law. In addition, any combination of the above elements in all possible variations thereof is included in the present invention unless otherwise specified herein or clearly contradicted by the context.

Claims

1. A right-angle male terminal of a connector assembly of an electrical connector, configured to be electrically connected to a socket of a wire connected to the electrical connector and a circuit board, comprising: a first pin, including a slender solid conductive rod having opposite first and second ends and defining an axial centerline, the first pin being configured to be electrically connected to the socket of the wire; and a second pin, including a slender solid conductive rod having opposite first and second ends and defining an axial centerline, the second pin being configured to be electrically connected to the circuit board, one of the first pin and the second pin having a non-threaded socket provided thereon and the other of the first pin and the second pin having a pair of docking protrusions, wherein the docking protrusions and the socket are connected by an interference fit, and wherein the axial centerline of the first pin is perpendicular to the axial centerline of the second pin.

2. The male terminal according to claim 1, wherein, the socket is cylindrical and the docking protrusions are cylindrical.

3. The male terminal according to claim 1, wherein, the second pin has a blind hole configured to receive a threaded screw passing through the circuit board.

4. The male terminal according to claim 3, wherein, the first pin has the non-threaded socket.

5. The male terminal according to claim 3, wherein, the second pin has the non-threaded socket.

6. The male terminal according to claim 1, wherein, the second pin has an enlarged portion having a flat lower surface configured to rest on the circuit board.

7. The male terminal according to claim 1, wherein, the second pin is welded to a through hole of the circuit board.

8. The male terminal according to claim 7, wherein, the first pin has the non-threaded socket.

9. The male terminal according to claim 7, wherein, the second pin has the non-threaded socket.

10. The male terminal according to claim 1, wherein, each pin is formed of a copper alloy.

11. An electrical connector for connection to a circuit board, comprising: a socket having a wire connected thereto; and a connector assembly including a housing and a male terminal insert molded into the housing, the male terminal being configured to be connected to the wire and the circuit board, the male terminal including: a first pin, including a slender solid conductive rod having opposite first and second ends and defining an axial centerline, the first pin being configured to be electrically connected to the wire, and a second pin, including a slender solid conductive rod having opposite first and second ends and defining an axial centerline, the second pin being configured to be electrically connected to the circuit board, wherein one of the first pin and the second pin has a non-threaded socket provided thereon and the other of the first pin and the second pin has a pair of docking protrusions, wherein the docking protrusions and the socket are connected by an interference fit, and Wherein, the axial centerline of the first pin is perpendicular to the axial centerline of the second pin.

12. The electrical connector according to claim 11, wherein, the socket is cylindrical and the docking protrusion is cylindrical.

13. The electrical connector according to claim 11, wherein, the second pin is configured to be connected to the circuit board, the second pin has a blind hole, and the blind hole is configured to receive a threaded screw passing through the circuit board.

14. The electrical connector according to claim 13, wherein, the first pin has the non-threaded socket.

15. The electrical connector according to claim 13, wherein, the second pin has the non-threaded socket.

16. The electrical connector according to claim 11, wherein, the second pin has an enlarged portion, and the enlarged portion has a flat lower surface configured to rest on the circuit board.

17. The electrical connector according to claim 11, wherein, the second pin is soldered to a through hole of the circuit board.

18. The electrical connector according to claim 17, wherein, the second pin has the non-threaded socket.

19. The electrical connector according to claim 17, wherein, the second pin has an enlarged portion, and the enlarged portion has a flat lower surface configured to rest on the circuit board.

20. A combination of the electrical connector according to claim 11 and a circuit board, wherein the second pin is electrically connected to the circuit board.

21. The combination according to claim 20, wherein, the circuit board has a flat surface and a through hole in which the second pin is installed, the second pin has a blind hole, and the blind hole is configured to receive a threaded screw passing through the circuit board.

22. The combination according to claim 21, wherein, the second pin has an enlarged portion, and the enlarged portion has a flat lower surface resting on the flat surface of the circuit board.

23. The combination according to claim 21, wherein, the first pin has the non-threaded socket.

24. The combination according to claim 21, wherein, the second pin has the non-threaded socket.

25. The combination according to claim 20, wherein, the circuit board has a flat surface and a through hole, and the second pin is soldered to the through hole.

26. The combination according to claim 25, wherein, the first pin has the non-threaded socket.

27. The combination according to claim 25, wherein, the second pin has the non-threaded socket.

28. A method of forming a male terminal at a right angle, comprising: providing a first pin, the first pin including an elongated solid conductive rod having opposite first and second ends and defining an axial centerline, the first pin being configured to be electrically connected to a socket for connecting a wire; and providing a second pin, the second pin including an elongated solid conductive rod having opposite first and second ends and defining an axial centerline, the second pin being configured to be electrically connected to a circuit board; and Insert a pair of docking protrusions in one of the first pin and the second pin into a threadless socket in the other of the first pin and the second pin, and connect the docking protrusion and the socket by an interference fit, wherein the axial centerline of the first pin is perpendicular to the axial centerline of the second pin.

29. A method of forming a connector assembly comprising: providing a first pin including an elongate solid conductive rod having opposite first and second ends and defining an axial centerline, the first pin configured to be electrically connected to a socket for connecting a wire, and providing a second pin including an elongate solid conductive rod having opposite first and second ends and defining an axial centerline, the second pin configured to be electrically connected to a circuit board; insert a pair of docking protrusions in one of the first pin and the second pin into a threadless socket in the other of the first pin and the second pin, and connect the docking protrusion and the socket by an interference fit, wherein the axial centerline of the first pin is perpendicular to the axial centerline of the second pin; and molding a housing around the first pin and the second pin.

30. A method, comprising: providing a first pin including an elongate solid conductive rod having opposite first and second ends and defining an axial centerline, the first pin configured to be electrically connected to a socket for connecting a wire, and providing a second pin including an elongate solid conductive rod having opposite first and second ends and defining an axial centerline; insert a pair of docking protrusions in one of the first pin and the second pin into a threadless socket in the other of the first pin and the second pin, and connect the docking protrusion and the socket by an interference fit, wherein the axial centerline of the first pin is perpendicular to the axial centerline of the second pin; molding a housing around the first pin and the second pin; and electrically connecting the second pin to a circuit board.

31. The method of claim 30, wherein the second pin is electrically connected to the circuit board by a fastener extending through the circuit board and into the second pin.

32. The method of claim 30, wherein the second pin is electrically connected to a circuit board by soldering.

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