Reinforced electrical terminals

Abstract

The electrical contact (10) includes a mating portion (12) for mating with a mating contact. The mating portion (12) has a contact portion (16) and a retention portion (32). The mating portion (12) has a mating portion bottom wall (18), a mating portion top wall (20), and mating portion side walls (22, 24). The corresponding mating portion side wall (22) has an upper portion (26) extending beyond the top wall (28). The retention portion (32) has a retention portion top wall (28), a retention portion side wall (30), and a retention portion rear wall (50). The retention portion rear wall (50) is configured to approximate the space defined between the mating portion top wall (20), the upper portion (26) of the corresponding mating portion side wall (22), the retention portion top wall (28), and the retention portion side wall (30). The retaining portion rear wall (50) prevents damage or deformation of the retaining portion (32) as forces are applied to the retaining portion (32).

Description

[Technical Field]

[0001] The present invention is directed to an electrical terminal having improved strength, particularly to avoid damage during quality inspection or assembly into a connector housing. [Background technology]

[0002] The demand for smaller sized electrical connectors continues to grow. As connectors get smaller, the electrical terminals located on the connectors must also get smaller. Smaller terminals require terminal manufacturers to use less material, which makes the terminals more susceptible to damage or deformation during use or during testing, quality inspection, or assembly into connector housings. Summary of the Invention [Problem to be solved by the invention]

[0003] The problem to be solved is to provide a terminal having improved strength to prevent damage or deformation. It would also be beneficial to provide such a reinforced terminal without increasing the overall size of the terminal. [Means for solving the problem]

[0004] This problem is solved by a one-piece connector, which eliminates loose components that can fall out during installation or come loose during operation.

[0005] One embodiment is directed to a mating portion for mating with an electrical contact, a mating portion having a contact portion and a retention portion. The mating portion has a mating portion bottom wall, a mating portion top wall, and a mating portion side wall. The corresponding mating portion side wall has an upper portion extending beyond the top wall, the upper portion extending to form the retention portion. The retention portion has a retention portion top wall, a retention portion side wall, and a retention portion rear wall. The retention portion rear wall is configured to approximate a space defined between the mating portion top wall, the upper portion of the corresponding mating portion side wall, the retention portion top wall, and the retention portion side wall. The retention portion rear wall cooperates with one or more of the mating portion top wall, the upper portion of the corresponding mating portion side wall, the retention portion top wall, and the retention portion side wall to prevent damage or deformation of the retention portion due to application of force to the retention portion.

[0006] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a front perspective view of an exemplary embodiment of an electrical terminal according to the present invention; [Figure 2] FIG. 2 is a rear perspective view of the electrical terminal of FIG. 1; [Figure 3] FIG. 3 is a cross-sectional view taken along line 3-3 in FIG. [Figure 4] FIG. 2 is a rear view of the electrical terminal of FIG. 1. [Figure 5] FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 2. [Figure 6] FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 2. [Figure 7] FIG. 2 is a rear perspective view of a first alternative embodiment of the electrical terminal of the present invention. [Figure 8] FIG. 8 is a rear view of the electrical terminal of FIG. 7. [Figure 9] FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 7. DETAILED DESCRIPTION OF THE INVENTION

[0008] 1 and 2, the receptacle contact 10 includes a mating portion 12 and a transition portion or region 14. The transition portion 14 extends to a termination portion (not shown), such as, but not limited to, a crimp portion. The entire receptacle contact 10 is formed from a unitary stamped thin metal film form that is stamped and formed or bent into the configuration shown in FIGS. 1 and 2.

[0009] 1, mating portion 12 includes a front or mating contact-receiving end 13 and a rear end 15 adjacent a transition portion 14. Mating portion 12 includes a box-shaped contact portion 16 for receiving a corresponding mating contact or mating pin contact (not shown). Box-shaped contact portion 16 has a bottom wall 18, a top wall 20, and side walls 22, 24.

[0010] The corresponding side wall 22 has an upper portion 26 that extends beyond the top wall 20. The upper portion 26 of the side wall 22 is formed to provide a top wall 28 and a sloped side wall 30. The upper portion 26, top wall 28, and sloped side wall 30 of the side wall 22 form a retention portion 32 of the mating portion 12 of the contact 10. The retention portion 32 extends from the front end 13 to the rear end 15 of the mating portion 12.

[0011] 1 and 2, the upper portion 26, top wall 28, and angled sidewalls 30 of the sidewalls 22 are provided with cavities or openings 34. The openings 34 are configured to receive locking projections (not shown) of a connector housing (not shown) into which the contacts 10 are inserted. The locking projections are sized to cooperate with the cavities or openings 34 to maintain the receptacle contacts 10 in place in the housing. The locking projections cooperate with the receptacle contacts 10 to provide temporary retention of the receptacle contacts 10 in the housing.

[0012] In alternative embodiments, the upper portion 26, top wall 28, or angled sidewall 30 of sidewall 22 may have an outwardly protruding orientation and / or locking feature or locking projection (not shown). The locking projection is dimensioned to cooperate with a cavity in a housing (not shown) to maintain the receptacle contact 10 in place within the housing. The locking projection cooperates with the housing to provide temporary retention of the receptacle contact 10 within the housing. The locking projection may also function as a polarizing means. If the housing into which the receptacle contact 10 is inserted has a corresponding cavity within which the projection is located, this ensures that the receptacle contact 10 cannot be improperly inserted into the housing.

[0013] As shown in FIG. 3, the one-piece receptacle contact 10 has a first resilient contact protrusion 36 and a second resilient contact protrusion or spring arm 38, which are integrally formed from the bottom wall 18 and the top wall 20, respectively. Portions of the two resilient contact arms 36, 38 extend toward one another. The resilient contact protrusions 36, 38 are provided with respective freely movable contact areas 44, 46 (FIGS. 4 and 6) adjacent thereto. In the illustrated embodiment, the contact areas 44, 46 are rounded and laterally offset, but are relatively close to one another, ensuring a stable and reliable mechanical and electrical connection even when small contact pins are inserted. Preferably, at least in the region of the contact areas 44, 46, the resilient contact protrusions 36, 38 are provided with a plating or metallization layer, such as a gold or tin overlay, to provide an improved electrical connection with the inserted contact pin. An overstress protection portion 21 extends from the side wall 24 (as shown in FIG. 6 ) to cooperate with the free end 42 of the resilient contact arm 38 to prevent overstress of the contact protrusion 38. The overstress protection portion 21 extends substantially parallel to the top wall 20.

[0014] 1 , free end 48 of sloped sidewall 30 is positioned near top wall 20 of box-shaped contact portion 16. Free end 48 may be positioned near or in engagement with top wall 20 when no force is applied to contact 10. When force is applied to upper portion 26 of sidewall 22, top wall 28, or sloped sidewall 30, retention portion 32 may compress or rotate, causing free end 48 to engage top wall 20, thereby preventing deformation of retention portion 32.

[0015] As shown in FIGS. 2 and 4 , the retention portion 32 has a rear wall 50 extending from the angled side wall 30. The rear wall 50 extends at approximately 90 degrees from the angled side wall 30. The rear wall 50 is configured to approximate the space provided between the angled side wall 30, the top wall 20 of the box-shaped contact portion 16, the upper portion 26 of the side wall 22, and the top wall 28. A fixed portion 52 of the rear wall 50 extends into a cavity 54 formed in the top wall 20 of the box-shaped contact portion 16 near the rear end 15. The cavity 54 is a cutout or opening that extends through the top wall 20 and is sized to receive and retain the fixed portion 52 of the rear wall 50, as shown in FIGS. 2 and 4 .

[0016] As shown in Figures 1, 2, 5, and 6, the retention portion 32 has a plurality of detents 60 spaced along the length of the angled sidewall 30. The detents 60 extend from the free end 48 of the angled sidewall 30. In the exemplary embodiment shown, two detents 60 are shown; however, other numbers and configurations of detents may be used. As shown in Figure 5, the detents 60 have an engagement shoulder 62 located near the free end 48 of the angled sidewall 30.

[0017] 5, a plurality of detent-receiving openings 64 are spaced along the length of the top wall 20 of the box-shaped contact portion 16. The detent-receiving openings 64 are positioned in alignment with the detents 60. In the exemplary embodiment shown, two detent-receiving openings 64 are shown. The detent-receiving openings 64 have an engagement shoulder 66 located adjacent the side wall 24 of the box-shaped contact portion 16.

[0018] In use, contact 10 is inserted into a contact-receiving cavity in a contact-receiving housing (not shown). If contact 10 is not fully or properly inserted, the contact-receiving cavity will not completely enclose or seal contact 10. This allows contact 10, and particularly retention portion 32, to be engaged from the top or side, such as by a secondary lock. In known contacts, the forces associated with such engagement can cause retention portion failure because top wall 28 and angled sidewalls 30 can easily move or deform. In contrast, retention portion 32 of the present invention is reinforced to prevent damage or deformation without increasing the overall size of the terminal.

[0019] 4-6, force F1 applied to top surface 28 of retention portion 32 causes fixation portion 52 of rear wall 50 to move further downward (as viewed in FIGS. 4-6 ) into cavity 54. As this occurs, side wall 70 of rear wall 50 engages one of side walls 22. Alternatively, as force F1 is applied, side wall 72 of fixation projection 52 engages side wall 74 of cavity 54 formed in top wall 20. In either case, lateral movement of rear wall 50 and retention portion 32 relative to box-shaped contact portion 16 is prevented.

[0020] Additionally, as force F1 is applied to top surface 28 of retention portion 32, engagement shoulder 62 of detent 60 engages engagement shoulder 66 of detent-receiving opening 64, preventing downward and lateral movement of detent 60 and retention portion 32 relative to box-shaped contact portion 16. In doing so, retention portion 32 and contact 10 are reinforced to prevent damage or deformation without increasing the overall size of the terminal.

[0021] 4-6, force F2 applied to side wall 22 causes fixed portion 52 of rear wall 50 to engage side wall 74 of cavity 54 formed in top wall 20, thereby preventing lateral movement of rear wall 50 and retention portion 32 relative to box-shaped contact portion 16. Additionally, engagement shoulder 62 of detent 60 engages engagement shoulder 66 of detent-receiving opening 64, preventing downward and lateral movement of detent 60 and retention portion 32 relative to box-shaped contact portion 16. In this manner, retention portion 32 and contact 10 are reinforced to prevent damage or deformation without increasing the overall size of the terminal.

[0022] 4-6, force F3 applied to angled sidewall 30 causes sidewall 70 of rear wall 50 to engage sidewall 22, preventing lateral movement of rear wall 50 and retention portion 32 relative to box-shaped contact portion 16. In doing so, retention portion 32 and contact 10 are reinforced to prevent damage or deformation without increasing the overall size of the terminal.

[0023] An alternative embodiment of contact 110 is shown in Figures 7-9. Contact 110 is stamped from a single piece of material and formed into the configuration shown in Figure 7. In this embodiment, contact 110 has a mating portion 112 and a transition portion or transition region 114. Contact 110, mating portion 112, and transition portion 114 are similar to those of contact 10, mating portion 12, and transition portion 14.

[0024] The retention portion 132 has a rear wall 150 extending from the angled side wall 130. The rear wall 150 extends at approximately 90 degrees from the angled side wall 130. The rear wall 150 is configured to approximate the space defined between the angled side wall 130, the top wall 120 of the box-shaped contact portion 116, the upper portion 126 of the side wall 122, and the top wall 128. As shown in FIG. 8 , a locking tab 152 defined at the distal end of the top wall 120 extends into a cavity 154 defined in the side wall 122 near the rear end 115. The cavity 154 is a cutout or opening extending through the side wall 122 and sized to receive and retain the locking tab 152, as shown in FIGS. 7 and 8 .

[0025] The retention portion 132 has a detent 160 disposed on the angled sidewall 130. The detent 160 extends from the free end 148 of the angled sidewall 130. In the exemplary embodiment shown, one detent 160 is shown; however, other numbers and configurations of detents may be used. The detent 160 has an engagement shoulder 162 (FIG. 9) disposed near the free end 148 of the angled sidewall 130.

[0026] 9, a detent-receiving opening 164 is provided in the top wall 120 of the box-shaped contact portion 116. The detent-receiving opening 164 is aligned with the detent 160. In the exemplary embodiment shown, one detent-receiving opening 164 is shown. The detent-receiving opening 164 has an engagement shoulder 166 provided adjacent the side wall 124 of the box-shaped contact portion 116.

[0027] In use, the contact 110 is inserted into a contact-receiving cavity of a contact-receiving housing (not shown). If the contact 110 is not fully or properly inserted, the contact-receiving cavity will not completely enclose or seal the contact 110, thereby allowing the contact 110, and particularly the retention portion 132, to be engaged from the top or side with a secondary lock or the like.

[0028] 8 and 9, force F4 applied to top surface 128 of retention portion 132 causes bottom wall 171 of rear wall 150 to engage top wall 120. Because locking tab 152 of top wall 120 is located in cavity 154, locking tab 152 engages wall 173 of cavity 154, preventing downward movement of locking tab 152 and top wall 120. Because top wall 120 is prevented from moving downward, rear wall 150 is also prevented from moving downward (as seen in FIGS. 8 and 9).

[0029] As force F4 is applied to top surface 128 of retention portion 132, side wall 170 of rear wall 150 may also engage side wall 122, preventing lateral movement of rear wall 150 and retention portion 132 relative to box-shaped contact portion 116. Additionally, engagement shoulder 162 of detent 160 engages engagement shoulder 166 of detent-receiving opening 164, preventing downward and lateral movement of detent 160 and retention portion 132 relative to box-shaped contact portion 116. In this manner, retention portion 132 and contact 110 are reinforced to prevent damage or deformation without increasing the overall size of the terminal.

[0030] 8 and 9, force F5 applied to side wall 122 causes engagement shoulder 162 of detent 160 to engage engagement shoulder 166 of detent-receiving opening 164, preventing downward and lateral movement of detent 160 and retention portion 132 relative to box-shaped contact portion 116. In doing so, retention portion 132 and contact 110 are reinforced to prevent damage or deformation without increasing the overall size of the terminal.

[0031] 8 and 9, force F6 applied to angled sidewall 130 causes sidewall 170 of rear wall 150 to engage sidewall 122, preventing lateral movement of rear wall 150 and retention portion 132 relative to box-shaped contact portion 116. In doing so, retention portion 132 and contact 110 are reinforced to prevent damage or deformation without increasing the overall size of the terminal.

[0032] The contacts 10, 110 have improved strength to prevent damage or deformation. The contacts 10, 110 provide increased strength and stability without increasing the overall size of the terminal, allowing them to be used in smaller contacts.

Claims

1. A mating portion (12) for mating with a mating contact An electrical contact (10) comprising: The mating portion (12) has a contact portion (16) and a retaining portion (32); The mating portion (12) has a mating portion bottom wall (18), a mating portion top wall (20), and mating portion side walls (22, 24); the corresponding mating portion side wall (22) has an upper portion (26) extending beyond the top wall (20), said upper portion (26) extending to form said retaining portion (32); The retaining portion (32) has a retaining portion top wall (28), a retaining portion side wall (30), and a retaining portion rear wall (50), and the retaining portion rear wall (50) is configured to approximate a space defined between the mating portion top wall (20), the upper portion (26) of the corresponding mating portion side wall (22), the retaining portion top wall (28), and the retaining portion side wall (30); the retaining portion rear wall (50) cooperates with one or more of the mating portion top wall (20), the upper portion (26) of the corresponding mating portion side wall (22), the retaining portion top wall (28), and the retaining portion side wall (30) to prevent damage or deformation of the retaining portion (32) due to the application of force to the retaining portion (32); The retaining portion side wall (30) is inclined relative to the retaining portion top wall (28) and the mating portion top wall (20); The free end (48) of the inclined holding portion side wall (30) is located near the mating portion top wall (20); The retaining portion rear wall (50) extends from the inclined retaining portion side wall (30) at approximately 90 degrees from the inclined retaining portion side wall (30). Electrical contact (10).

2. A mating portion (12) for mating with a mating contact An electrical contact (10) comprising: The mating portion (12) has a contact portion (16) and a retaining portion (32); The mating portion (12) has a mating portion bottom wall (18), a mating portion top wall (20), and mating portion side walls (22, 24); the corresponding mating portion side wall (22) has an upper portion (26) extending beyond the top wall (20), said upper portion (26) extending to form said retaining portion (32); The retaining portion (32) has a retaining portion top wall (28), a retaining portion side wall (30), and a retaining portion rear wall (50), and the retaining portion rear wall (50) is configured to approximate a space defined between the mating portion top wall (20), the upper portion (26) of the corresponding mating portion side wall (22), the retaining portion top wall (28), and the retaining portion side wall (30); the retaining portion rear wall (50) cooperates with one or more of the mating portion top wall (20), the upper portion (26) of the corresponding mating portion side wall (22), the retaining portion top wall (28), and the retaining portion side wall (30) to prevent damage or deformation of the retaining portion (32) due to the application of force to the retaining portion (32); a detent (60) is provided on the retaining portion sidewall (30), the detent (60) extending from the free end (48) of the retaining portion sidewall (30); Electrical contact (10).

3. The detent (60) has an engagement shoulder (62) located adjacent the free end (48) of the retention portion sidewall (30). The electrical contact (10) of claim 2.

4. a detent receiving opening (64) is provided in the mating portion top wall (20), the detent receiving opening (64) being aligned with the detent (60); The electrical contact (10) of claim 3.

5. The detent receiving opening (64) has an engagement shoulder (66) located adjacent the mating portion sidewall (24). The electrical contact (10) of claim 4.

6. A fixing portion (52) extends from the retaining portion rear wall (50); The fixed portion (52) extends into a cavity (54) formed in the mating portion top wall (20). An electrical contact (10) according to claim 1 or 2.

7. A mating portion (12) for mating with a mating contact An electrical contact (10) comprising: The mating portion (12) has a contact portion (16) and a retaining portion (32); The mating portion (12) has a mating portion bottom wall (18), a mating portion top wall (20), and mating portion side walls (22, 24); the corresponding mating portion side wall (22) has an upper portion (26) extending beyond the top wall (20), said upper portion (26) extending to form said retaining portion (32); The retaining portion (32) has a retaining portion top wall (28), a retaining portion side wall (30), and a retaining portion rear wall (50), and the retaining portion rear wall (50) is configured to approximate a space defined between the mating portion top wall (20), the upper portion (26) of the corresponding mating portion side wall (22), the retaining portion top wall (28), and the retaining portion side wall (30); the retaining portion rear wall (50) cooperates with one or more of the mating portion top wall (20), the upper portion (26) of the corresponding mating portion side wall (22), the retaining portion top wall (28), and the retaining portion side wall (30) to prevent damage or deformation of the retaining portion (32) due to the application of force to the retaining portion (32); The retaining portion (32) has an opening (64) extending through the mating portion top wall (20) and the mating portion side wall (24); The opening (64) is sized to receive a locking projection of a connector housing into which the electrical contact (10) is inserted. Electrical contact (10).

8. The mating portion (12) has a first resilient contact protrusion (36) and a second resilient contact protrusion (38) integrally formed from the mating portion bottom wall (18) and the mating portion top wall (20), respectively. The electrical contact (10) of claim 7.

9. The resilient contact protrusions (36, 38) have movable contact areas (44, 46); The contact areas (44, 46) are rounded and laterally offset. The electrical contact (10) of claim 8.

10. an overstress protection portion (21) extending from said mating portion sidewall (24) to cooperate to prevent overstress of the corresponding contact protrusion (38); The electrical contact (10) of claim 9.

Images