U.S. patent number 3,853,389 [Application Number 05/333,400] was granted by the patent office on 1974-12-10 for electrical connector and contact.
This patent grant is currently assigned to Bunker Ramo Corporation. Invention is credited to Carl Occhipinti.
United States Patent |
3,853,389 |
Occhipinti |
December 10, 1974 |
**Please see images for:
( Certificate of Correction ) ** |
ELECTRICAL CONNECTOR AND CONTACT
Abstract
A connector including a body having a plurality of cavities, and
socket contacts in the cavities; the cavities have ledges for
supporting or limiting insertion of the contacts, the contacts
having corresponding shapes engaging the ledges and contact fingers
struck in from opposite sidewalls which in one embodiment are
oriented in opposite longitudinal directions to provide an early
wipe with reduced insertion forces; the contacts are of closed
entry type, formed from a single stamped metal blank, shaped to
generally tubular form, having a portion defining closed entry
aperture, in one embodiment formed by a bent-over piece forming
cirumferentially continuously element, and in another embodiment
formed by inwardly bent tabs supported by the walls of the cavity;
the contacts have reduced tail portions extending through the
cavities beyond the body enlarged or otherwise shaped resisting
removal from the cavities.
Inventors: |
Occhipinti; Carl (Melrose Pk.,
IL) |
Assignee: |
Bunker Ramo Corporation (Oak
Brook, IL)
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Family
ID: |
26948781 |
Appl.
No.: |
05/333,400 |
Filed: |
February 16, 1973 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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261698 |
Jun 12, 1972 |
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Current U.S.
Class: |
439/747;
439/852 |
Current CPC
Class: |
H01R
13/114 (20130101); H01R 13/432 (20130101) |
Current International
Class: |
H01R
13/115 (20060101); H01R 13/428 (20060101); H01R
13/432 (20060101); H01r 009/08 () |
Field of
Search: |
;339/217R,217S,15,49R,49F,221R,221L,221M,256R,256A,258R,258A,258P |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1,187,323 |
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Feb 1965 |
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DT |
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2,036,990 |
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Feb 1971 |
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DT |
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Primary Examiner: Gilliam; Paul R.
Assistant Examiner: Hafer; Robert A.
Attorney, Agent or Firm: Arbuckle; F. M. Lohff; William
Parent Case Text
RELATED APPLICATIONS
This is a continuation-in-part of my co-pending application, Ser.
No. 261,698 now abandoned, titled "Electrical Connector and
Contact."
Claims
I claim:
1. An electrical connector comprising a body of insulating material
having a front face and a cavity extending longitudinally therefrom
in a rearward direction, and
a contact at least partially disposed in said cavity and including
a front elongated socket section for front engagement with a mating
contact and a rear tail section for engagement with an external
conductor, said socket section including at least one pair of
opposite outer sidewalls and at least one pair of contact fingers
outwardly supported by said sidewalls, said fingers including
longitudinally offset contact engagement surfaces inwardly disposed
within said socket section and beam sections inclined outwardly
from said surfaces toward said sidewalls in opposite longitudinal
directions, each of said beam sections being integral with one of
said side walls and supporting one of said engagement surfaces, one
of said contact-engagement surfaces being frontwardly disposed so
that said mating contact will initially engage only one of said
surfaces with the other of said contact engagement surfaces being
rearwardly disposed and the beam section with said rearwardly
disposed surface being inclined rearwardly and disposed laterally
opposite said frontwardly disposed surface to guide said mating
contact to a center position in said socket section and into
engagement with said frontwardly disposed surface.
2. The connector of claim 1 wherein the frontwardly disposed
contact-engagement surface includes a convex curve with an end
opposite said beam section which is inclined outwardly to funnel a
mating contact into engagement with said inwardly disposed
surface.
3. The connector of claim 1 wherein said beam sections of said
fingers are essentially of equal length to develop essentially
equal forces against said mating contact when completely
inserted.
4. The connector of claim 2 wherein the sidewalls of said contact
form a front entry aperture with a pair of opposite front edges
having converging tapers.
5. The connector of claim 1 wherein said body includes a rear face,
said cavity includes an enlarged portion opening through the front
face and a reduced portion opening through the rear face, the
socket section of the contact is snugly fitted in the enlarged
portion of the cavity, and the tail section is offset laterally
from the socket section and extends through the reduced portion of
the cavity.
6. A contact for an electrical connector comprising a front
enlarged socket section elongated longitudinally and a rear reduced
tail section, the socket section including at least one pair of
opposite outer sidewalls frontwardly forming an entry aperture and
at least one pair of contact fingers outwardly supported by said
sidewalls and rearwardly disposed from said entry aperture, said
fingers including longitudinally offset contact-engagement surfaces
inwardly disposed within said socket section for engagement with a
mating contact inserted through said entry aperture, and beam
sections inclined outwardly in opposite longitudinal directions to
said sidewalls, each of said beam sections being integral with one
of said sidewalls and supporting one of said engagement surfaces,
one of said contact-engagement surfaces being frontwardly disposed
near said entry aperture with the other of said contact engagement
surfaces being rearwardly disposed and the beam section with said
rearwardly disposed surface being inclined rearwardly and disposed
laterally opposite said frontwardly disposed surface to guide said
mating contact to a center position in said socket section and into
engagement with said frontwardly disposed surface.
7. The contact of claim 6 wherein said beam sections are
essentially of equal length to develop essentially equal forces
against said mating contact when completely inserted, said
frontwardly disposed contact-engagement surface is curved convexly
and includes an end opposite said beam section inclined
outwardly.
8. An electrical connector comprising
a body having front and rear faces and walls defining a cavity
therebetween, said cavity being substantially rectangular in cross
section and having an enlarged portion opening through the front
face and a reduced portion opening through the rear face,
the walls of the cavity defining, at least on one side of the
cavity, an abrupt ledge between the enlarged and reduced portions
of the cavity and laterally disposed ledges on the remaining walls
tapering downwardly and inwardly, and
a contact in the cavity having an enlarged socket section with
sides snugly fitted in the enlarged portion of the cavity, and a
reduced tail section extending through the reduced portion of the
cavity,
the tail section of the contact being offset laterally from the
socket section, exposing an abrupt inner end surface on the socket
section engaging said ledge and providing positive stop means.
9. An electrical connector according to claim 8 wherein the contact
has tapered surfaces snugly engaging the tapered ledges when the
abrupt inner end surface on the socket section engages the abrupt
ledges in the cavity walls.
10. An electrical connector according to claim 9 wherein the
tapered ledges extend from a point substantially in the plane of
the aburpt ledge downwardly therefrom.
11. An electrical connector according to claim 8 wherein the
contact is formed of a single integral sheet metal piece, the
socket section is tubular in shape and the tail section is channel
shape with a web and side flanges, and disposed with its web on the
side of the contact opposite the abrupt end surface of the socket
section and the flanges extend from the web a distance less than
the corresponding width of the contact, and the tapered surfaces on
the contact are provided on the three sides represented by the web
and the flanges.
12. An electrical connector according to claim 8 wherein the
enlarged portion of the cavity is substantially uniform in cross
section throughout its length, the socket section engages the walls
in said portion and has an outer surface, the contact has a length
and a front entry end and an integral flat section disposed against
the sides at the entry end extending generally perpendicular to the
length of the contact, circumferentially continuous, and has an
outer surface substantially flush with the outer surface of the
socket section of the contact.
13. An electrical connector according to claim 8 wherein the
enlarged portion of the cavity is of substantially uniform cross
sectional shape from a position at the juncture with the reduced
portion longitudinally outwardly to a position adjacent to but
short of the front face of the body, the cavity walls include an
outwardly facing ledge adjacent the front face, and the contact has
a closed entry construction including tabs extending laterally
outwardly beyond the remaining surface of the contact and engaging
said ledge, said tabs being confined within that portion of the
wall cavities longitudinally beyond the ledge.
14. An electrical connector according to claim 13 wherein the
contact has fingers struck in from opposite sidewalls of the
contact to a position transversely inwardly beyond the confining
edges of the entry aperture.
15. A contact for an electrical connector formed of an integral
sheet metal piece having an enlarged socket section, a reduced tail
section, and juncture therebetween, the socket section having at
least one pair of opposite sides, contact fingers struck in from
said opposite sides, and a construction having an entry aperture of
dimensions greater than the distance between the contact fingers
but less than the distance between the wall elements from which
they were struck, said contact having a length and an integral,
flat section forming said construction and extending generally
perpendicular to the length of the contact and disposed against the
sides thereof, the contact having, at the juncture between the
socket section and the tail section, one side of the contact, an
abrupt shoulder facing longitudinally in a direction away from the
closed entry aperture, and having ledges other than the abrupt
shoulder at other sides of the contact.
16. A contact according to claim 15 wherein the socket section is
substantially tubular in shape and the tail section is
substantially channel form in shape.
17. An electrical contact according to claim 15 wherein the closed
entry construction includes a plurality of tabs joined to and
extending from the socket section at the closed entry end thereof
extending longitudinally from the socket section and having a
component of extension transversely outwardly beyond the outer
perimeter surface of the socket section.
18. An electrical connector comprising
a body of insulating material having a front face and rear face and
a cavity therethrough, said cavity having a portion of
substantially uniform cross-sectional shape extending from a
position intermediate said faces to a position adjacent to but
short of the front face of the body, said cavity also including an
outwardly facing ledge adjacent said front face and at least one
rearwardly disposed contact-retaining shoulder
a contact in said cavity having a socket section with at least a
portion being snugly fitted in said cavity portion of uniform shape
and a tail section, said socket section including at least one pair
of opposite sides, contact fingers struck in from said opposite
sides of said socket section, a construction having a frontwardly
disposed entry aperture with dimensions greater than the distance
between the contact fingers but less that the distance between said
sides, said construction including a plurality of entry tabs
extending laterally beyond the cavity portion of uniform shape and
abutting against said ledge
said contact including a rearwardly disposed locking member having
a laterally extending portion abutting said contact-retaining
shoulder of said body.
19. An electrical connector according to claim 18 wherein said
ledge adjacent the front face of the cavity is tapered at an acute
angle to the longitudinal axis of the cavity and said entry tabs on
the contact are complementally inclined.
20. An electrical connector according to claim 19 wherein said
contact includes a plurality of said locking members with each
member formed as a resilient locking tab disposed on one of said
sides of said socket section and tapering outwardly and frontwardly
to a free end locked behind said contact-retaining shoulder.
21. An electrical connector according to claim 20 wherein said
entry tabs include an outwardly extending component extending
beyond the outer perimeter of said locking tabs.
22. A contact for frontwardly mounting in an electrical connector
and formed of an integral sheet metal piece, said contact
comprising socket and tail sections with said socket section being
substantially tubular in shape with opposite sides, an elongated
length and frontward and rearward ends, contact fingers disposed
intermediate said ends and struck in from said opposite sides of
said socket section, a construction at said forward end having an
entry aperture with dimensions greater than the distance between
the contact fingers but less than the distance between said
opposite sides and including a plurality of entry tabs extending
longitudinally from the socket section and having a component of
extension transversely outwardly beyond the outer perimeter surface
of the socket section, said socket section including locking tabs
disposed on a plurality of said sides of said socket section
rearwardly with respect to said contact tabs and tapering outwardly
in a frontward direction, said locking tabs being resiliently
yieldable inwardly to permit said contact to be frontwardly mounted
in said connector.
23. A rectangularly shaped contact for an electrical connector
formed of an integral sheet metal member having a generally flat
base portion with laterally separated U-shaped and L-shaped
portions stamped out to form a pair of free-ended oppositely
directed fingers and a tail portion integrally formed on the base
portion and extending away therefrom, said U-shape portion being
inverted with respect to said L-shaped portion with each of said
portions being formed by stamped out longitudinal sides and lateral
end portions, said base portion being bent along the side portions
of the U-shaped and L-shaped portions to form said rectangular
shape and said fingers being bent inwardly to longitudinally offset
said free ends and form longitudinally offset contact engagement
surfaces.
24. The contact of claim 23 wherein the free end of one of said
fingers includes an inwardly directed convex curve forming one of
said contact engagement surfaces.
25. The contact of claim 24 wherein said fingers are essentially of
equal length to develop essentially equal forces against said
mating contact when completely inserted.
26. The contact of claim 25 wherein said contact includes an
inwardly tapered entry aperture frontwardly disposed from said
fingers and directing said mating contact to contact engagement
surfaces.
27. The contact of claim 26 wherein said L-shaped portion includes
a second side portion forming a second U-shaped portion.
Description
OBJECTS OF THE INVENTION
A broad object of the invention is to provide an electrical
connector of novel construction, including a body with cavities
therein, and contacts in the cavities, the contacts being of closed
entry type.
Another broad object is to provide an electrical connector of the
foregoing character having novel construction of both the cavity
walls and the contacts, providing effective interaction between the
body and the contacts, for effectively positioning the contacts in
the cavities, enabling the contacts to be made of thin wall
material and of simple form.
Still another object is to provide a connector of the foregoing
character including a body with cavities, and contacts insertable
through a front face of the body, and the contacts having reduced
tail portions extending through the cavities, and wherein the tail
portions of the contacts are enlarged or otherwise shaped resisting
removal of the contacts in direction opposite the insertion
thereof.
A further object of the invention is to provide an electrical
connector and contact which provide a frontwardly disposed
contact-engagement surface for a mating contact with reduced
insertion force.
A still further object is to provide a contact of extremely simple
form and construction which is easily fabricated, and which
notwithstanding such simple form and construction, provides
effective electrical connection with associated electrical
elements.
Still another object is to provide an electrical contact of the
kind just referred to, for use in mounting in a cavity in a body,
having novel shape and construction enabling it to be fabricated in
a simple manner, and also providing effective mounting in the
cavity.
A further object of the invention is to provide an electrical
contact of simple form, fabricated from a single integral stamping,
having a circumferentially integral end element defining a reduced
dimension closed entry aperture.
Yet another object is to provide a contact of simple construction,
fabricated from a single integral stamping, having a novel
construction of tabs defining a closed entry construction, wherein
such tabs, when the contact is inserted in the cavity, are
supported by the walls of the cavity.
DESCRIPTION OF A PREFERRED EMBODIMENT
In the Drawings
FIG. 1 is a cutaway perspective view of a connector made according
to the present invention, showing a portion of the body of the
connector and contacts in certain of the cavities.
FIG. 2 is a face view of a blank from which the contact, in one
form, is fabricated.
FIG. 3 is a longitudinal sectional view of a contact shown in FIG.
1, oriented according to line 3--3 of FIG. 1.
FIG. 4 is an end view taken from the top of FIG. 3.
FIG. 5 is a view taken from the right of the lower portion of FIG.
3.
FIG. 6 is a sectional view similar to FIG. 3 showing a slightly
modified form.
FIG. 7 is a view similar to FIG. 1, but showing a single cavity and
a modified form of contact in that cavity.
FIG. 8 is a longitudinal sectional view of the contact of FIG. 7
and oriented according to line 8--8 of FIG. 7, this figure being
similar to FIG. 3.
FIG. 9 is an end view taken from the top of FIG. 8.
FIG. 10 is a view similar to FIG. 8 but showing a slightly modified
form thereof.
FIG. 11 is a perspective view of another modified form of contact
in addition to the form in FIG. 7.
FIG. 12 is a longitudinal sectional view of the contact of FIG. 11
and oriented according to line 12--12 of FIG. 11.
FIG. 13 is a side view of further modified contact with a cutaway
sectional view of an associated connector body.
FIG. 14 is a face view of a blank from which the contact in FIG. 13
is fabricated.
The connector illustrated herein in its general overall nature is
known. The connector is indicated in its entirety at 20 and
includes a body or block or mounting member 22 in a known manner,
and having a plurality of cavities 24 in which are disposed socket
contacts or female contacts 26. The connector cooperates with a
plug having pins or pin contacts 28 received in the contacts 26 and
the connector may have any desired number of cavities and contacts
such as 10 or 20 or more, and as many as for example 200 or more.
The contacts have tail portions or sections 30 for connection with
corresponding electrical elements. Since the manner of use of the
connector is known, the following description will be directed to
the specific mechanical construction. The pins 28 which can be
received in the contacts are not limited to any particular shape,
and they may be, for example, round as at 28 a or square as at
28b.
The body or mounting member 22 has a front face 32 and a rear face
34. The cavities 24 defined by surrounding walls in the body extend
through the body or mounting member 22, each having an enlarged
portion 36 rectangular and preferably square in cross section and
opening through the front face 32. Each cavity also has a reduced
portion 38 opening through the rear face 34 and being at least
partially laterally offset from the enlarged portion 36. At the
juncture of the two portions of the cavity is a ledge or shoulder
40 on one side that is abrupt or square, and preferably
perpendicular to the axis of the cavity; on the other three sides
of the cavity are tapered or laterally disposed, inclined ledges or
surfaces 42 extending downwardly from the plane of the ledge 40 and
inclined downwardly and inwardly toward the center axis of the
cavity, the longitudinal dimension of these ledges not being
critical. The three tapered ledges 42 are individually identified,
for convenience, as 42a on the rear side and 42b, 42c on the sides
(see FIG. 5).
The contact is shaped from a single integral blank 44 shown in face
view in FIG. 2, which includes a main portion 46 and a tail portion
48 extending longitudinally from one side thereof. At the other end
from the tail portion is a ring or loop 50, in this case square,
and having a square aperture 52. The main portion 46 is stamped to
form fingers or tangs 54 in openings 56.
The blank 44 after being thus stamped, is formed or shaped into the
contact as shown in FIGS. 1, 3 and 4. The blank is bent at lines 58
thus forming an enlarged box portion or socket section 60 (FIG. 1),
tubular in form and in this case square in cross section. The tail
portion 48 in being thus shaped is formed into channel form,
forming a tail section 62 (FIG. 1) the flanges of which extend in
the neighborhood of one-half of the transverse dimension of the
socket section 60. The blank is further shaped so as to provide at
the juncture between the socket section 60 and the tail section 62,
tapered or inclined surfaces 64 on the three elements of the
channel, i.e., the web and the flanges. Additionally, the ring or
loop 50 illustrated in construction as an integral, flat section is
bent over to a 90.degree. position, overlying the upper end of the
socket section 60, with the outer peripheral surfaces thereof
substantially flush with the outer surfaces of the walls of the
socket section.
Additionally, the fingers or tangs 54 are bent inwardly and at
their free ends are shaped with convex inner surfaces 66 for more
effective contact engagement with the pins inserted in the
contacts. The tail section 62 is swaged or otherwise shaped or
enlarged at 68 at such location as to be positioned outwardly of
the cavity beyond the rear face 34, to resist removal of the
contact from the cavity through the front face 32. The partial
offset position of the tail section 30 provides a free edge or
shoulder of the socket section 60, as indicated at 70, which forms
an abutment engaging the ledge 40 in the wall of the cavity.
The contact is positioned in the cavity by inserting it through the
front face 32, in the proper position of rotation, the tail section
30 proceeding through the reduced portion of the cavity and
extending beyond the rear face 34. The three tapered surfaces 64 of
the contact engage the corresponding tapered ledges 42 in the
cavity, while the shoulder 70 solidly engages the ledge 40. The
contact is thus firmly held in position both by the abrupt surfaces
70, 40, and the inclined surfaces 64, 42 both in longitudinal and
lateral direction. The enlargement 68 further aids in further
securing the contact in place.
The ring or loop 50 is, of course, integral and it is
circumferentially continuous so as to positively prevent entry of a
pin of excess dimension. In accordance with the nature of a closed
entry contact, it will be understood that the fingers 54 are
preformed inwardly to such a position that the contact surfaces 66
extend inwardly beyond the corresponding side edges of the aperture
52 so that upon insertion of a pin of maximum size as determined by
the aperture, the pin will engage those surfaces. However, the
aperture 52 prevents the entry of a pin of any dimension beyond a
predetermined safe maximum which might otherwise deflect or bend
the fingers outwardly sufficiently to damage their resilience.
FIG. 6 is a sectional view of slightly modified form, this view
corresponding to FIG. 3. In the first form (FIGS. 1-5) the fingers
54 extend upwardly, or toward the entry end, while in FIG. 6 the
fingers 54a extend in the opposite direction, both forms being
effective for the purpose, and the two illustrations indicating
equal effectiveness of the two different forms.
FIGS. 7-10 show a form of connector modified from that of FIGS.
1-6. FIG. 7, for example, shows only the upper portion of the
contact and cavity in the body, the lower portions thereof being
identical with the corresponding elements in FIGS. 1-6. In FIG. 7,
the contact 80 is shaped from a blank similar to that of FIG. 2,
but having a closed entry construction 82 different from that of
the first embodiment. In the present case the closed entry
construction includes a plurality of tabs 84 extending upwardly
from the socket or box section 86, each having an inwardly directed
convex limiting surface 88 and terminal elements 90 inclined
upwardly and outwardly. The cavity 24 is provided with a ledge 92
adjacent the outer end of the enlarged portion of the cavity,
tapered or inclined correspondingly to the elements 90 and surfaces
94 therebeyond that are longitudinally straight, but spaced
transversely apart greater than the surfaces longitudinally
inwardly of the ledge.
Upon insertion of the contact into the cavity, the elements 90
engage the tapered ledge 92, as well as the longitudinal surfaces
94, and the tabs 84 are confined by the surface 94 against outward
or spreading movement. The limiting surfaces 88 thus define an
entry aperture limiting the maximum size of pin that can be
inserted into the contact, having corresponding relation with the
fingers 54 as described above.
FIG. 8 includes an indication of a portion of the body 22,
including the tapered ledge 92 and the straight portions 94.
As in the case of the first embodiment, the fingers 54 may extend
toward the entry end as in FIG. 8, or in the opposite direction as
in FIG. 10.
Preferably, the construction is such that the transversely aligned
contacts are disposed oppositely, i.e., the open sides of the
channels of the tail sections are directed outwardly from each
other.
FIGS. 11-12 illustrate another form of connector modified from
those in FIGS. 1-6 and 7-10. As illustrated in FIGS. 11-12, contact
100 is of one-piece construction and includes socket 102
frontwardly constructed in a similar manner to contact 80 of FIG.
7. Socket section 102 includes a closed entry construction 104 with
a plurality of entry tabs 106 extending upwardly from socket
section 102 with each being provided with an inwardly directed
convex limiting surface 108 and terminal elements 110. Also in a
similar manner to cavity 24, cavity 112 is provided with ledges 114
and surfaces 116.
Intermediate the forward and rearward ends 118 and 120 of socket
section 102 are contact tabs 122 similar to tabs 54. Rearwardly
disposed on socket section 102 are locking members represented by
locking tabs 124 having frontwardly directed free ends 126 locked
behind contact retaining shoulders 128 of body 22.
Tail section 130 rearwardly extends from socket section 102 and is
shaped to receive an external conductor by wire wrapping.
Contact 100 is advantageously constructed for frontward mounting in
cavity 112 in a manner whereby the entry tabs 106 resiliently abut
ledges 114, preventing rearward movement and locking tabs 124 abut
shoulders 128, preventing frontward movement of the contact. During
the mounting operation, tail section 130 is inserted through cavity
112 from front face 132 and locking tabs 124 yield inwardly to
permit passage of contact 100 until entry tabs 106 are forced
against ledges 114. As entry tabs 106 are pushed against ledges
114, locking tabs 124 pass beyond shoulders 128 and spring
outwardly to lock contact 100 in position.
Since contact 100 is frontwardly mounted, entry tabs 106 are
advantageously constructed so as to laterally extend beyond the
outer perimeter of locking tabs 124 with tabs 124 tapering
outwardly and frontwardly to free ends 126. In this construction,
locking tabs 124 resiliently yield inwardly to permit the desired
insertion of contact 100 with entry tabs 106 providing a stop.
The construction is extremely simple, the contact is made from a
single integral stamping, the metal from which the contact is made
is easily fabricated to form the various shapes for cooperation
with corresponding shapes in the walls of the cavity, the socket of
the contact provides effective engagement with a pin, while the
tail section 30 or 130 is usually effective for connection with
other electrical elements.
The tapered surfaces on the cavity walls and the contact being
disposed at the juncture of the respective enlarged end reduced
portions in FIGS. 1 and 7 facilitate shaping the contact in that in
working the metal as between a large portion and a small portion,
both portions can more easily be maintained in regular and uniform
shape, such as rectangular in cross section.
The complementary shape of the cavity and contact whereby the
contact engages the walls of the cavity substantially throughout
the length of the cavity, enables the contact to be made of
extremely thin material, while still maintaining the proper shape
and strength of the contact.
For convenience in fully appreciating the construction and
character of the connector the following are dimensions that may be
representative of a specific construction: the socket section of
the contact may be 0.080 inches on edge, and having a length of
about 0.300-0.400 inches, while the thickness of the material may
be about 0.008 inches.
FIGS. 13-14 illustrate a further modification of the contact
according to the invention. In FIG. 13, connector 140, similar to
connector 20 of FIG. 1, is provided with mounting member or body
142 of insulating material. Cavity 144 extends longitudinally
through member 142 and includes an enlarged front portion 156 open
to front face 152 and a reduced rear portion 158 open to the rear
face 154 with rear portion 158 being axially aligned with groove
159, thereby permitting front mounting of contact 146. As
illustrated, contact 146 of one-piece construction is at least
partially disposed in cavity 144 and includes a frontentry aperture
172 for receiving a mating contact 148. Frontwardly disposed in
contact 146 is an enlarged socket section 180 generally tubular in
form and constructed of thin sheet metal. Laterally offset from
socket section 180 is tail section 182 generally smaller in size
and constructed of dual thickness material advantageously to
provide a strong, sturdy post for wire wrapping. Further as
illustrated, each of beam sections 185-186 is integral with one of
side walls 183-184 affording support for one of the engagement
surfaces on convex curves 185-186.
For electrical engagement with mating contact 148, socket section
180 is provided with one or more pairs of contact fingers 174-175,
which are rearwardly disposed from entry aperture 172 and
longitudinally offset on opposite sidewalls 183-184, respectively.
Fingers 174-175 extend inwardly to convex curves 185-186 providing
contact-engaging surfaces for mating contact 148. As illustrated,
curve 185 is longitudinally offset from curve 186 and is
frontwardly disposed near entry aperture 172 to provide an early
wiping surface for contact 148. Beam sections 192-193 are inclined
outwardly from convex curves 185-186 to sidewalls 183-184 and
provide cantilever beam action as contact 148 engages the
inwardly-disposed surfaces on curves 185-186. Advantageously, beam
sections 192-193 are essentially of equal length to develop
essentially equal force, thereby reducing such problems as
permanent contact deformation which may result when one beam
section is of much shorter length than the other and the problem of
improper centering by unequal deflection forces. It is a further
advantage if socket section 100 is elongated longitudinally to
provide elongated beam sections and is snugly fitted in enlarged
portion 156 of cavity 144. Curves 185-186 are further provided with
ends 194-195 opposite to beam sections 192-193 which are inclined
outwardly. For curve 185, and 194 serves to funnel contact 148 into
engagement with the inwardly disposed surfaces of fingers
174-175.
Further in accordance with the invention, beam section 193 is
rearwardly inclined inwardly and disposed laterally opposite curve
185 to guide mating contact 148 to a center position 197. As an
additional aid for the insertion of contact 148, sidewalls 183-184
include converging tapers 191 on the forward end 187 at entry
aperture 172. Socket section 180 is also provided with shoulder 190
at its rearward end 188 to limit rearward movement of the contact
in cavity 144.
FIG. 14 illustrates a blank 164 forming an integral sheet metal
member from which contact 146 is formed by bending the sheet-like
metal at lines 178 representing U-shaped and L-shaped portions 165
and 167 in generally flat main base portion 166 into the shape
illustrated in FIG. 13. Free-ended oppositely directed fingers
174-175 are formed by openings 176 and 177 representing sides and
ends respectively of U-shaped and L-shaped portions 165 and 167 and
are also bent in the shape illustrated in FIG. 13. L-shaped portion
167 may inclue a second side 179 to form a second U-shaped portion.
Tail section 168 is provided with two opposite pairs of lateral
flanges 196 longitudinally separated by concave curved recesses 198
which aid in mounting contact 146. In the resulting construction,
the contact is formed of an integral sheet metal member represented
by blank 164 having a generally flat base portion 166 with
laterally separated U-shaped and L-shaped portions 165 and 167
stamped out to form a pair of free-ended oppositely directed
fingers 174-175 and a tail 168 integrally formed on the base
portion 166 and which extends away from the base portion. As
illustrated, the U-shaped portion 165 is inverted with respect to
L-shaped portion 167 with each of the portions being formed by
stamped out longitudinal sides and lateral end portions 176-177.
Base portion 166 is bent along the side portions of the U-shaped
and L-shaped portions to form a rectangular shape and the fingers
174-175 are bent inwardly to longitudinally offset the free ends
and form longitudinally offset contact engagement surfaces.
Contact 146 is mounted frontwardly in cavity 144 by inserting tail
section 182 with taper 189 into groove 159 axially aligned with
rear cavity portion 158 and forcing tail section 182 rearwardly
until it extends beyond rear face 154. Final positioning is
accomplished by pulling tail section 182 rearwardly to force
plastic deformation of member 142 and force material into recesses
198, thereby locking contact 146 in place.
The resultant construction as illustrated in FIG. 13 positions
front contact-engagement surface 186 near entry aperture 172 to
provide a long wiping action against contact 148 without requiring
higher insertion forces normally occurring when both contact
engaging surfaces simultaneously engage contact 148.
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