Terminal locking mechanism for hybrid electrical connector

A hybrid electrical connector includes both signal and power contacts in the same connector housing. The housing includes a plurality of axially extending passageways for receipt of the signal contacts and a plurality of axially extending cavities for receipt of the power contacts. The connector housing further includes a plurality of transversely extending slots extending through the connector housing intersecting with individual power contact cavities. A Y-shaped terminal retaining member is insertable in the slots and is resiliently held in place in the slots. The power terminals include an opening therethrough forming a locking shoulder for receipt of the transversely extending locking member.

The subject invention relates to an improved electrical connector housing and more particularly to an improved secondary retention feature for the retention of electrical terminals within their housing.

BACKGROUND OF THE INVENTION

It is quite common in the electrical connector industry today to require that electrical terminals have redundant retention means within their connector housings. The first or primary means of retaining the electrical terminals within the housing is to have a stamped-out lance from the electrical terminal metal body, which abuts a shoulder within the housing. The redundant or secondary retention means is typically profiled as a plastic movable member, which can be moved into place over the terminal to lock the terminal in place. Some of these members are moved transversely of the axial direction, while some are defined as hinged flaps, which are rotated into place. These flaps include plastic tabs which, when rotated, reside in a groove or gap within the terminal to retain the contact in place.

In one prior method, as shown for example in U.S. Pat. No. 4,750,893, an electrical connector housing has a hinged flap which rotates into place. The electrical connector has an insulating housing and a plurality of electrical terminals disposed in terminal receiving passageways within the housing. The housing includes an upper retention flap including a retention tab which, when in its locked location, is positioned adjacent to an edge of the terminal to retain the terminal in the passageway. The flap has tabs which reside at an edge of the contact to  prevent withdrawal thereof. If more than one row of contacts is present, then two hinged flaps on the outside of each of the two rows are used to retain the terminals in place.

It is also well known in the industry to provide a hybrid electrical connection system, comprised of both signal and power contacts. See, for example, U.S. Pat. No. 5,785,557 and EP Patent Application 0951102. In particular with hybrid connectors, given the complexity and cost, it is desirable to be able to remove and/or replace contacts within the connector without destroying or damaging the electrical connector or any of the connections thereto.

The objects of the invention are therefore to improve upon these known connection systems.

SUMMARY OF THE INVENTION

The objects of the invention have been accomplished by providing an electrical connector, comprising an insulative housing having at least one contact receiving cavity therethrough, the housing having a transversely extending slot intersecting the cavity. At least one electrical terminal is positioned in the cavity, the terminal having a locking shoulder adjacent to the transversely extending slot. A terminal locking member also has resilient fork members, the resilient fork members having locking members, and the resilient fork members being resiliently biasable into a locked position within the transversely extending slot, with a portion of the terminal locking member engaging the locking shoulder of the terminal, thereby retaining the terminal in the cavity.

Preferably, the terminal locking member is Y-shaped, and comprises two locking forks having latching members thereon, for latching the forks in the slot. The terminal has a front U-shaped contact section defined by two side-by-side contact plates interconnected by a bight portion, the bight portion having an opening therethrough defining the locking shoulder. The Y-shaped terminal locking member further comprises a leg portion, which extends through the bight portion opening. The housing further comprises a central rib extending intermediate the side-by-side contact plates, opposite the bight portion with the side-by-side contact plates flanking the central rib, the central rib terminating to form a forwardly facing shoulder adjacent to the bight portion opening. The terminal locking member extends through the transversely extending slot and the bight portion opening, with the leg portion positioned forward of the forwardly facing shoulder, thereby locking the electrical terminal in place.

In another aspect of the invention, an electrical connector comprises an insulative housing having at least one contact receiving cavity therethrough, the housing having a transversely extending slot intersecting the cavity. At least one electrical terminal is positioned in the cavity, the terminal having a front U-shaped contact section defined by two side-by-side contact plates interconnected by a bight portion, the bight portion having an opening therethrough defining a locking shoulder. A central rib is defined in the insulative housing and extends intermediate the side-by-side contact plates, opposite the bight portion with the side-by-side contact plates flanking the central rib, the central rib terminating to form a forwardly facing shoulder adjacent to the bight portion opening. A terminal locking member extends through the  transversely extending slot, the bight portion opening, and is positioned forward of the forwardly facing shoulder, thereby locking the electrical terminal in place.

Preferably, the terminal locking member has resilient fork members having locking members, and the resilient fork members are resiliently biasable into a locked position within the transversely extending slot. The terminal locking member is Y-shaped, and the Y-shaped terminal locking member comprises two locking forks having latching members thereon, for latching the forks in the slot. The Y-shaped terminal locking member further comprises a leg portion, which extends through the bight portion opening.

The plurality of electrical terminals are alternately positioned within the housing with some of the terminal bight portions along a lower side of the cavities, and some of the terminal bight portions positioned along an upper side of the cavities; and a plurality of central ribs are alternately positioned in the housing to cooperate with the terminals.

In yet another aspect of the invention, an electrical connector comprises an insulative housing having at least one contact receiving cavity therethrough, the housing having a transversely extending slot intersecting the cavity. At least one electrical terminal is positioned in the cavity, the terminal having a front U-shaped contact section defined by two side-by-side contact plates interconnected by a bight portion. The terminal has an opening therethrough extending through the bight portion and partially into the side-by-side contact plates defining a locking shoulder. A terminal locking member extends through  the transversely extending slot and the opening, the terminal locking member is longitudinally locked in the transversely extending slot and within the opening, thereby locking the electrical terminal in place.

The terminal locking member is Y-shaped, and comprises two locking forks having latching members thereon, for latching the forks in the slot. The Y-shaped terminal locking member further comprises a leg portion, which extends through the bight portion opening.

The insulative housing further comprises a central rib extending intermediate the side-by-side contact plates, opposite the bight portion with the side-by-side contact plates flanking the central rib, the central rib terminating to form a forwardly facing shoulder adjacent to the bight portion opening. The terminal locking member extends through the transversely extending slot, the bight portion opening, with the leg portion positioned forward of the forwardly facing shoulder, thereby locking the electrical terminal in place. The terminal locking member is Y-shaped and comprises two locking forks having latching members thereon, for latching the forks in the slot. The Y-shaped terminal locking member further comprises a leg portion, which extends through the bight portion opening, and is positioned forwardly of the forwardly facing shoulder. The electrical connector can also comprise a plurality of electrical terminals, where the terminals are alternately positioned within the housing with some of the terminal bight portions along a lower side of the cavities, and some of the terminal bight portions positioned along an upper side of the cavities, and a plurality of central ribs, alternately positioned in the housing to cooperate with the terminals.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference first toFIG. 1, a connector is shown at2as a hybrid electrical connector, having a housing4with a plurality of contact cavities6for receipt of power contacts, and a plurality of contact receiving cavities8for receipt of signal contacts. The housing4further includes polarizing lugs at10and mounting apertures at12. With reference still toFIG. 1, the power terminal receiving cavities include terminal locking members14snapped in place to retain the terminals in the individual passageways6, as will be described further herein. As shown inFIG. 2, a rear perspective view of the connector housing4is shown, where the power terminal receiving cavities6are shown in greater detail, as will be described herein. Finally, the connector housing4includes a plurality of locking inserts16to lock the signal contacts in place, which are further described in co-pending patent application Ser. No. 10/460,900, filed on even date herewith, and incorporated herein by reference.

With reference toFIGS. 2 and 3, the detail of the power cavities6will be described in greater detail. As shown inFIG. 2, each of the cavities6include an enlarged opening portion20having rib portions22positioned opposite the enlarged portions20. The rib portion is positioned centrally so as to define two slot portions at24, which flank the rib22. As shown best inFIG. 3, the central rib22terminates in a forwardly facing shoulder at26, as will be described herein. As also shown best inFIG. 3, the housing4includes a slot at28, which extends transversely of the longitudinal axis of the cavity6and intersects with the cavity to communicate  therewith. It should be noted that a rear surface36defining the cavity28is proximate to the forwardly facing shoulder26. Slot28extends through top surface30of housing4and through inner surface32of housing4.

With respect now toFIG. 4, terminal locking member14is shown in greater detail. Terminal locking member14is Y-shaped in configuration, including two resilient fork members40and a lower leg portion42. Each of the fork members40are resiliently biasable inwardly and include locking members at44. The locking members44are defined by upper and lower surfaces44aand44b, which are spaced apart slightly greater than the distance between surfaces30and32of the housing member4(FIG. 3). The terminal locking member14further includes gripping area46for removal of the terminal locking member14, as described herein.

With respect now toFIG. 8, an electrical terminal50is shown as a power terminal, generally comprised of a front contact portion52, a crimp barrel54, and a strain relief member at56. The front contact portion52is generally comprised of a contact having a U-shaped cross-section, generally comprised of side-by-side parallel contact plates58(only one of which is shown inFIG. 8) connected together by way of a bight portion60. As shown inFIG. 8, the terminal50also includes an opening62, which extends through the bight portion60and partially into the side-by-side contact plates58, thereby defining a retaining and locking shoulder64on the terminal50. With the above elements as described, the assembly and application of the connector will now be described in detail.

With respect first toFIGS. 2 and 8, it should be appreciated that the conductors for the power are terminated to contacts in a conventional manner, that is, by stripping the end of the insulation, then placing the bared conductors in the crimp barrel portion54of the terminals and crimping the conductors to the crimp barrel, at the same time applying the strain relief56around the insulation of the wire. As shown inFIG. 2, the connector is designed to accommodate10power conductors, and therefore10such terminals would be prepared. It is also evident fromFIG. 2that some of the cavities6for receiving the power terminals are inverted relative to each other, and that the enlarged opening portion20is to receive the crimp barrel strain relief and conductor therein.

Therefore, the terminals50, when prepared, are inserted such that the side-by-side contact plates are positioned in the slots24, with the contact plates flanking the rib22and are slidably received therein, with the bight portion60positioned on a lower surface of the enlarged opening20. Thus, when the terminals50are fully positioned in their cavities6, a front edge of the contact plates58abut the corresponding shoulder34of housing4to locate the terminals therein. When in this position, and as shown inFIG. 5, the retaining members14can be received transversely into the slot28, which then causes leg42to communicate within the cavity6and lock terminals50in place, as to be described.

It should also be appreciated fromFIGS. 7 and 8that, when terminal50is fully positioned as described above, and as retaining member14is fully positioned as shown inFIG. 8, the yoke members40of retaining member14project into the portion of opening62, which extends  into the opposed contact plates58, while the leg portion42extends between the side-by-side contact plates and is positioned adjacent to the forwardly facing surface26of rib22. Thus, as shown inFIG. 8, the power terminals are fixedly held in place in their corresponding cavities6by the retaining members14.

For example, if a strain is placed on the conductors towards the right as viewed inFIG. 8, the locking surface64of opening62would cause an abutment against the retaining member14. Retaining member14is held fixed against surface36, and even leg portion42is backed up by forwardly facing surface26of rib member22.

It should also be appreciated fromFIG. 7that the retaining members14extend in alternate directions, such that one retaining member extends with the leg portion42extending downwardly, whereas an adjacent or alternate cavity has a retaining member14, with the leg portion42extending upwardly. This is consistent with the alternate staggering of the contact cavity6as shown inFIG. 2. It should also be appreciated fromFIG. 4that the portions46of the retaining members14are exterior to surface30, such that a common gripping tool, such as standard hook-nose tweezers, can be used for extracting the retaining meters14.

With reference now toFIGS. 9 and 10, it should be appreciated that various cavities are staggered, from the front face38to a front edge of the contact plate58. For example, as shown inFIG. 9, the front edge of the contact plate58is positioned a distance X1from the front faced38of the housing4. With respect now toFIG. 10, other power cavities can be configured as shown at106, with a  shoulder such as134positioned further inwardly than shoulder34, such that the front edge of contact plate58is positioned a distance X2from the front edge38of housing4, to perform a first-mate, last-break sequencing of the power terminals. Contacts50are modified slightly in the length of the contact plate58to accommodate this difference.

In the preferred embodiment, the dimensions X1and x2are on the order of 0.035 inches and 0.073 inches, respectively.