Electrical connector and method of making same

Abstract: An electrical connector (10) comprises a housing (12) of electrically insulative material and defining an interior compartment and passages extending from the interior compartment to an exterior surface of the housing. Electrical contact members (18,20,22) are resident in the housing passages. At least one of the passages (12a) is circular in configuration and a power contact member (22) resident in the one passage has a portion resident in the one passage circular in configuration and in press-fit sealed relation with the housing. The contact member (22) resident in the one passage (12a) has a further portion resident in the interior compartment of blade-shaped configuration. A method of making the connector includes a step of press-fitting the power contact member into the one passage from the interior compartment with the contact member circular portion leading the contact member blade portion, such that the circular portion is in interference fit in the one passage and that the blade portion is resident in the interior compartment.

Description: Field of the Invention This invention relates generally to electrical connectors and pertains more particularly to connectors having both signal and power contact members therein. Background of the Invention In typical applications in the electronics industry, electrical connectors need only conduct therethrough relatively low level, i.e., low voltage, signals. Given such signal levels, the sealing relationship between the connector housing and the contact members carrying the signals is not critical. On the other hand, certain applications in the electronics industry require that both low level signals and power be conducted through the connector. Given that the power voltage level is relatively high, need arises for a high degree of sealing relationship between the power contact member and the connector housing, such that moisture does not have a path along the power contact member into the housing interior. The power contact member is typically required to be of blade shape interiorly of the connector housing. One known practice for obtaining a high degree of sealing relationship between the power contact member and the connector housing is to mold the housing about the contact members, including the fully blade-shaped power contact member. This practice is relatively costly and complicated as compared to the practice of press-fitting contact members into a pre-existing housing. Difficulty attends press-fitting of a blade-shaped contact member into a housing and obtaining a high degree of sealing relationship between the contact member and the housing. Assuming there to be a housing contact member receiving passage which is likewise complemental to the blade shape of the contact member, edge warpage attends press-fitting, as does non-uniform hoop stress. US-A-3670294 discloses an electrical connector comprising a body and passages extending through the body, there being electrical contact members resident in the passages, the passages being circular in configuration at one end and rectangular at the other, and each contact member having a portion being circular in configuration resident in the circular part of the associated passage, but without contact therewith, and a portion of blade-shaped configuration extending through the rectangular portion of the passage, the contact pins each having a retention portion with elements to engage the body material in the region of the rectangular part of the passage. The arrangement involves no sealing between the contacts and the body. Summary of the Invention The present invention has as its primary object the provision of a connector having a press-fit power contact member meeting the requirements of a sealed relation between the contact member and the connector housing and of presenting a blade-shaped contact portion interiorly of the connector housing. In attaining this and other objects, the invention provides an electrical connector comprising a housing of electrically insulative material defining an interior compartment and passages extending from said interior compartment to an exterior surface of said housing, and electrical contact members resident in said housing passages, at least one of said passages being circular in configuration, the contact member resident in said one passage having a portion being circular in configuration and in press-fit sealed relation with said housing, said contact member resident in said one passage having a further portion resident in said interior compartment of blade-shaped configuration. The invention further provides a method of making a connector having a power contact in sealed relation therein, comprising the steps of: (a) preforming a housing of electrically insulative material with an interior compartment and passages extending from said interior compartment to an exterior surface of said housing, at least one of said passages being of circular configuration and of a first diameter; (b) forming an elongate power contact member of electrically conductive material with a blade-shaped portion at one end thereof and a circular portion longitudinally adjacent said blade-shaped portion, with the circular portion having a diameter exceeding said first diameter; and (c) press-fitting said power contact member into said one passage from said interior compartment with said contact member circular portion leading said contact member blade portion, such that said circular portion is in interference fit in said one passage and that said blade portion is resident in said interior compartment. The foregoing and other objects and features of the invention will be further understood from the following detailed description of preferred embodiments thereof and from the drawings, wherein like reference numerals identify like components throughout. Brief Description of the Drawings Fig. 1 is a perspective view of a connector in accordance with the invention. Fig. 2 is a perspective view of the Fig. 1 connector as would be seen from viewing its undersurface. Fig. 3 is a perspective view of the power contact member of the connector of Figs. 1 and 2. Fig. 4 is a front elevation of the power contact member of the connector of Figs. 1 and 2. Fig. 5 is a plan view of Fig. 4 Fig. 6 is a left side elevation of Fig. 4. Fig. 7 is a right side elevation of Fig. 4. Description of the Preferred Embodiment and Practice Referring to Figs. 1 and 2, connector 10 has a housing 12 comprised of electrically insulative material. Housing 12 is preformed to define interior compartments 14 and 16 and passages for receipt of press-fit contact members, inclusive of two groups of contact members 18 and 20, and press-fit power contact member 22. All contact members define exterior contact portions, shown in Fig. 2 as accessible at the connector undersurface and contact portions (not shown) in compartments 14 and 16 for mating engagement with contact portions of contact members of a mating connector (not shown). As is seen also in Fig. 2, mounting post 24, formed integrally with housing 12, extends below the connector undersurface and is adapted to seat in a recess of a printed circuit board which has plated through holes (not shown) for receipt of contact members 18, 20 and 22. Turning to Figs. 3-7, power contact member 22 has two dissimilarly configured portions, portion 22a being cylindrical and portion 22b being blade-shaped. The housing passage 12a (Fig. 2) for residence of power contact member 22 is circular and of diameter somewhat less than the diameter of portion 22a, whereby upon press-fitting of power contact member portion 22a into passage 12a from the interior of compartment 16, a round pin, round hole situation is at hand, giving rise to fully uniform hoop stress and a water-tight relation between contact member 22 and housing 12. Various changes to the particularly disclosed connector may evidently be introduced without departing from the invention. Accordingly, it is to be appreciated that the particularly discussed and depicted preferred embodiment and practice of the invention are intended In an illustrative and not in a limiting sense.

Claims: An electrical connector (10) comprising a housing (12) of electrically insulative material defining an interior compartment (14,16) and passages (12a) extending from said interior compartment to an exterior surface of said housing (12), and electrical contact members (18,20,22) resident in said housing passages, at least one (12a) of said passages being circular in configuration, the contact member (22) resident in said one passage (12a) having a portion being circular (22a) in configuration and in press-fit sealed relation with said housing (12), said contact member (22) resident in said one passage having a further portion (22b) resident in said interior compartment of blade-shaped configuration. The connector claimed in claim 1, wherein said contact member (22) resident in said one passage has another portion (22a) disposed exteriorly of said housing and of circular configuration. A method of making a connector (10) having a power contact (22) in sealed relation therein, comprising the steps of: (a) preforming a housing (12) of electrically insulative material with an interior compartment (14,16) and passages extending from said interior compartment to an exterior surface of said housing, at least one (12a) of said passages being of circular configuration and of a first diameter; (b) forming an elongate power contact member (22) of electrically conductive material with a blade-shaped portion (22b) at one end thereof and a circular portion (22a) longitudinally adjacent said blade-shaped portion (22b), with the circular portion (22a) having a diameter exceeding said first diameter; and (c) press-fitting said power contact member (22) into said one passage (12a) from said interior compartment with said contact member circular portion (22a) leading said contact member blade portion (22b), such that said circular portion (22a) is in interference fit in said one passage and that said blade portion (22b) is resident in said interior compartment.

Inventors: EGGERS ARTHUR, HENDERSON KEVIN G, EGGERS, ARTHUR, HENDERSON, KEVIN G.
Applicants: THOMAS & BETTS CORP, THOMAS & BETTS CORPORATION (A TENNESSEE CORPORATION)
Application year: 1995
Main classification: H01R13
IPC codes: H01R13, H01R9, H01R43