Electrical connector having an improved female contact

Abstract: An electrical connector comprises a female contact (1) having a pair of contact receiving cavities (5a) and (5b) at both ends that are capable of accommodating mating contacts (A, B). One mating contact (A) is inserted into and removed from one of the contact receiving cavities (5a). A pair of lances (9a) and (9b) extend outwardly from the female contact and contact the side walls (16) of the cavity (14) of the housing (10), to allow contact float.

Description: The present invention relates to electrical connectors and, more particularly, to a female contact which is constructed to receive mating contacts at both ends. A female contact is disclosed in Japanese Utility Model Application Kokoku No. H3-13987 and is shown in Figure 3 of the accompanying drawings. In this female contact 100, a contact receiving cavity 102, which accommodates the tab terminal A of a blade type fuse 120, is disposed in one end of a base part 101. A contact receiving cavity 103, which accommodates the tab terminal B of a bus bar, is disposed in the other end of the base part 101. A housing 110 supports the female contact 100. The contact receiving cavity 102 is located at one end and the contact receiving cavity 103 is located at the other end and they have the same structure. Each of these contact receiving cavities has an cantilever arm 106 which is folded back to the inside from a top wall 104, via a bent section 105, and a contact section 107 which is stamped out from the base part 101. Here, the tip of each cantilever arm 106 is protected by an anti-overstress member 108. The tab terminal A of the blade type fuse 120 is clamped between the cantilever arm 106 and contact section 107 of the contact receiving cavity 102 located at one end, while the tab terminal B of the bus bar is clamped between the cantilever arm 106 and contact section 107 of the contact receiving cavity 103 located at the other end, so that the respective tab terminals are electrically connected to each other. Here, the tab terminal B of the bus bar located at the second end of the female contact is generally a terminal that is not pulled out again once it has been accommodated in the contact receiving cavity 103. However, the tab terminal A of the blade type fuse 120 located at the first end of the female contact is inserted into and removed from the contact receiving cavity 102 repeatedly. A problem exists in that the female contact 100 accommodated in the housing 110 is fastened in place so that it does not move with respect to the cavity of the housing 110. As a result, when the tab terminal A of the blade type fuse 120 is inserted into or removed from the female contact 100,it may stub against either the cantilever arm 106, or the anti-overstress member 108, resulting in poor electrical connection. A further electrical connector is described in patent US 5 431 576 which discloses the features of the preamble of claim 1. The connector includes a housing containing a contact, one end of which has tabs with holes for bolting to a back plane. The opposite end of the contact includes a slot for receiving a male contact and two lances which engage recesses in the housing to restrain the contact against axial separation from the housing. Opposite side walls of the contact bear against opposed inner walls of the housing thereby restraining the contact against lateral displacement with respect to the housing. Misalignment of a mating contact is accommodated by contact band inserts which are resilient. Another electrical connector is disclosed in EP 0 352 088. The connector comprises a housing containing a rolled socket surrounded by a helper spring sleeve. The sleeve has spring arms which are provided about the circumference of the sleeve. The spring arms engage with the inner wall of the housing to prevent the socket from movement in a lateral direction upon mating with a misaligned mating pin. Accordingly, the present invention was devised in order to address these problems. An object of the present invention is to provide a female contact that can accommodate mating contacts from both ends. The connector can accommodate a male contact improperly inserted in a misaligned orientation. This is achieved by an electrical connector according to claim 1. The electrical connector of the invention has female contacts each disposed in a housing for receiving mating contacts. A plurality of cavities are formed in the housing each for receiving a respective one of the female contacts. A pair of lances are disposed on and extend outward from each female contact. The pair of lances resiliently engage opposing side walls of a respective one of the cavities such that either lance is compressible to cause a shift of the female contact within the respective cavity upon mating with a misaligned mating contact. The invention will now be described, by way of example, with reference to the accompanying drawings, in which:- Figure 1 illustrates the female contact of the present invention. Figure 1 (a) is a front view, Figure 1 (b) is a right-side view, Figure 1 (c) is a sectional view along line 1c-1c in Figure 1 (b) and Figure 1 (d) is a plan view. Figure 2 shows the state in which the female contact shown in Figure 1 is inserted in a housing. Figure 2 (a) is a plan view, Figure 2 (b) is a sectional view along line 2b-2b in Figure 2 (a) and Figure 2 (c) is a sectional view along line 2c-2c in Figure 2 (a). In Figures 2 (b) and 2 (c), the mating contact on the mating side and the main-body side mating contact B disposed on the main body housing are indicated by dotted lines. Figure 3 is a sectional view of a prior art example of a female contact. The female contact of the present invention will now be described in greater detail with reference to the attached figures. In Figure 1, the female contact 1 is formed in a substantially box shape comprising a base 2, a pair of side walls 3a, 3b extending from both sides of the base 2, and a lower top wall 4a and an upper top wall 4b which are bent from the respective side walls 3a and 3b to overlap each other. The female contact 1 is formed by stamping and bending a metal plate. Furthermore, the respective ends of the female contact 1 form a pair of contact receiving cavities 5a and 5b for receiving a male terminal A on the mating side and a male terminal B on the main body side. One contact receiving cavity 5a has a cantilever arm 6a which is folded back to the inside from one end of the base 2, via a bent section 8a, and a protrusion 7a which is stamped out from a portion of the lower top wall 4a in a position facing the above-mentioned cantilever arm 6a. One male terminal A is received between the cantilever arm 6a and protrusion 7a and is thus electrically connected to the female contact 1. In this case, the contact surface 6a' of the cantilever arm 6a elastically contacts the male terminal A and presses the male terminal A against the protrusion 7a. Meanwhile, the other contact receiving cavity 5b has a cantilever arm 6b which is folded back to the inside from the other end of the base 2, via a bent section 8b, and a protrusion 7b which is stamped out from a portion of the lower top wall 4a. The other male terminal B is received between the cantilever arm 6b and protrusion 7b and is thus electrically connected to the female contact 1. In this case, the contact surface 6b' of the cantilever arm 6b elastically contacts the male terminal B and presses the male terminal B against the protrusion 7b. Furthermore, a plurality of anti-overstress members 9 which extend between the respective cantilever arms 6a and 6b of the contact receiving cavities 5a and 5b and the base 2 are cut out and raised from both side walls 3a and 3b of the female contact 1. These anti-overstress members 9 contact the cantilever arms 6a and 6b to prevent excessive deformation. As a result, the generation of an excessive bending stress in the bent parts 8a and 8b is prevented. A pair of lances 9a and 9b extend from the base 2 toward one of the contact receiving cavities. As will be described later, these lances 9a and 9b elastically contact the inside surfaces of both side walls 16 of the cavity 14 of the housing 10 when the female contact 1 is inserted into this cavity 14. Contact parts 9a' and 9b' which contact the inside surfaces of both side walls 16 of the cavity 14 are formed on the free ends of the lances 9a and 9b. Lead in surfaces 9a" and 9b" are positioned at the free ends and are bent toward the inside at an angle. These lead in surfaces 9a" and 9b" facilitate the introduction of the lances 9a and 9b into the cavity 14 of the housing 10 when the female contact 1 is received inside the cavity 14. As is shown in Figure 2, the housing 10 for receiving the female contact 1 is equipped with a terminal receiving section 11, which is formed in substantially the shape of a rectangular solid, and a pair of securing sections 12 which protrude from both ends of the terminal receiving section 11. The housing 10 is preferably formed by molding an insulating resin. A plurality of cavities 14 which receive respective female contacts 1 are formed in the terminal receiving section 11. Each of these cavities 14 is defined by a pair of side walls 15, 15 which face each other and a pair of side walls 16, 16 which are perpendicular to the side walls 15, 15. Furthermore, an opening 17 which has substantially the same diameter as the internal diameter of the corresponding cavity 14, is formed at one end of each cavity 14. A passageway 18, which has a diameter that is smaller than the internal diameter of the corresponding cavity 14, and which is used for the insertion and removal of an male terminal A, is formed at the other end of each cavity 14. Tapered surfaces 18a which are used to facilitate the insertion of the male terminal A are formed on edges of the passageway 18. Securing openings 13 are formed in the respective securing section 12 for receiving posts 21 which are integrally formed on a main body housing 20. Next, the method used to accommodate the female contacts 1 in the cavities 14 of the housing 10, and the method used to make electrical connections between the mating contact A and mating contact B, via the female contacts 1, will be described with reference to Figure 2. The female contacts 1 are inserted into the cavities 14 of the housing 10 with the lances 9a and 9b facing the side walls 16, 16 of the cavity 14 until the end of the contact receiving cavity 5a contacts the inside surface of the wall 19. The lances 9a and 9b of each female contact 1 first bend inward toward each other, as a result of the lead in surfaces 9a" and 9b" contacting the corner edges of the side walls 16, 16, and then the lances 9a' and 9b' enter the interior of the cavity 14 while sliding along the inside surfaces of the side walls 16, 16. When the female contact 1 has been fully inserted into the cavity 14, it is secured by the outward elastic force of the lances 9a and 9b against the side walls 16, 16. The female contact 1 is therefore positioned in the center of the cavity 14. The mating contacts B extend from the main body housing 20 and are inserted into the other contact receiving cavities 5b through the openings 17 to contact the female contact 1. At the same time, the posts 21 on the main body housing 20 are inserted into the securing openings 13 of the housing 10, and are then staked to secure the housing 10 to the main body housing 20. Each male terminal B is received between the cantilever arm 6b and protrusion 7b. The mating contacts B are therefore, preferably, permanently fixed within the cavities 14 and electrically connected to the female contactsl. The posts 21 staked in the housing 10 prevent the female contacts 1 from slipping out of the cavities 14. The terminals are preferably shipped in a state in which the main body housing 20 is attached to the housing 10. Afterward, as is shown in Figure 2 (c), the mating contacts A are inserted into the contact receiving cavities 5a of the female contacts 1, as described above. As a result, the mating contacts A are electrically connected to the female contacts 1 and mating contacts B. If necessary, the mating contacts A can be inserted into and removed from the contact receiving cavities 5a. The connector of this invention is designed to prevent contact stubbing. For example, in a case in which the male terminal A is improperly inserted, stubbing is prevented by the tapered surface 18a, so that the male terminal A rides along this tapered surface 18a and then contacts the protrusion 7a. When the male terminal A contacts the protrusion 7a, the female contact 1 moves to the right, thus increasing the force on the lance 9b contacting the right side wall 16 of the cavity 14, and decreasing the force on the lance 9a contacting the left side wall 16. In this state, the male terminal A is clamped between the cantilever arm 6a and the protrusion 7a. Furthermore, in cases where the male terminal A is shifted to the right, but is inserted without contacting the inclined surface 18a, the male terminal A directly contacts the protrusion 7a and is clamped between the cantilever arm 6a and protrusion 7a such that the force on the lance 9b contacting the right side wall 16 of the cavity 14 is increased and the force on the lance 9a contacting the left side wall 16 is decreased. On the other hand, in cases where the male terminal A is inserted while being shifted to the left, the shift to the left is similarly corrected along the tapered surface 18a, so that the male terminal A contacts the cantilever arm 6a. When the male terminal A contacts the cantilever arm 6a, the female contact 1 moves to the left, thus increasing the force on the lance 9a and decreasing the elastic force on the lance 9b. In this state, the male terminal A is clamped between the cantilever arm 6a and the protrusion 7a. Furthermore, in cases where the male terminal A is shifted to the left, but is inserted without contacting the inclined surface 18a, the male terminal A directly contacts the cantilever arm 6a and is clamped between the cantilever arm 6a and protrusion 7a such that the force on the lance 9a is increased and the force on the lance 9b. Accordingly, even if the male terminal A is inserted while being shifted either to the right or left, the female contact 1 can absorb the shift of this insertion and make an appropriate electrical connection with the male terminal A. An embodiment of the present invention has been described here, however, the invention is not limited to this embodiment because various alterations are possible and within the scope of the invention. For example, it would also be possible to have lances 9a and 9b extend from the base 2 and the upper top wall 4b which is located on the side of the female contact 1 receiving the male terminal A. Furthermore, the cantilever arms 6a, 6b and the contacts A and B lie on parallel planes. The connector may be modified so that the contacts A and B enter at angles to each other. In such a case, the pair of lances 9a and 9b extend in the direction perpendicular to the contact surface 6a' and the male terminal A. Advantageously, even if the male terminal A, which is inserted and removed, is inserted while being shifted or misaligned with the contact surface of the cantilever arm, the female contact 1 can absorb the shift or misalignment and make an appropriate electrical connection with the male terminal A. An additional advantage is that when the female contact 1 is accommodated in the cavity 14 of the housing 10, the female contact 1 is positioned so that both ends are supported thus ensuring that the female contact 1 is appropriately centered with respect to the cavity 14.

Claims: An electrical connector having one or more female contacts (1) disposed in a housing (10) for receiving a mating contact (A, B), the connector comprising: one or more cavities (14) formed in the housing (10) for receiving the female contact(s) (1), and a pair of lances (9, 9b) disposed on and extending outwardly from the or each female contact (1), the pair of lances (9a, 9b) resiliently engaging opposing side walls (16) of the associated cavity (14), characterised in that , for the or each female contact (1): the female contact (1) forms a pair of contact receiving cavities (5a, 5b) on respective ends of the female contact (1) for receiving mating contacts (A, B); the pair of lances (9a, 9b) is integral with the female contact (1); the pair of lances (9a, 9b) extends into gaps between walls (2, 4a, 4b) of the female contact (1) and the cavity side walls (16) whereby both lances (9a, 9b) are compressible to allow a lateral shift of the female contact (1) within the cavity (14) towards the opposing side walls (16) upon mating with a misaligned mating contact (A,B); and the female contact (1) is centred in the cavity (14) by elastic forces of the lances (9a, 9b) whereby stubbing of the mating contacts (A,B) upon insertion into the female contact (1) is avoided. The electrical connector of claim 1 wherein the lances (9a, 9b) include lead-in surfaces (9a", 9b") angled inward toward the female contact (1). The electrical connector of claim 1 or 2 wherein the or each female contact (1) includes a cantilever arm (6a) bent from a wall into the female contact (1) at a mating end. The electrical connector of claim 3 wherein the female contact (1) includes a second cantilever arm (6b) bent from a wall into the female contact (1) at a mounting end opposite the mating end. The electrical connector of claim 3 or 4 wherein the female contact (1) includes a protrusion (7a) extending into the female contact (1) opposite the cantilever arm (6a). The electrical connector of claims 4 and 5 including a second protrusion (7b) extending into the female contact (1) opposite the second cantilever arm (6b). The electrical connector of any preceding claim wherein the housing (10) is secured to a main body housing (20) by the interaction of posts (21) with securing openings (13) formed on the housing (10). The electrical connector of claims 6 and 7 wherein a second mating contact (B) extends from the main body housing (20) into the female contact (1) to electrically engage the second protrusion (7b).

Inventors: ODA KENZO, SAGAWA TETSUYA, ODA, KENZO, SAGAWA, TETSUYA
Applicants: TYCO ELECTRONICS AMP KK, TYCO ELECTRONICS AMP K.K.
Application year: 2001
Main classification: H01R13
IPC codes: H01R13