Abstract:
An electrical connector including a housing comprising at least two contact receiving areas and at least two contact terminals connected to the housing in the contact receiving areas. A first one of the contact terminals includes a combined housing latch and shorting member. The combined housing latch and shorting member is latched behind a portion of the housing to retain the first contact terminal to the housing. The combined housing latch and shorting member directly electrically contacts a second one of the contact terminals. The combined housing latch and shorting member is resiliently deflectable and adapted to be moved by a portion of a mating electrical connector to electrically disconnect from the second contact terminal and still be retained latched behind the portion of the housing.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This is a continuation-in-part patent application of U.S. patent application Ser. No. 11/395,694 filed Mar. 31, 2006, which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to an electrical terminal and, more particularly, to an electrical terminal having an anti-snag feature. 
         [0004]    2. Brief Description of Prior Developments 
         [0005]    U.S. Pat. Nos. 6,247,975 and 6,056,604, which are hereby incorporated by reference in their entireties, disclose multi-piece electrical receptacle terminals. Springs are provided to mechanically and electrically connect a male contact or blade terminal from a mating electrical connector in the receptacle terminals. These types of terminals are used in electrical connector housings which have plastic connector primary lock fingers to lock the terminals inside the housings. However, terminals with primary lock tangs are more space efficient than terminals that require housings with plastic connector primary lock fingers. 
         [0006]    A problem exists with terminals that have primary lock tangs in that they typically cannot pass through a mat wire seal of the electrical connector without cutting or tearing the seal. There is a desire to provide an anti-snag feature in a terminal with a primary lock tang that will allow the terminal to be installed and removed through a mat seal without cutting or tearing, and will also not interfere with the primary lock function of the tang. 
       SUMMARY OF THE INVENTION 
       [0007]    In accordance with one aspect of the present invention, an electrical connector is provided including a housing comprising at least two contact receiving areas and at least two contact terminals connected to the housing in the contact receiving areas. A first one of the contact terminals includes a combined housing latch and shorting member. The combined housing latch and shorting member is latched behind a portion of the housing to retain the first contact terminal to the housing. The combined housing latch and shorting member directly electrically contacts a second one of the contact terminals. The combined housing latch and shorting member is resiliently deflectable and adapted to be moved by a portion of a mating electrical connector to electrically disconnect from the second contact terminal and still be retained latched behind the portion of the housing. 
         [0008]    In accordance with another aspect of the invention, an electrical terminal is provided comprising a conductor connection section; a mating terminal connection section connected to the conductor connection section; a deflectable latch proximate the mating terminal connection section; and a deflectable anti-snag ramp located generally behind the deflectable latch. The electrical terminal is a two-piece terminal comprising a first piece forming the conductor connection section and the mating terminal connection section, and a second piece connected over the mating terminal connection section comprising the deflectable latch and the deflectable anti-snag ramp. 
         [0009]    In accordance with another aspect of the invention, a method of forming an electrical contact terminal is provided comprising forming a conductor connection section; forming a mating terminal connection section connected to the conductor connection section, wherein the mating terminal connection section comprises deflectable contact arms forming a female receiving area; forming a deflectable latch proximate the mating terminal connection section; and forming a deflectable anti-snag ramp located generally behind the deflectable latch. The electrical contact terminal is a two-piece terminal comprising a first piece forming the conductor connection section and the mating terminal connection section, and a second piece connected to the first piece over the mating terminal connection section. The second piece comprises the deflectable latch and the deflectable anti-snag ramp. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein: 
           [0011]      FIG. 1  is an exploded perspective view of an electrical connection system; 
           [0012]      FIG. 2  is a cross sectional view of one of the electrical connectors shown in  FIG. 1 , but without showing the terminals; 
           [0013]      FIG. 3  is a perspective view of one of the terminals used in the connector shown in  FIG. 2 ; 
           [0014]      FIG. 4  is a perspective view of the terminals shown in  FIG. 3  from another direction; 
           [0015]      FIG. 5  is a cross sectional view of the terminal shown in  FIGS. 3-4 ; 
           [0016]      FIG. 6  is a partial cross sectional view showing insertion of one of the terminals into the housing; 
           [0017]      FIG. 7  is a partial cross sectional view showing one of the terminals in a fully inserted position in the housing; 
           [0018]      FIG. 8  is a partial cross sectional view showing removal of one of the terminals from the housing; 
           [0019]      FIG. 9  is a cross sectional view similar to  FIG. 7  showing two of the contact terminals mounted in an alternate housing of an electrical connector; 
           [0020]      FIG. 10  is a cross sectional view as in  FIG. 9  showing partial connection of the electrical connector to a mating electrical connector; 
           [0021]      FIG. 11  is a cross sectional view as in  FIG. 10  showing full connection of the electrical connector to the mating electrical connector; 
           [0022]      FIG. 12  is a perspective view of an alternate embodiment of a contact terminal incorporating features of the invention; 
           [0023]      FIG. 13  is a perspective view of the contact terminal shown in  FIG. 12  from another direction; 
           [0024]      FIG. 14  is an exploded perspective view of the contact terminal shown in  FIGS. 12-13 ; and 
           [0025]      FIG. 15  is an exploded perspective view of the contact terminal shown in  FIG. 14  from another direction. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0026]    Referring to  FIG. 1 , there is shown an exploded perspective view of an electrical connection system  10  for electrically connecting two groups  12 ,  14  of electrical conductors to each other. The electrical connection system  10  comprises a first electrical connector  16  incorporating features of the invention. Although the invention will be described with reference to the exemplary embodiments shown in the drawings, it should be understood that the invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used. 
         [0027]    The first electrical connector  16  is connected to the first group  12  of electrical conductors  13 . The mating second electrical connector  18  is connected to the second group  14  of electrical conductors. The first electrical connector  16  comprises a housing  20  and electrical contacts  22  located inside the housing  20 . The housing  20  has receiving areas  24  in its front face for receiving male contacts  26  of the second electrical connector  18 . The housing  20  also comprises the receiving area  28  for receiving the front end of the housing  30  of the second electrical connector  18 . The receiving area  28  comprises slots  32  for receiving polarizing ribs  34  of the second electrical connector  18 . The housing  20  also comprises a latch  36  which extends into the receiving area  28 . The latch  36  is adapted to snap lock latch with the latch protrusion  38  of the housing  30  of the second electrical connector  18 . 
         [0028]    Referring also to  FIG. 2 , a cross sectional view of the first electrical connector  16  is shown, but without the electrical terminals  22  and the electrical conductors  13  merely for the sake of clarity.  FIGS. 3 and 4  show perspective views of one of the terminals  22 . The electrical connector  16  comprises a housing  20 , 
         [0029]    The housing  20  comprises a main housing member  46  and a seal retainer  48 . The seal retainer  48  is fixedly connected to the rear end of the main housing member  46 , such as by a snap lock connection, to capture a mat wire seal  50  between the seal retainer  48  and the main housing member  46 . The seal  50  is preferably a flexible, resiliently deformable rubber or polymer member which provides a seal with the electrical conductors  13 . The seal has multiple holes  51  for individual ones of the conductors  13  to pass through. The electrical connector  16  also comprises a second seal  52  adapted to engage the housing  30  of the second electrical conductor  18  in the receiving area  28  of the main housing member  46 . A front seal retainer  53  is attached to the front of the main housing member  46  to retain the front seal  52  on the main housing member  46 . 
         [0030]    The main housing member  46  comprises contact receiving areas  56 . The electrical contacts  22  are located in the contact receiving areas  56 . The front end of the main housing member  46  comprises apertures  58  into the contact receiving areas  56 . The apertures  58  are adapted to allow insertion of the male contacts  26  into the contact receiving areas  56  and into mating electrical connection with the electrical contacts  22 . The electrical conductors  13  are adapted to extend through apertures  60  of the seal retainer  48  and into the contact receiving areas  56  where they are connected to the electrical contacts  22 . The seal  50  is adapted to seal the rear end of the contact receiving areas  56  at the rear end of the main housing member  46  where the electrical conductors  13  pass into the rear end of the main housing member  46 . 
         [0031]    The main housing member  46  comprises a mating electrical connector latch  62 . When the electrical connector  16  is- connected to the second electrical connector  18 , the latch  62  is adapted to removably latch with the latch protrusion  38  of the second electrical connector  18 . The latch  62  is described in U.S. patent application Ser. No. 10/806,731 which is hereby incorporated by reference in its entirety. However, in alternate embodiments any suitable mating connector latching system could be provided. 
         [0032]    The electrical terminals or contacts  22  comprise contacts which are coupled to the electrical conductors  13  in the first group  12  of electrical conductors. The electrical contacts  22  comprise female contact sections adapted to receive the male contacts  26  of the second electrical connector  18 . Referring to  FIGS. 3-5 , the electrical terminals  22  generally comprise a main member or frame  64  and a spring member  66 . The main member  64  is a one piece metal member which is cut and formed into the shape shown. The main member  64  comprises a conductor connection section  68 , a mating terminal connection section  70 , a latch  72  and an anti-snag feature  74 . The conductor connection section  68  is for connecting the terminal  22  to one of the wires  13 . The conductor connection section  68  comprises insulation grip members  76  and conductor grip members  78 . However, in alternate embodiments any suitable configuration for attaching the terminal  22  to one of the wires  13  could be provided. 
         [0033]    The mating terminal connection section  70  has the spring member  66  connected inside of it. The mating terminal connection section  70  forms a female connection section which is adapted to receive one of the contacts  26  of the mating connector  18  and clamp the contact  26  between the spring contact member  66  and the fixed contact surface  77 . The terminal connection section  70  has a general box shape with side holes  79  which form shelves  80  for movably capturing lateral sides the spring contact member  66 . A top side also has a downward projection  82  which forms an overstress protection feature for the spring contact member  66 . A secondary lock surface  81  is also provided at the rear of the female connection section. An orientation feature  87  is also provided on the terminal for orientating the terminal in the housing  20 . In alternate embodiments any suitably shaped mating terminal connection section, including perhaps a male connection section. 
         [0034]    The latch  72  is a flexible primary lock for latching the terminal  22  with the housing  20  inside one of the contact receiving areas  56 . The latch  72  extends rearward from the front end of the mating terminal connection section  70  as a general resiliently deflectable cantilevered arm. The end  83  of the arm forms a latching surface  84  to snap-lock latch with a portion of the housing  20 . The top side of the latch  72  forms a forward facing ramp surface  85 . 
         [0035]    The anti-snag feature  74  comprises two resiliently deflectable cantilevered arms  86  which extend forward from a rear end of the mating terminal connection section  70 . The front end of the arms  86  have pocket areas  88  which receive the end  83  of the latch  72 . Distal tips  90  of the arms  86  are located beneath the end  83  of the latch  72 . However, in an alternate embodiment the distal tip of the arms might not be provided beneath the latch  72 . A top side of the arms  86  extend above the top side of the surface  84  when the arms  86  are not deflected. Alternatively, the top sides of the arms  86  could be at the same height as the top of the surface  84  when the arms  86  are not deflected. The top sides of the arms  86  form rearward facing ramp surfaces  92 . 
         [0036]    Referring also to  FIG. 6 , one of the terminals  22  is shown being inserted through the rear end of the connector housing  20  into one of the contact receiving areas  56  as indicated by arrow  94 . The main housing member  46  causes the latch  72  to deflect inward. The anti-snag feature  74  is also deflected inward; first by contact with the end  83  of the latch  72  and then by direct contact with the main housing member  46 . The seal  50  is resiliently deformed during this insertion of the terminal into the connector housing with the ramp surface  85  helping to prevent snagging of the anti-snag feature  74  on the seal  50  during insertion. 
         [0037]    Referring also to  FIG. 7 , with further insertion of the terminal  22  into the housing, the terminal reaches its fully inserted position inside the receiving area  56 . The main housing member  46  has a snap-lock recess  96  for each contact receiving area  56 . When the terminal reaches its fully inserted position, the latch  72  can deflect back to its outward position. This results in the surface  84  being located in the recess  96  in front of the latching surface or shelf  98 . The primary lock provided by the latch  72  snaps over the shelf in the connector cavity, thus, providing retention while the snag-resistant feature remains deflected. The two surfaces  84 ,  98  cooperate to prevent unintentional withdrawal of the terminal from the receiving area  56  reverse to direction  94 . The anti-snag feature  74  can remain deflected inward at the fully inserted position. Thus, the anti-snag feature does not interfere with the operation of the latch  72 . 
         [0038]    Referring also to  FIG. 8 , the terminal  22  can be removed from the housing  20  with the aid of a servicing tool  100 . The tool  100  can be inserted through the front of the housing  20  into the recess  96 . The front of the tool  100  contacts the ramp surface  85  of the latch  72  and deflects the latch inward. This moves the latch surfaces  84 ,  98  apart to allow the terminal  22  to be pulled rearward as indicated by arrow  102 . Referring back to  FIG. 6 , as the terminal  22  is pulled rearward the ramp surface  92  on the arms  86  can resiliently deform the seal  50  and prevent the latching surface  84  from snagging on the seal  50 . This prevents the latching surface  84  from cutting or tearing the seal  50  as the terminal  22  is being withdrawn through the seal  50 . 
         [0039]    With the invention, the primary lock  72  and the anti-snag lock  74  can be separate and flexible. When the contact  22  is inserted in the housing  20  through the mat seal, the primary lock  72  and the anti-snag lock  74  are pressed down. Once the primary lock  74  clears the inner wall of the housing cavity, it snaps upward adjacent to a shelf to prevent the contact terminal from being pulled backward out of the housing. The flexible lock beams or arms  86  are located on the terminal, and have free ends that extend in a direction opposite to the direction of insertion into the housing cavity. In an alternate embodiment, more or less than two arms  86  could be provided. In another alternate embodiment, the spring contact member  66  could be formed from the terminal body  64  (i.e., integral with the terminal body) rather than a separate member captured inside the terminal body as shown in the drawings. 
         [0040]    Referring also to  FIGS. 9-11 , two of the electrical contact terminals  22  are shown connected to an alternate housing  110  to form an electrical connector  108 .  FIG. 9  shows the electrical connector  108  before connection to a mating electrical connector  112 . The housing  110  comprises contact receiving areas  56 . The electrical contacts  22  are located in the contact receiving areas  56 . The front end of the housing  110  comprises apertures  58  into the contact receiving areas  56 . The apertures  58  are adapted to allow insertion of the male contacts  26  into the contact receiving areas  56  and into mating electrical connection with the electrical contacts  22 . 
         [0041]    As shown in  FIG. 9 , the housing  110  has a snap-lock recess  114  which is open to two of the contact receiving areas  56 . When the terminals  22  are inserted into the receiving areas  56  and reach their fully inserted positions, the latches  72  can deflect back to their outward positions. This results in the surface  84  of both latches being located in the recess  114  in front of the latching surface or shelf  116 . The primary lock provided by the latch  72  snaps over the shelf in the connector cavity, thus, providing retention while the snag-resistant feature  74  remains deflected. The surfaces  84 ,  116  cooperate to prevent unintentional withdrawal of the terminals  22  from the receiving areas  56 . The anti-snag feature  74  can remain deflected inward at the fully inserted position. 
         [0042]    The recess  114  and latches  72  are sized and shaped to allow the latches  72  to directly contact each other. This electrically connects the two terminals  22  to each other before connection of the electrical connector  108  to the mating electrical connector  112 . Thus, the latches  72  each form a combined housing latch and shorting member. As seen in  FIGS. 10 and 11 , when the mating electrical connector  112  is connected to the electrical connector  108 , a portion  118  of the housing of the mating electrical connector  112  is inserted between the two latches  72  and deflects the latches  72  apart. Thus, when the mating electrical connector  112  is connected to the electrical connector  108 , the shorting contact provided by the latches  72  is automatically disconnected. 
         [0043]    Referring also to  FIGS. 12-15 , an alternate embodiment of an electrical contact terminal  120  is shown temporarily connected to a carry strip  124 . The terminal is similar to the terminal  22 . The terminal  120  comprises a female contact section adapted to receive the male contacts  26  of the second electrical connector  18 ,  112 . The terminal  120  is a two-piece terminal comprising a first piece  126  and a second piece  128 . The electrical terminal  120  generally comprises a conductor connection section  68 , a mating terminal connection section  122 , a latch  72  and an anti-snag feature  74 . The first piece  126  comprises the conductor connection section  68  and the mating terminal connection section  122 . The second piece  128  comprises the latch  72  and the anti-snag feature  74 . 
         [0044]    The conductor connection section  68  is for connecting the terminal  120  to one of the wires  13 . The mating terminal connection section  122  forms part of the female connection section which is adapted to receive one of the contacts  26  of the mating connector  18 ,  112 . In this embodiment, as seen best in  FIGS. 14 and 15 , the mating terminal connection section  122  has top and bottom inwardly projecting connecting arms  130  which connect to a front section  132 , and two rearward extending, cantilevered lateral side contact arms  134 . The second piece  128  fits over the mating terminal connection section  122  and is crimped onto the mating terminal connection section  122  by crimped connection  136  at the rear of the second section  128 . In alternate embodiments, any suitable type of connection of the two pieces to each other could be provided. Alternatively, the contact terminal could be a one-piece member, or comprise more than two members. In one type of embodiment, the two pieces  126 ,  128  could be comprised of different materials. In the embodiment shown the front of the second piece  128  has forward, inward projecting guides  138 . The guides  138  help guide the male contact  26  into the receiving area formed by the arms  130 ,  134 . The guides  138  could also interact with the housing to center the contact terminal relative to the apertures  58 . [ 0043 ] As seen in  FIGS. 12 and 13 , the latch  72  is a flexible primary lock for latching the terminal  120  with the housing  20  or  110  inside one of the contact receiving areas  56 . The latch  72  extends rearward from the front end of the second piece  128  as a general resiliently deflectable cantilevered arm. The end  83  of the arm forms a latching surface  84  to snap-lock latch with a portion  98  or  116  of the housing  20  or  110 . The top side of the latch  72  forms a forward facing ramp surface  85 . 
         [0045]    The anti-snag feature  74  comprises two resiliently deflectable cantilevered arms  86  which extend forward from a rear end of the second piece  128 . The front end of the arms  86  have pocket areas which receive the end  83  of the latch  72 . Distal tips of the arms  86  are located beneath the end  83  of the latch  72 . However, in an alternate embodiment the distal tip of the arms might not be provided beneath the latch  72 . A top side of the arms  86  extend above the top side of the surface  84  when the arms  86  are not deflected. Alternatively, the top sides of the arms  86  could be at the same height as the top of the surface  84  when the arms  86  are not deflected. The top sides of the arms  86  form rearward facing ramp surfaces  92 . 
         [0046]    When the terminal  120  is inserted into the housing,  20  or  112  for example, the housing causes the latch  72  to deflect inward. The anti-snag feature  74  is also deflected inward; first by contact with the end  83  of the latch  72  and then by direct contact with the housing. With further insertion of the terminal  120  into the housing, the terminal reaches its fully inserted position inside the receiving area  56  and the latch  72  can deflect back to its outward position. This results in the surface  84  being located in front of the latching surface or shelf  98  or  116 . The primary lock provided by the latch  72  snaps over the shelf in the connector cavity, thus, providing retention while the snag-resistant feature remains deflected. The two surfaces  84 ,  98  or  116  cooperate to prevent unintentional withdrawal of the terminal from the receiving area  56  reverse to the direction of insertion. The anti-snag feature  74  can remain deflected inward at the fully inserted position. Thus, the anti-snag feature does not interfere with the operation of the latch  72 . 
         [0047]    Similar to that shown in  FIG. 8 , the terminal  120  can be removed from the housing  20  or  110  with the aid of the servicing tool  100 . The tool  100  can be inserted through the front of the housing into the recess  96 . The front of the tool  100  contacts the ramp surface  85  of the latch  72  and deflects the latch inward. This moves the latch surfaces  84 ,  98  or  116  apart to allow the terminal  120  to be pulled rearward and out of the housing. As the terminal  120  is pulled rearward, the ramp surface  92  on the arms  86  can resiliently deform the seal  50  and prevent the latching surface  84  from snagging on the seal  50 . This prevents the latching surface  84  from cutting or tearing the seal  50  as the terminal  120  is being withdrawn through the seal  50 . 
         [0048]    It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.