Abstract:
An electrical connector assembly includes a housing having a chamber that retains a contact deflectable over a range of motion and a contact deflecting member. The chamber is configured to receive a wire and the contact is deflectable to make and break an electrical connection with the wire. The contact deflecting member is formed integrally with the housing and extends into the chamber. The contact deflection member is positioned to engage and deflect the contact to make and break the electrical connection with the wire.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention generally relates to an electrical connector, and more particularly to an electrical connector that may be used to carry high-voltage power signals.  
           [0002]    Electrical connectors are used to connect various forms of components and equipment. For example, some electrical connectors connect printed circuit boards to wires, which are used to convey power to appliances and utilities, such as lighting fixtures, ballasts and the like. Many appliances and utilities have high power demands. For example, many devices, such as lighting assemblies operate at very high voltage levels.  
           [0003]    Conventional connectors include a housing that retains a plurality of electrical contacts. Each electrical contact has a pin that is configured to be retained within a receptacle of a printed circuit board. Within the connector, the contacts are also connected to wires from one or more appliances or utilities. Power signals are transferred between the wire and the printed circuit board through the electrical connector.  
           [0004]    In many applications, it is desirable to have a wire release capable of repeatedly inserting and removing the wire from the connector. To afford the wire release, many connectors are configured to pinch or sandwich each individual wire between a corresponding contact and an interface wall of the connector housing. Certain connectors include contacts having a base portion secured in the housing and a contact tip that engages the wire. The base and contact tip of the contact are joined by a flexible portion that spring biases the contact tip toward the wire. The contact tip is deflected away from the electrical wire to remove the wire from the connector. However, if the contact tip is bent too far, the elasticity of the contact may be lost. When the contact elasticity is lost, the contact tip no longer returns to its original position and thus does not adequately pinch the wire against the wall of the connector once the wire is inserted. Thus, great care typically must be exercised when removing electrical wires from connectors to ensure that the contacts within the connector are not overly deflected in order to maintain the contact elasticity.  
           [0005]    Recently, connectors have been proposed that include a contact deflection member that limits the range over which the contact is deflected when inserting and releasing a wire. The contact deflection member may simply constitute a push button that is slidably held in the connector housing. A lower end of the push button engages the contact tip, while an opposite end of the push button is configured to be pressed by the user. When the user presses the button, the lower end of the button bends the contact tip away from the wire. The connector housing may include stop features that permit the button to slide over a limited range of motion within the connector housing, thereby similarly limiting the amount of contact deflection.  
           [0006]    However, the push button is a separate component that is individually inserted into a receptacle within the connector housing. Hence, separate and distinct molds and/or dies must be used to form the push button and the connector housing. Further, during assembly, each push button must be individually positioned within a corresponding receptacle in the connector housing. The separate molding and assembly steps unduly add cost and expense to the manufacturing process of the electrical connector.  
           [0007]    Thus, a need exists for an electrical connector that maintains proper elasticity of electrical contacts housed within the electrical connector. A need also exists for a more cost-effective and efficient electrical connector that utilizes a contact deflection member.  
         BRIEF SUMMARY OF THE INVENTION  
         [0008]    Embodiments of the present invention provide an electrical connector comprising a housing, contacts and contact deflecting members. The housing includes a plurality of chambers that retain an equal plurality of contacts. The chambers are configured to receive individual wires. The electrical contacts are deflectable to make and break electrical connections with the wires. The contact deflecting members are positioned proximate corresponding contacts and are configured to deflect the electrical contacts to break connections with corresponding wires. The contact deflecting members are disposed within channels formed in the housing and are integrally formed with the housing. Each contact deflecting member includes an end formed integrally with the housing through a hinge that pivotally joins the contact deflecting member to the housing. The electrical connector may also include an anti-overstress member provided in the chamber and positioned at an end of the range of motion of the contact to limit deflection of the contact. The range of motion may also be limited by an abutment of a contact end of the contact deflecting member and an interior wall of the housing. The electrical connector assembly may be a push button having an engagement surface extending from an exterior of the housing. The engagement surface is configured to receive a tool used to actuate the push button. The channel and the contact deflecting member are formed integrally with one another through a hinge that permits pivotal motion of the contact deflecting member laterally within the channel. The hinge is integrally formed with the contact deflecting member and the housing to enable pivotal motion of the contact deflecting member. 
       
    
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS  
       [0009]    [0009]FIG. 1 illustrates an isometric view of a fully-assembled electrical connector according to an embodiment of the present invention.  
         [0010]    [0010]FIG. 2 illustrates a transverse cross-sectional view of an electrical connector taken along line  2 - 2  in FIG. 1.  
         [0011]    [0011]FIG. 3 illustrates an isometric view of a fully-assembled electrical connector according to an alternative embodiment of the present invention.  
         [0012]    [0012]FIG. 4 illustrates an isometric partial interior view of an electrical connector showing a contact in an undeflected position according to an alternative embodiment of the present invention.  
         [0013]    [0013]FIG. 5 illustrates an isometric partial interior view of an electrical connector showing a contact in a deflected position according to an alternative embodiment of the present invention.  
         [0014]    [0014]FIG. 6 illustrates an isometric partial interior view of an integrally formed push button according to an alternative embodiment of the present invention.  
         [0015]    [0015]FIG. 7 illustrates an isometric partial interior view of an electrical connector showing a contact in an undeflected position according to a second alternative embodiment of the present invention.  
         [0016]    [0016]FIG. 8 illustrates an isometric partial interior view of an electrical connector showing a contact in a deflected position according to a second alternative embodiment of the present invention. 
     
    
       [0017]    The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentalities shown in the attached drawings.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0018]    [0018]FIG. 1 illustrates an isometric view of a fully-assembled electrical connector  10  according to an embodiment of the present invention. The electrical connector  10  includes a contact housing  12 . The contact housing  12  includes an open end (not shown) exposing contact chambers (not shown) that receive and retain electrical contacts. A bottom cover may pivotally open and close over the open end through an integrally formed hinge. The electrical contacts may be loaded into the contact chambers through the open end.  
         [0019]    The contact housing  12  has a plurality of wire troughs  14 , which are configured to support wires in a desired orientation with respect to the contact housing  12 , and contacts  16  (shown in greater detail, for example, with respect to FIG. 2) having circuit board engaging portions  18  extending downwardly from a bottom surface of the connector  10 . Each wire trough  14  includes lateral support walls  20  and a rear support wall  22  that may conform to the contours of a wire.  
         [0020]    The contacts  16  are further described with respect to U.S. application Ser. No. 10/197,161, entitled, “Anti-Overstress Electrical Connector,” filed Jul. 17, 2002, and listing Navin Patel and William Lenker as inventors (“the &#39;161 application). The &#39;161 application is incorporated by reference herein in its entirety.  
         [0021]    The electrical connector  10  also includes contact deflecting members, or push buttons  24 , retained within channels  26 . The push buttons  24  are integrally formed with the contact housing  12 .  
         [0022]    [0022]FIG. 2 illustrates a transverse cross-sectional view of the electrical connector  10  taken along line  2 - 2  in FIG. 1. A majority of each contact  16  is retained within an inner chamber  25  formed within the contact housing  12 . The electrical contact  16  includes a contact tip  27  formed integrally with a curved flex portion  29 , which is in turn joined with a base  31 . The base  31  is, in turn, joined to the circuit board engaging portion  18 , which extends downwardly from the contact housing  12 . As shown in FIG. 2, the contact tip  27  is proximate the push button  24 . The push button  24  may pivot into the inner chamber  25 , thereby engaging and deflecting the contact tip  27  of the contact  16  (as discussed below).  
         [0023]    Each push button  24  integrally connects with the contact housing  12  through a top surface  28  of the contact housing  12 , or within the channel  26 . The push button  24  is integrally formed with the contact housing  12 , for example the top surface  28 , as contiguous molded material. The push button  24  may integrally connect with the top surface  28  through an integral hinge  30 , which integrally connects the top surface  28  and the push button  24 .  
         [0024]    The push button  24  may be used with or without anti-overstress features. The push button  24  includes an engagement surface  32  integrally formed with a main body  34 . The main body  34  is, in turn, formed with a contact end  36  that is distally located from the engagement surface  32 . The contact end  36  is located proximate the contact tip  27  of the contact  16 . The contact end  36  includes a lower surface  40  sloped to abut against the contact  16  when the push button  24  is pressed in the direction of line A. The lower surface  40  includes an upper contact comer  42  and a lower contact comer  44 .  
         [0025]    The push button  24  is formed within the channel  26  that is defined by first and second interior walls  46  and  48  of the contact housing  12 . The push button  24  connects to the first interior wall  46  through the hinge  30  proximate the top surface  28 . The hinge  30  extends downwardly from the top surface  28  along the first interior wall  46  toward a termination point  50 . The termination point  50  may be anywhere along the first interior wall  46  provided that the hinge  30  allows the push button  24  to pivot sufficiently with respect to the first interior wall  46 , while ensuring that the hinge  30  does not break away from the first interior wall  46  when the push button  24  is depressed.  
         [0026]    In order to deflect the contact tip  27  of the electrical contact  16 , the engagement surface  32  of the push button  24  is pressed in the direction of line A. Because the push button  24  is integrally formed with the contact housing  12  at hinge  30 , the main body  34  of the push button  24  pivots toward the interior wall  46  along arc B. Consequently, the upper and lower contact comers  42  and  44  of the lower surface  40  move downward in the direction of line A, and toward the interior wall  46  in the direction of line C. The lower surface  40 , or at least one of the contact comers  42  and  44 , engages and deflects the contact tip  27  in the direction of arrow D. The range of deflection of the contact  16  may be limited by the range of motion of the push button  24 . The movement of the push button  24  in the direction of arc B stops when the contact end  36  of the push button  24  abuts the first interior wall  46 .  
         [0027]    An electrical wire  52  is positioned within the wire trough  14 . The wire trough  14  is in communication with the inner chamber  25  through a wire passage  54 . The electrical wire  52  includes a stripped conducting portion  56  that is inserted into the electrical connector  10  until it contacts and extends past the contact tip  27 . Once the electrical wire  52  is fully inserted into the electrical connector  10 , the stripped conducting portion  56  is pinched between the contact tip  27  and an interior wall  58  of the electrical connector  10 . Thus, an electrical path may be established between the electrical contact  16  and the electrical wire  52 .  
         [0028]    In order to release the electrical wire  52  from the electrical connector  10 , the contact tip  27  of the electrical contact  16  is deflected. As mentioned above, when the electrical wire  52  is in a fully engaged position within the electrical connector  10 , the electrical wire  52  is pinched between the electrical contact  16  and the interior wall  58  within the contact housing  12 . To disengage the wire  52 , the user presses downward on the engagement surface  32  in the direction of arrow A, thereby causing the push button  24  to pivot about hinge  30  along arc B. As the push button  24  pivots, it deflects the contact tip  27  of the contact  16  in the direction of arrow D. As the contact tip  27  deflects, it separates from the wire  52 , thereby permitting the wire  52  to be easily removed from the wire passage  54 .  
         [0029]    [0029]FIG. 3 illustrates an isometric view of a fully assembled electrical connector  60  according to an alternative embodiment of the present invention. The electrical connector  60  includes similar components to the embodiment described above. Like reference numerals are numbered the same as those described and shown with respect to FIGS.  1 - 2 . The electrical connector  60  includes a contact housing  62  having wire channels  64 , which are configured to support wires in a substantially vertical (or horizontal) orientation. Each wire channel  64  extends downwardly into the contact housing  62  from a top surface  66  of the contact housing  62 .  
         [0030]    The electrical connector  60  includes push buttons  68  retained within channels  70 . The push buttons  68  include an engagement surface  72  that includes a divot  74  formed between two peaks  76  and  78 . The engagement surface  72  is configured in this fashion so as to receive a tool, such as a screwdriver, which is used to actuate the push button  68 . A screw head may be securely received within the divot  74 .  
         [0031]    [0031]FIG. 4 illustrates an isometric partial interior view of the electrical connector  60  showing a contact  16  in an undeflected position. The push buttons  68  are integrally formed with the top surface  66  of the contact housing  62 , or at a position within the channel  70 , through a hinge  80 . Each push button  68  is integrally formed with the contact housing  62 . The push button  68  may be integrally formed within an electrical connector that may or may not include anti-overstress members  82 .  
         [0032]    [0032]FIG. 6 illustrates an isometric partial interior view of the integrally formed push button  68 . The engagement surface  72  is integrally formed with a main body  84  of the push button  68 . The main body  84  is joined with a contact end  86  that is distally located from the engagement surface  72 . The contact end  86  is located proximate the contact  16 . The contact end  86  includes a lower surface  88  that abuts the contact  16  when the push button  68  is pressed in the direction of line A. The lower surface  88  includes an upper edge  90  and a lower rounded projection  92 .  
         [0033]    The push button  68  is formed within a channel  70  that is defined by first and second interior walls  94  and  96  of the contact housing  62 . The push button  68  connects to the first interior wall  94  through the hinge  80  that is proximate the top surface  66 . The hinge  80  extends downwardly from the top surface  66  along the first interior wall  94  toward a termination point  98 . The termination point  98  may be anywhere along the first interior wall  94  provided that the hinge  80  allows the push button  68  to pivot with respect to the first interior wall  94 , while ensuring that the hinge  80  does not break away from the first interior wall  94  when the push button  68  is depressed.  
         [0034]    [0034]FIG. 5 illustrates an isometric partial interior view of the electrical connector  60  showing a contact  16  in a deflected position. In order to deflect the electrical contact  16 , the push button  68  is pressed in the direction of line A. Because the push button  68  is integrally formed with the contact housing  62  at the hinge  80 , the main body  84  of the push button  68  pivots toward the interior wall  94  along arc B. Consequently, the upper edge  90  and the lower rounded projection  92  moved downwardly in the direction of line A, and toward the interior wall  94  in the direction of line C. Consequently, the lower rounded projection  92  and/or the upper edge  90  engages and deflects the contact  16  in the direction of arrow D. The upper edge  90  and the lower rounded projection  92  may both be rounded to minimize the possibility of damage to the contact  16  caused by scratching and/or snagging the contact  16 . The range of deflection of the contact  16  is limited by the range of motion of the push button  68 . The movement of the push button  68  in the direction of arc B stops when the contact end  86  of the push button  86  abuts the first interior wall  94 .  
         [0035]    The anti-overstress members  82  form a shelf or ledge, which also limits the movement of the electrical contact  16  in the direction of D. The anti-overstress members  82  are positioned so that the electrical contact  16  is not pushed past the point in which the electrical contact  16  loses, or substantially loses, its original elasticity.  
         [0036]    [0036]FIGS. 7 and 8 illustrates an isometric partial interior view of an electrical connector  100  showing a contact in non-deflected and deflected positions, respectively, according to a second alternative embodiment of the present invention. The connector  100  includes a main housing  102  that houses a plurality of contacts  104  and integrally formed push buttons  106 . The push buttons  106  include a hinge  108  integrally formed with an outer lateral surface  110  of the housing  102 . The housing  102  is formed so that a contact end  112  of the push button  106  is disposed within, and passes through, a slot  114  formed through the top surface  116  of the housing  102 . The contact end  112  may slidably move through the slot  114 .  
         [0037]    The push button  106  also includes a ramped upper engagement surface  118  that is integrally formed with a lower motion limiting surface  119 . The motion limiting surface  117  is in turn integrally formed with the contact end  112 . The contact end  112  includes a protrusion  120 , which may operatively abut the contact  104 .  
         [0038]    As the upper engagement surface  118  is pushed downwardly in the direction E, or in the direction F, the movement of the engagement surface  118  is translated through the push button  106  into the contact end  112 . Similar to the embodiments described above, the push button  106  pivots relative to the housing  102  by way of the integrally formed hinge  108 . Thus, the hinge  108  remains attached to the housing  102  and the contact end  112  moves through the slot  114 . As the push button  106  moves toward the contact  104 , the protrusion  120  engages and deflects the contact  104 , thereby deflecting the contact  104 . The movement of the push button  106  is limited by the lower motion-limiting surface  119  contacting the top surface  116  of the housing  102 . That is, because the slot  114  is not wide enough to allow the lower motion-limiting surface  119  to pass through, the motion of the push button  106  toward the contact  104  is halted by the lower motion-limiting surface  119  contacting the top surface  116 . Thus, the range of motion that the contact  104  may move during deflection is limited by the interaction of the lower motion- limiting surface  119  and the top surface  116  of the housing  102 .  
         [0039]    Embodiments of the present invention may be used with a wide variety of electrical equipment. For example, embodiments of the present invention may be used in high-voltage applications such as connecting components of fluorescent lighting ballasts. Embodiments of the present invention provide a more cost-effective and efficient electrical connector that utilizes an integrally formed push buttons to deflect electrical contacts within the electrical connector. Because the push buttons are integrally formed, there is no need to separately mold and manufacture the push buttons. Also, because the push buttons are integrally formed, there are less component parts to assemble into the electrical connector during the manufacturing process, thereby saving time and labor.  
         [0040]    While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.