Patent Publication Number: US-7909667-B1

Title: Crimp contacts and electrical connector assemblies including the same

Description:
BACKGROUND OF THE INVENTION 
     The subject matter herein relates generally to electrical contacts and, more specifically, to crimp contacts that are compressed to grip one or more conductors and establish an electrical connection. 
     Conventional crimp contacts include a mating end that electrically engages a mating contact (e.g., socket or pin contact) and a loading end that includes a passage configured to receive one or more conductors (e.g., a stripped cable wire). Using a crimping tool, the crimp contact may be compressed or deformed at the loading end thereby causing the crimp contact to grip the conductors within the conductor passage. The deformed crimp contact (or crimped contact) may then be inserted into a contact cavity of a connector housing where the crimped contact is positioned to engage the mating contact from another connector. 
     Dimensions of crimp contacts may be set by industry or customer-specified requirements. For example, an outer diameter of the crimp contact may be sized so that a crimping tool may engage the crimp contact and compress the crimp contact in a predetermined manner. An inner diameter that defines the conductor passage may be sized to effectively engage the conductors when the crimp contact is deformed. In order to satisfy the industry or customer-specified dimensions, crimp contacts are typically machined. For example, a conductive material in the form of a block or rod may be machined (e.g., by a screw machine) to form the conductor passage of the crimp contact as well as other features. Such crimp contacts may be called screw-machine contacts. However, these manufacturing methods may be costly to perform and the removed conductive material is no longer usable. 
     In addition, in some electrical connector assemblies, it may be desirable to have a plurality of crimp contacts where at least some of the crimp contacts project different distances from a side of the connector housing. By projecting different distances from the side of the connector housing, a user may control an order or sequence in which the crimp contacts electrically engage the corresponding mating contacts. To provide crimp contacts that project various distances away from the connector housing, the above machining methods may be adjusted to form crimp contacts of different lengths. Again, such manufacturing methods may be costly to operate and waste the conductive material. Changing a manufacturing process to adjust the final dimensions of the crimp contacts may further increase the overall costs. 
     Accordingly, there is a need for crimp contacts that may be manufactured in a less costly manner than some known processes for manufacturing crimp contacts. There is also a general need from alternative crimp contacts than those currently available today. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one embodiment, a crimp contact is provided that includes an elongated contact body having loading and mating ends and a central axis extending therebetween. The contact body includes a contact wall that extends around the central axis and that defines a conductor-receiving passage of the contact body proximate to the loading end. The contact wall has an outer surface. The crimp contact also includes a sleeve wall that extends around the central axis and the outer surface of the contact wall proximate to the loading end of the contact body. The sleeve wall is sized to engage a crimping tool and the contact wall is configured to grip a conductor within the conductor-receiving passage when the sleeve and contact walls are deformed by the crimping tool. 
     In another embodiment, an electrical connector assembly is provided that includes a connector housing having opposite mounting and mating sides. The connector housing includes a contact cavity that extends axially through the connector housing. The contact cavity is defined by an interior surface of the connector housing. The connector assembly also includes a crimp contact that has loading and mating ends and a central axis extending therebetween. The crimp contact is held within the contact cavity and is coupled to the interior surface. The crimp contact includes an elongated contact body comprising a contact wall. The contact wall extends around the central axis and defines a conductor-receiving passage of the contact body proximate to the loading end. The contact wall has an outer surface. The crimp contact also includes a sleeve wall that extends around the central axis and the outer surface of the contact wall proximate to the loading end of the contact body. The sleeve wall is sized to engage a crimping tool and the contact wall is configured to grip a conductor within the conductor-receiving passage when the sleeve and contact walls are deformed by the crimping tool. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of an electrical system formed in accordance with one embodiment. 
         FIG. 2  is a plan view of a contact sheet of material that may be formed into a crimp contact in accordance with one embodiment. 
         FIG. 3  is a perspective view of a crimp contact formed in accordance with one embodiment. 
         FIG. 4  is a side view of the crimp contact of  FIG. 3 . 
         FIG. 5  is a cross-sectional view of the crimp contact of  FIG. 3 . 
         FIG. 6  is a perspective view of a crimp contact formed in accordance with another embodiment that includes a sleeve member. 
         FIG. 7  is a cross-sectional view of the crimp contact of  FIG. 6 . 
         FIG. 8  is an end view of the sleeve member that may be used by the crimp contact of  FIG. 6 . 
         FIG. 9  is a cross-sectional view of an electrical connector assembly formed in accordance with another embodiment that includes a plurality of crimp contacts having sleeve members. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is an exploded perspective view of an electrical system  100  that includes an electrical connector assembly  102  that is formed in accordance with one embodiment. The connector assembly  102  is configured to be mounted to a support structure  104  of the electrical system  100 . In the illustrated embodiment, the support structure  104  includes a circuit board. However, in alternative embodiments, the support structure  104  may include a panel or other structural support that is capable of having the connector assembly  102  mounted thereto. The connector assembly  102  may be configured to communicatively engage or mate with a mating connector (not shown). For example, the connector assembly  102  may be used in pluggable wire-to-board applications and may be configured to transmit electrical data signals and power. 
     The connector assembly  102  includes a connector housing  106  comprising an insulative material and electrical contacts  108 - 110  that are held by the connector housing  106 . As shown, the connector assembly  102  is oriented with respect to mutually perpendicular axes  190 - 192  (also referred to as a longitudinal axis  190  and lateral axes  191  and  192 ). The connector housing  106  includes opposite mounting and mating sides  112  and  114 . The mounting side  112  is configured to be mounted to the support structure  104 , and the mating side  114  is configured to engage the mating connector. The connector housing  106  is configured to hold the electrical contacts  108 - 110  in predetermined orientations so that the electrical contacts  108 - 110  may electrically engage corresponding mating contacts (not shown) of the mating connector. For example, the connector housing  106  may include contact cavities  118 - 120  that extend axially through the connector housing  106  (e.g., in a direction along the longitudinal axis  190 ). The contact cavities  118 - 120  may be shaped to hold the electrical contacts  108 - 110  in the predetermined orientations. The connector assembly  102  may also include other features, such as guide pins  116 , which may facilitate engaging the mating connector. 
     The electrical contacts  108 - 110  are configured to electrically connect with corresponding conductors  128 - 130 , respectively. The conductors  128 - 130  may be single conductors or a plurality of conductors that are, for example, grouped together within a cable. Before the electrical contacts  108 - 110  are disposed within the corresponding contact cavities  118 - 120 , the electrical contacts  108 - 110  may be electrically coupled or connected to the respective conductors  128 - 130 . By way of example only, the electrical contact  108  may be a solder-type contact in which a loading end of the electrical contact  108  is soldered to the conductor  128 . The electrical contacts  109  and  110  may be crimp-type contacts in which corresponding conductor-receiving passages of the electrical contacts  109  and  110  receive the conductors  129  and  130 . After interconnecting the conductors  128 - 130  to the corresponding electrical contacts  108 - 110 , the electrical contacts  108 - 110  may be inserted into the respective contact cavities  118 - 120 . In alternative embodiments, the electrical contacts  108 - 110  may be positioned within the respective contact cavities  118 - 120  before the conductors  118 - 120  are electrically connected. The electrical contacts  108 - 110  may couple to the connector housing  106  so that the electrical contacts  108 - 110  are held in fixed positions with respect to the connector housing  106 . For example, the connector housing  106  may have various elements or features that form an interference fit with the electrical contacts  108 - 110 . 
     Embodiments described herein include crimp contacts, such as the electrical contacts  109  and  110 , which are configured to electrically engage corresponding conductors at loading ends of the crimp contacts. Embodiments also include electrical connector assemblies that include such crimp contacts. The crimp contacts may include a plurality of layers or walls that extend around a central axis and form an interface between each other. The walls (or layers) may form a crimp portion of the crimp contact that receives a conductor. The walls may have predetermined dimensions. The crimp portion is configured to be compressed or deformed radially inward by a crimping tool so that one of the walls grips the conductors. In some embodiments, the walls may be formed from a continuous sheet of material. The continuous sheet of material may be folded along a wall joint or somehow shaped to form the crimp portion of the crimp contact. In other embodiments, the walls may be separate components. For example, a separate jacket or sleeve member may be mounted to a loading end of a contact body. 
       FIG. 2  is a plan view of a contact sheet of material  200  that may be shaped to form a crimp contact  202  (shown in  FIG. 3 ). The contact sheet  200  is oriented with respect to a longitudinal sheet axis  290  and a lateral sheet axis  292 . The contact sheet  200  has a sheet length L 1  and a sheet width W 1 . As shown, the contact sheet  200  may include a plurality of sheet sections  211 - 214  that are defined between side edges  215 - 218 . The sheet sections  211 - 214  may be coupled to each other in a series and arranged side-by-side along the longitudinal sheet axis  290  between opposite side edges  215  and  217 . The contact sheet  200  may comprise one or more materials. In the illustrate embodiment, the contact sheet  200  comprises a solid material that is malleable or capable of being formed (e.g., through rolling, bending, folding, and the like) into a predetermined shape. As shown, the sheet sections  211 - 214  may have section borders  207 - 209  that indicate where the contact sheet  200  is folded, bent, rolled, or somehow shaped. The section borders  207 - 209  may also be referenced as fold lines or areas. 
     In the illustrated embodiment, the contact sheet  200  is a continuous structure such that the sheet sections  211 - 214  are not separate parts. For example, the contact sheet  200  may be stamped from a larger sheet of material. The larger sheet of material may comprise one type of solid material such that the contact sheet  200  is a common solid material throughout. In some embodiments, the contact sheet  200  is stamped from a sheet of a solid material that is malleable and electrically conductive. By way of example only, the material may be a copper alloy plated with silver or gold. A sheet, of material is not required to have only one type of material. For example, the plurality of sheet sections  211 - 214  may comprise two or more different solid materials that are bonded together (e.g., through an adhesive, soldering, welding, or mechanical means) along the section borders  207 - 209 . As another example, the contact sheet  200  may be manufactured so that the material has different properties in different areas or regions. For example, a resin injected into a mold may have magnetic particles that are attracted to a predetermined area or region of the contact sheet  200 . As another example, the contact sheet  200  may be plated. 
     Also shown, the contact sheet  200  may have opposite plan surfaces  204  and  206  where a thickness T 1  (shown in  FIG. 5 ) of the contact sheet  200  extends therebetween. In the illustrated embodiment, the thickness T 1  may be substantially uniform between the side edges  215 - 218 . In alternative embodiments, the thickness T 1  may be different at different portions of the contact sheet  200 . For example, the sheet section  214  may have a thickness that is different from a thickness of the sheet section  213 . Furthermore, the plan surfaces  204  and  206  may be modified in predetermined areas. For example, the plan surfaces  204  and  206  may have a chemical substance (e.g., adhesive) deposited thereon or may be machined or etched to have predetermined surface properties. 
     As shown in  FIG. 2 , the side edges  215 - 218  may have predetermined elements or features that facilitate forming the contact sheet  200  into the crimp contact  202  ( FIG. 3 ). For example, the side edge  216  may have coupling projections  222  that project away from the contact sheet  200  in a direction along the lateral sheet axis  292 . The side edge  218  may have corresponding coupling recesses  224  that project into the contact sheet  200 . The coupling recesses  224  may be cut-outs that occur when the contact sheet  200  is stamped from a larger sheet of material. The coupling projections and recesses  222  and  224  may be shaped relative to each other so that the corresponding coupling projections and recesses  222  and  224  interlock with each other. The coupling projections and recesses  222  and  224  may form an interference fit when the contact sheet  200  is shaped. In the illustrated embodiment, the coupling projections  222  have a dovetail-like shape; however, the coupling projections and recesses  222  and  224  may have other shapes. Also shown in  FIG. 2 , the contact sheet  200  may have locking projections  226  that project away from the side edge  215  in a direction along the longitudinal sheet axis  290 . 
     The sheet sections  211 - 214  may have predetermined sizes, dimensions, and shapes for forming the crimp contact  202 . For example, the sheet sections  213  and  214  may have axial lengths L 2  and L 3 . The axial lengths L 2  and L 3  may be substantially equal. Moreover, the coupling projections  222  of the sheet sections  213  and  214  may be located along the corresponding side edge  216  so that, when the contact sheet  200  is folded over the section border  209 , the coupling projections  222  substantially overlap each other. Likewise, the coupling recesses  224  of the sheet sections  213  and  214  may be located along the corresponding side edge  218  so that, when the contact sheet  200  is folded over the section border  209 , the coupling recesses  224  substantially overlap each other. In alternative embodiments, at least one of the sheet sections  213  and  214  does not include coupling projections  222  or coupling recesses  222  and  224 . Furthermore, in other embodiments, each side edge  216  and  218  may include at least one coupling projection and at least one coupling recess. 
     Also shown, the sheet sections  211 ,  213 , and  214  may have respective widths W 2 , W 3 , and W 4 . The width W 4  may be greater than the width W 3 , which may be greater than the width W 2 . A width W 5  of the sheet section  212  may gradually increase or decrease as the sheet section  212  extends along the longitudinal sheet axis  290  between the side edges  215  and  217 . When the contact sheet  200  is shaped, the different widths W 2 , W 3 , and W 4  may account for circumferences or perimeters of different portions of the crimp contact  202 . Also shown, the sheet section  211  can have tabs  274  that are capable of being partially folded or flexed. 
     The contact sheet  200  may be shaped to form the crimp contact  202  ( FIG. 3 ). In the illustrated embodiment, the sheet section  214  may be folded onto the sheet section  213  at the section border  209  such that the plan surface  206  is folded onto itself (i.e., the plan surface  206  of the sheet section  214  interfaces with the plan surface  206  of the sheet section  213 ). The section border  209  may become a wall joint  236  as shown in  FIG. 3 . The sheet sections  211  and  212  may be bent or folded with respect to each other at the section border  207  such that the sheet sections  211  and  212  form a non-orthogonal angle. Similarly, the sheet sections  212  and  213  may be bent or folded at the section border  208  to form another non-orthogonal angle. The sheet sections  211  and  213  may extend substantially parallel with each other and joined by the sheet section  212 . In such embodiments, the sheet section  212  would extend into the page as shown in  FIG. 2  at the non-orthogonal angle with respect to the sheet section  211 . 
     Before or after bending the sheet sections  211 - 213 , the locking projections  226  may be shaped to project away from the sheet section  214 . The contact sheet  200  may then be rolled about an axis (e.g., a central axis  234  shown in  FIG. 3 ) to have a curved contour. The contact sheet  200  may be rolled to have a circular cross-section. However, in alternative embodiments, the crimp contact  202  may have other geometrically shaped cross-sections (e.g., square, rectangular, or a partially curved and partially planar cross-section). When the contact sheet  200  is shaped about the central axis  234 , the coupling projections and recesses  222  and  224  may interlock with each other so that the contact sheet  200  is retained in the predetermined shape. The side edges  216  and  218  may directly abut each other along an interface  231  (shown in  FIGS. 3 and 4 ). 
       FIGS. 3-5  illustrate the crimp contact  202  formed in accordance with one embodiment. The crimp contact  202  may have an elongated contact body  228  that includes a loading end  230 , a mating end  232 , and a central axis  234  extending therebetween. The crimp contact  202  may be formed as described above by shaping the contact sheet  200  ( FIG. 2 ). Alternatively, the crimp contact  202  may be formed in other manners. For example, the crimp contact  202  may be partially shaped from a sheet of material and partially machined. As shown, the crimp contact  202  includes a contact wall  240  that extends around the central axis  234  and defines a conductor-receiving passage  242  ( FIGS. 3 and 5 ) of the contact body  228  proximate to the loading end  230 . In embodiments where the crimp contact  202  is shaped from the contact sheet  200  ( FIG. 2 ), the sheet sections  211 - 213  ( FIG. 2 ) become the contact wall  240 . As shown in  FIG. 5 , the contact wall  240  has an inner surface  244  that faces radially inward toward the central axis  234  and an outer surface  246  that faces radially outward away from the central axis  234 . The contact wall  240  may extend substantially an entire axial length L 4  ( FIG. 5 ) of the contact body  228 . 
     The crimp contact  202  also includes a sleeve wall  250  that covers at least a portion of the contact wall  240 . In the illustrated embodiment, the sleeve wall  250  extends completely around the central axis  234  and the outer surface  246  of the contact wall  240  proximate to the loading end  230 . However, in alternative embodiments, the sleeve wall  250  may extend around only a portion or different portions of the contact wall  240 . In embodiments where the crimp contact  202  is shaped from the contact sheet  200 , the sheet section  214  ( FIG. 2 ) becomes the sleeve wall  250 . As shown in  FIG. 5 , the sleeve wall  250  has an inner surface  252  and an outer surface  254 . The inner surface  252  may form an interface  270  with the outer surface of the  246  of the contact wall  240 . The interface  270  includes the inner and outer surfaces  252  and  246  directly abutting and making intimate contact with each other. The sleeve and contact walls  250  and  240  may substantially function as a single wall. As such, when the sleeve wall  250  is deformed inwardly the contact wall  240  is immediately affected or displaced by the deformed sleeve wall  250 . However, in alternative embodiments, a small gap may exist therebetween. As shown in  FIGS. 3 and 4 , the locking projections  226  extend radially outward from the outer surface  254 . 
     As shown in  FIG. 5 , the interface  270  extends from the wall joint  236  to a wall end  237  of the sleeve wall  250 . The wall end  237  includes the side edge  215  ( FIG. 2 ) in the illustrated embodiment. However, in alternative embodiments, the interface  270  may exist for only a portion of the axial length between the wall joint  236  and the wall end  237 . In some embodiments, the interface  270  may only exist for a portion of the sleeve wall  250  that contacts the crimping tool. 
     In the illustrated embodiment, both the inner surface  252  and the outer surface  246  are formed from the plan surface  206  ( FIG. 2 ) of the contact sheet  200 . The sleeve wall  250  may extend along the central axis  234  for only a portion of the axial length L 4 . For example, the sleeve wall  250  may extend only about half the axial length L 4 . The contact wall  240  projects beyond the sleeve wall  250  to the mating end  232 . In alternative embodiments, the sleeve wall  250  may extend more than or less than about half the axial length L 4 . 
     With specific reference to  FIG. 5 , the sleeve wall  250  is sized to engage a crimping tool (not shown) and the contact wall  240  is configured to grip a conductor (not shown) within the conductor-receiving passage  242  when the sleeve and contact walls  250  and  240  are deformed by the crimping tool. For example, the crimp contact  202  may have an outer diameter D 1  that extends through the central axis  234  between opposite portions of the outer surface  254  of the sleeve wall  250 . The crimp contact  202  may also have an inner diameter D 2  that extends through the central axis  234  between opposite portions of the inner surface  244  of the contact wall  240 . The contact and sleeve walls  240  and  250  may form a substantially continuous radial thickness RT 1  of the crimp contact  202 . The radial thickness RT 1  may be sized and shaped to deform in a predetermined manner so that the contact wall  240  effectively grips the conductor. For example, the contact wall  240  may be deformed in a manner that mechanically holds the conductor and establishes a sufficient electrical connection with the conductor. 
     The crimp contact  202  can include a crimp portion  260  and an engagement portion  262 . The crimp portion  260  is located proximate to the loading end  230  and is configured to be deformed by the crimping tool. The crimp portion  260  includes the overlapping contact and sleeve walls  240  and  250  proximate to the loading end  230  and the conductor-receiving passage  242 . The engagement portion  262  is configured to establish an electrical connection with an electrical element (e.g., mating contact). In the illustrated embodiment, the engagement portion  262  may establish an electrical connection with the electrical element without deformation of the engagement portion  262 . For example, the engagement portion  262  may removably engage a mating contact such that the engagement portion  262  is readily separated from the mating contact without damage to the mating contact or the engagement portion  262 . 
     In the illustrated embodiment, the engagement portion  262  is exclusively formed from the contact wall  240 . However, in some embodiments, the engagement portion  262  may include the sleeve wall  250 . The engagement portion  262  includes a contact passage  266  that is defined by the inner surface  244  of the contact wall  240 . Accordingly, the inner surface  244  may define the contact passage and the conductor-receiving passage  242 . The contact and conductor-receiving passages  266  and  242  may be in fluid communication with each other (e.g., the contact and conductor-receiving passages  266  and  242  may be portions of a single passage). 
     For each of the crimp and engagement portions  260  and  262 , the contact wall  240  may be shaped to have different dimensions. For example, the contact wall  240  may be shaped to have different diameters in the crimp and engagement portions  260  and  262 . As shown, the engagement portion  262  has inner and outer diameters D 3  and D 4 . In the illustrated embodiment, the inner diameter D 3  is smaller than the inner diameter D 2  of the crimp portion  260 . However, in alternative embodiments, the inner diameter D 3  may be substantially equal to or greater than the inner diameter D 2 . Also shown in  FIG. 5 , the engagement portion  262  may include inwardly projecting tabs  274 . The tabs  274  may be stamped from the contact sheet  200  ( FIG. 2 ) and facilitate holding or engaging an electrical element within the contact passage  266 . For example, the tabs  274  may hold a conductive band (not shown) within the contact passage  266  that electrically connects with a mating contact. 
       FIGS. 6 and 7  illustrate a crimp contact  302  formed in accordance with another embodiment. The crimp contact  302  may have similar features as the crimp contact  202  ( FIG. 3 ). The crimp contact  302  may be manufactured by various processes. For example, the crimp contact  302  or different components of the crimp contact  302  may be stamped and formed and/or machined. As shown in  FIGS. 6 and 7 , the crimp contact  302  includes an elongated contact body  328  that has loading and mating ends  330  and  332  and a central axis  334  extending therebetween. The contact body  328  includes a contact wall  340  that extends around the central axis  334  and defines a conductor-receiving passage  342  proximate to the loading end  330 . The contact wall  340  has an outer surface  346 . Also shown, the crimp contact  302  includes a sleeve wall  350  that extends around the central axis  334  and forms an interface  370  ( FIG. 7 ) with the outer surface  346  of the contact wall  340  proximate to the loading end  330 . The sleeve wall  350  is sized to engage a crimping tool (not shown) and the contact wall  340  is configured to grip a conductor (not shown) within the conductor-receiving passage  342  when the sleeve and contact walls  350  and  340  are deformed by the crimping tool. 
     Also shown in  FIGS. 6 and 7 , the sleeve wall  350  is shaped to form a separate sleeve member  306  that is mounted to the contact body  328 . The sleeve member  306  has a body-receiving cavity  308  ( FIG. 7 ). The sleeve and contact walls  350  and  340  are separate components, unlike the sleeve and contact walls  250  and  240  of the crimp contact  202 . The sleeve member  306  is configured to be mounted to the contact body  328  at the loading end  330 . For example, the body-receiving cavity  308  may be sized and shaped to receive the contact wall  340  of the contact body  328  and form an interference fit therewith. The sleeve member  306  may be stamped and formed or machined. The sleeve member  306  may also have an aperture  310  that permits the conductor(s) to access the conductor-receiving passage  342 . 
     With specific reference to  FIG. 7 , the sleeve wall  350  (and sleeve member  306 ) is sized to engage the crimping tool and the contact wall  340  is configured to grip a conductor (not shown) within the conductor-receiving passage  342  when the sleeve and contact walls  350  and  340  are deformed by the crimping tool. For example, the crimp contact  302  may have an outer diameter D 5  that extends through the central axis  334  between opposite portions of an outer surface  354  of the sleeve wall  350 . The crimp contact  302  may also have an inner diameter D 6  that extends through the central axis  334  between opposite portions of an inner surface  344  of the contact wall  340 . 
     The contact and sleeve walls  340  and  350  may form a substantially continuous radial thickness RT 2  of the crimp contact  302 . The radial thickness RT 2  may be sized and shaped to deform in a predetermined manner so that the contact wall  340  effectively grips the conductor. For example, an inner surface  352  of the sleeve wall  350  and the outer surface  346  can directly abut each other at the interface  370 . The sleeve and contact walls  350  and  340  may substantially function as a single wall. When the sleeve wall  350  is deformed inwardly, the contact wall  340  can be immediately affected or displaced by the deformed sleeve wall  350 . However, in alternative embodiments, a small gap may exist therebetween. 
     The crimp contact  302  also includes a crimp portion  360  and an engagement portion  362 . The crimp portion  360  is located proximate to the loading end  330  and is configured to be deformed by the crimping tool. The crimp portion  360  includes the overlapping contact and sleeve walls  340  and  350  proximate to the loading end  330  and the conductor-receiving passage  342 . In the illustrated embodiment, the engagement portion  362  is exclusively formed from the contact wall  340 . However, in some embodiments, the engagement portion  362  may include the sleeve wall  350 . The engagement portion  362  includes a contact passage  366  that is defined by the inner surface  344  of the contact wall  340 . The engagement portion  362  has inner and outer diameters D 7  and D 8 . In the illustrated embodiment, the inner diameter D 7  is smaller than the inner diameter D 6  of the crimp portion  360 . However, in alternative embodiments, the inner diameter D 7  may be substantially equal to or greater than the inner diameter D 6 . Also shown in  FIG. 7 , the engagement portion  362  may include inwardly projecting tabs  374 . The tabs  374  may facilitate holding or engaging an electrical element within the contact passage  366 . 
       FIG. 8  is an end view of the sleeve member  306 . The sleeve member  306  may include a wall joint  336  that extends radially inward from the loading end  330  of the crimp contact  302  ( FIG. 6 ). The wall joint  336  may provide a positive stop for the contact body  328  ( FIG. 6 ) when the contact body  328  is inserted into the body-receiving cavity  308  ( FIG. 7 ) of the sleeve member  306 . Also shown, the sleeve member  306  may include a locking feature  326  that projects radially outward from the sleeve member  306 . The locking feature  326  may be shaped like a rim or lip that extends completely around the circumference of the sleeve member  306 . In alternative embodiments, the locking feature  326  may include locking projections similar to the locking projections  226  shown in  FIG. 3  that are distributed about the central axis  334 . 
       FIG. 9  is a cross-sectional view of an electrical connector assembly  400  formed in accordance with another embodiment. The connector assembly  400  may be similar to the connector assembly  102  shown in  FIG. 1 . The connector assembly  400  includes a connector housing  401  having a plurality of crimp contacts  402 - 404 , which may also be referred to as a first crimp contact  402 , a second crimp contact  403 , and a third crimp contact  404 . Each of the crimp contacts  402 - 404  is positioned within a respective contact cavity  422 - 424 . The contact cavities  422 - 424  may be defined by corresponding interior surfaces  465  of the connector housing  401 . The crimp contacts  402 - 404  include respective contact bodies  432 - 434  and sleeve members  442 - 444 . The contact bodies  432 - 434  and sleeve members  442 - 444  may be similar to the contact bodies and the sleeve members described above. In the illustrated embodiment, the contact bodies  432 - 434  are substantially identical. For example, the contact bodies  432 - 434  may be stamped and formed as described above and have a common axial length L 5 . However, the sleeve members  442 - 444  may have different dimensions with respect to each other. For example, the sleeve members  442 - 444  may have different axial lengths  452 - 454 . 
     The crimp contacts  402 - 404  may project different distances Y 1 , Y 2 , and Y 3 , respectively, from a mating side  450  of the connector housing  401 . In such embodiments, a user may control an order or sequence in which the crimp contacts  402 - 404  electrically engage corresponding mating contacts of a mating connector (not shown). To assemble the connector assembly  400 , the sleeve members  442 - 444  may be inserted into the corresponding contact cavities  422 - 424 . When the sleeve members  442 - 444  are inserted, locking features  460  may engage corresponding locking elements  462  of the connector housing  401 . The locking elements  462  may be resilient fingers that flex to and from the corresponding interior surface  465  of the connector housing  401 . When the locking features  460  clear the locking elements  462 , the locking elements  462  may spring back into position thereby retaining the sleeve members  442 - 444  within the connector housing  401 . As shown in  FIG. 9 , ends of the sleeve members  442 - 444  may be substantially co-planar along a lateral plane P 1 . With the sleeve members  442 - 444  held by the connector housing  401 , the respective contact bodies  432 - 434  may then be inserted into the body-receiving cavities of the sleeve members  442 - 444 , similar to  FIG. 7  described above. The contact bodies  432 - 434  may be stopped by wall joints  412 - 414  of the sleeve members  442 - 444 , respectively. Because the sleeve members  442 - 444  have different axial lengths  452 - 454 , the contact bodies  432 - 434  project different distances Y 1 -Y 3  away from the mating side  450 . 
     In alternative embodiments, the crimp contacts  402 - 404  may be similar to the crimp contact  202  ( FIG. 3 ). In such embodiments, the crimp contacts may have identical dimensions or be manufactured to have different dimensions (e.g., axial lengths). 
     Thus, it is to be understood that the above description is intended to be illustrative, and not restrictive. In addition, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. Furthermore, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.