Patent Description:
Contact terminals are often mated with through holes on substrates, to provide an electrical connection between the of terminals to the substrate, etc. However, the proper termination of the contact terminals to the substrate often requires the use of a header and one or more tools, as the insertion force and the normal force of the contact terminals is significant. In addition, the use of such contact terminals causes deformation to both the contact terminals and the through holes, preventing the contact terminals from being used over many cycles.

It would, therefore, be beneficial to provide contact terminals which overcomes the issues associated with known contact terminals. In particular, it would be beneficial to provide contact terminals which can be used over many cycles and which do not require tooling for insertion. It would also be beneficial to provide the low insertion force contact terminals in a connector housing which can be mated to the substrate without the need of a header.

<CIT> discloses a male electrical terminal having a rear terminating portion, a front mating portion and an intermediate portion between them. The intermediate portion is of a box-like construction and the front mating portion comprises forwardly extending cantilevered beams to allow inward flexing of the beams relative to one another.

In accordance with the invention, there is provided a low insertion force contact terminal as defined in the appended claim <NUM>. The following provides a summary of certain illustrative embodiments of the present invention. This summary is not an extensive overview and is not intended to identify key or critical aspects or elements of the present invention or to delineate its scope.

An embodiment is directed to a low insertion force contact terminal which has a conductor mating portion, a securing portion and a substrate mating portion. The conductor mating portion is configured to terminate a conductor therein, using known methods of termination, such as, but not limited to, crimping, insulation displacement or welding. The securing portion is configured to secure the terminal in a terminal receiving cavity of a housing. The substrate mating portion extends from the securing portion. The substrate mating portion has at least two sections which have curved portions thereon. The at least two sections move independently, which allows the curved portions to exert a low normal force on walls of through holes of a substrate to which the contact terminal is mated. The low normal force is sufficient to provide a stable electrical connection while allowing for a low insertion force. The insertion or normal force is <NUM> Newtons or less.

In an illustrative embodiment, a first section of the at least two sections of the substrate mating portion is a first planar piece of conductive material and a second section of the at least two sections is a second planar piece of conductive material which is folded over at an edge to place second planar pieces of conductive material on top of the first planar pieces of conductive material.

In an illustrative embodiment, the securing portion is formed by folding planar conductive material into a box shaped member with a top wall, an oppositely facing bottom wall, a first side wall and a second side wall. A first section of the at least two sections of the substrate mating portion is a first resilient arm which extends from the first side wall and a second section of the at least two sections of the substrate mating portion is a second resilient arm which extends from the second side wall.

In an illustrative embodiment, the first resilient arm has a first planar portions, a first u-shaped portion and a first curved portion. The first curved portion extends from the first u-shaped portion back toward the securing portion, the second resilient arm has a second planar portion, a second u-shaped portion and a second curved portion. The second curved portion extends from the second u-shaped portion back toward the securing portion.

Additional features and aspects of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the illustrative embodiments. As will be appreciated by the skilled artisan, further embodiments of the invention are possible without departing from the scope of the invention. Accordingly, the drawings and associated descriptions are to be regarded as illustrative and not restrictive in nature.

The accompanying drawings, which are incorporated into and form a part of the specification, schematically illustrate one or more illustrative embodiments and, together with the general description given above and detailed description given below, serve to explain the principles of the invention. <FIG> show embodiments that are not in accordance with the invention, and <FIG> show embodiments that are in accordance with the invention.

Relative terms such as "lower," "upper," "horizontal," "vertical," "above," "below," "up," "down," "top" and "bottom" as well as derivative thereof (e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the invention expressly should not be limited to such preferred embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features, the scope of the invention being defined by the claims appended hereto.

Illustrative embodiments of the present invention are now described with reference to the Figures. Reference numerals are used throughout the detailed description to refer to the various elements and structures. Although the following detailed description contains many specifics for the purposes of illustration, a person of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.

As shown in <FIG>, a first illustrative embodiment of a connector <NUM> has a housing <NUM> with a wire receiving end <NUM> and a substrate mating end <NUM>. Latching arms <NUM> extend from proximate the wire receiving end <NUM> to beyond the substrate mating end <NUM>. The latch arms <NUM> have lead-in surfaces <NUM> proximate free ends thereof. Latching shoulders <NUM> are provided proximate the lead-in surfaces <NUM>. In the illustrative embodiment, three latching arms <NUM> are provided, with two extending from one side of the housing <NUM> and the third extending from the opposite side of the housing <NUM>. However, other numbers and configurations of latching arms <NUM> may be used. In addition, the latching arms may be provided on an additional part which is mated with the housing.

The housing <NUM> has terminal receiving cavities <NUM> extending from the wire receiving end <NUM> to the substrate mating end <NUM>. As shown in <FIG>, locking projections <NUM> are provided in the terminal receiving cavities <NUM>. The locking projections <NUM> are spaced from both the wire receiving end <NUM> and the substrate mating end <NUM>. The locking projections <NUM> have lead-in surfaces <NUM> which face toward the wire receiving end <NUM> and locking shoulders <NUM> which face toward the substrate mating end <NUM>.

Contact terminals <NUM> are positioned in the terminal receiving cavities <NUM>. As shown in <FIG>, the contact terminals <NUM> have conductor mating portions <NUM>, securing portions <NUM> and substrate mating portions <NUM>. The conductor mating portions <NUM> are configured to terminate conductors <NUM> therein. The conductors <NUM> may be terminated by crimping, insulation displacement, soldering or using other known methods of termination.

The securing portions <NUM> have resilient locking arms <NUM>. The resilient locking arms <NUM> extend from securing portions <NUM> whereby locking surfaces <NUM> are provided at free ends of the locking arms <NUM>. The locking arms <NUM> and the locking surfaces <NUM> cooperate with the locking projections <NUM> and the locking shoulders <NUM> to retain the terminals <NUM> in position in the terminal receiving cavities <NUM>, as shown in <FIG>.

The securing portions <NUM> and the substrate mating portions <NUM> are formed by first planar sections or pieces of conductive material <NUM> which are folded over at edges <NUM> to place folded over or second planar sections or piece/pieces of conductive material <NUM> on top of the first planar piece/pieces of conductive material <NUM>. This effectively doubles the thickness of the conductive material at the substrate mating portions <NUM>.

The first planar pieces of conductive material <NUM> extend from the securing portions <NUM> to free ends <NUM>. Curved portions <NUM> are provided proximate the free ends <NUM>. The second planar pieces of conductive material <NUM> extend from the securing portions <NUM> to free ends <NUM>. Curved portions <NUM> are provided proximate the free ends <NUM>. With the exceptions of the curved portions <NUM>, <NUM>, the first planar pieces <NUM> and the second planar pieces <NUM> are provided in line, with the second planar pieces <NUM> being positioned on top of the first planar pieces <NUM> in the illustrative orientation shown in <FIG>.

The curved portions <NUM> are curved such that edges <NUM> of the curved portions <NUM> extend away from the longitudinal axes <NUM> of the substrate mating portions <NUM>. The curved portions <NUM> are curved such that edges <NUM> of the curved portions <NUM> extend away from the longitudinal axes <NUM> of the substrate mating portions <NUM>. The curved portions <NUM> extend in a direction from the longitudinal axes <NUM> in the opposite direction as the curved portions <NUM>.

In use, the connector <NUM> is moved into engagement with a substrate <NUM>, such as, but not limited to a panel or a printed circuit board, as shown in <FIG>. In the fully inserted position, the ends of the latching arms <NUM> are positioned in latch receiving openings <NUM> in the substrate <NUM>. When fully inserted, the latching shoulders <NUM> are engage, and are biased against, a surface <NUM> of the substrate <NUM> to removably retain the connector <NUM> in position on the substrate <NUM>. Alternatively, the latch arms <NUM> may have an interference fit with the latch receiving openings <NUM> or an additional component may be provided to ensure that the connector <NUM> is positively positioned and prevented from movement relative to the substrate <NUM>.

As the connector <NUM> is moved from the position shown in <FIG> to the position shown in <FIG>, the substrate mating portions <NUM> are moved into plated through holes <NUM> in the substrate <NUM>. As insertion continues, the curved portions <NUM>, <NUM> engage the walls of the through holes <NUM>, causing the curved portions <NUM>, <NUM> and the first and the second planar pieces <NUM>, <NUM> to be resiliently deformed inward, toward each other, while retaining elastic energy. As the curved portions <NUM> are on the first planar pieces <NUM> and the curved portions <NUM> are on the second planar pieces <NUM>, the movement of the curved portions <NUM> is independent of the movement of the curved portions <NUM>. This allows the movement of the curved portions <NUM>, <NUM> to occur with little force, thereby allowing the terminals <NUM> and the connector <NUM> to be inserted onto the substrate <NUM> with low insertion force. The low insertion force allows the connector <NUM> to be inserted onto the substrate by a user or operator without the need for additional tooling.

Once inserted and positioned in the through holes <NUM>, as shown in <FIG>, the edges <NUM>, <NUM> of the curved portions <NUM>, <NUM> engage the walls of the through holes <NUM> and exert normal forces on the walls of the through holes <NUM>, as the first and the second planar pieces <NUM>, <NUM> attempt to move back toward their unstressed position. The normal force is sufficient to provide a stable electrical connection while allowing for a low insertion force. The normal force may be, for example, <NUM> Newtons or less. However, other normal forces may be obtained by alterations of the configuration of the first and the second planar pieces <NUM>, <NUM>. The use of terminals <NUM> with low normal forces allows the terminals <NUM>, connector <NUM> and the through holes <NUM> to be used over many cycles. For example, by adding a detent to the first planar piece <NUM> and/or the second planar piece <NUM>, the first planar piece <NUM> and the second planar piece <NUM> may be locked together, thereby adjusting the normal force exerted by the terminals <NUM> on the walls of the through holes <NUM>. This also can help prevent deflection stress or strain transition from being transferred to the securing portions <NUM>.

As shown in <FIG>, a second illustrative embodiment of a connector <NUM> has a housing <NUM> with a wire receiving end <NUM> and a substrate mating end <NUM>. Latching arms <NUM> extend from proximate the wire receiving end <NUM> to beyond the substrate mating end <NUM>. The latch arms <NUM> have lead-in surfaces <NUM> proximate free ends thereof. Latching shoulders <NUM> are provided proximate the lead-in surfaces <NUM>.

The housing <NUM> has terminal receiving cavities <NUM> extend from the wire receiving end <NUM> to the substrate mating end <NUM>. As shown in <FIG>, locking projections <NUM> are provided in the terminal receiving cavities <NUM>. The locking projections <NUM> are spaced from both the wire receiving end <NUM> and the substrate mating end <NUM>. The locking projections <NUM> have lead-in surfaces <NUM> which face toward the wire receiving end <NUM> and locking shoulders <NUM> which face toward the substrate mating end <NUM>.

The securing portions <NUM> have locking walls <NUM>. The locking walls <NUM> have locking surfaces <NUM>. The locking walls <NUM> and the locking surfaces <NUM> cooperate with the locking projections <NUM> and the locking shoulders <NUM> to retain the terminals <NUM> in position in the terminal receiving cavities <NUM>, as shown in <FIG>. The securing portions <NUM> are formed by folding planar conductive material into box shaped members with top walls <NUM>, oppositely facing bottom walls <NUM>, first side or locking walls <NUM> and second side walls <NUM>.

The substrate mating portions <NUM> have first resilient sections or arms <NUM> which extend from the first side walls <NUM> and second resilient sections or arms <NUM> which extend from the second side walls <NUM>.

The first resilient arms <NUM> extend from the securing portions <NUM> to free ends <NUM>. The first resilient arms <NUM> are formed to have curved portions <NUM> provided proximate the free ends <NUM>. The second resilient arms <NUM> extend from the securing portions <NUM> to free ends <NUM>. The second resilient arms <NUM> are formed to have curved portions <NUM> provided proximate the free ends <NUM>.

The curved portions <NUM> are curved such that faces <NUM> of the curved portions <NUM> extend away from the longitudinal axes <NUM> of the substrate mating portions <NUM>. The curved portions <NUM> are curved such that faces <NUM> of the curved portions <NUM> extend away from the longitudinal axes <NUM> of the substrate mating portions <NUM>. The curved portions <NUM> extend in a direction from the longitudinal axes <NUM> in the opposite direction as the curved portions <NUM>. Projections or dimples <NUM> are provide on the faces <NUM>, <NUM> of the curved portions <NUM>, <NUM>.

In use, the connector <NUM> is moved into engagement with a substrate <NUM>, such as, but not limited to a panel or a printed circuit board. In the fully inserted position, the ends of the latching arms <NUM> are positioned in latch receiving openings (not shown) in the substrate <NUM>. When fully inserted, the latching shoulders <NUM> are positioned below or engage a surface <NUM> of the substrate <NUM> to removably retain the connector <NUM> in position on the substrate <NUM>. Alternatively, the latch arms <NUM> may have an interference fit with the latch receiving openings <NUM> or an additional component may be provided to ensure that the connector <NUM> is positively positioned and prevented from movement relative to the substrate <NUM>.

As the connector <NUM> is inserted onto the substrate <NUM>, the substrate mating portions <NUM> are moved into plated through holes <NUM> in the substrate <NUM>. As insertion continues, the curved portions <NUM>, <NUM> engage the walls of the through holes <NUM>, causing the curved portions <NUM>, <NUM> and the first and second resilient arms <NUM>, <NUM> to be resiliently deformed inward, toward each other, while retaining elastic energy. As the curved portions <NUM> are on first resilient arms <NUM> and the curved portions <NUM> are on the second resilient arms <NUM>, the movement of the curved portions <NUM> is independent of the movement of the curved portions <NUM>. This allows the movement of the curved portions <NUM>, <NUM> to occur with little force, thereby allowing the terminals <NUM> and the connector <NUM> to be inserted onto the substrate <NUM> with low insertion force. The low insertion force allows the connector <NUM> to be inserted onto the substrate by a user or operator without the need for additional tooling.

Once inserted and position in the through holes <NUM>, as shown in <FIG>, the projections <NUM> of the curved portions <NUM>, <NUM> engage the walls of the through holes <NUM> and exert normal forces on the walls of the through holes <NUM>, as the first and the second resilient arms <NUM>, <NUM> attempt to move back toward their unstressed position. The normal force is sufficient to provide a stable electrical connection while allowing for a low insertion force. The normal force may be, for example, <NUM> Newtons or less. However, other normal forces may be obtained by alterations of the configuration of the first and the second resilient arms <NUM>, <NUM>. The use of terminals <NUM> with low normal forces allows the terminals <NUM>, connector <NUM> and the through holes <NUM> to be used over many cycles.

<FIG> illustrates contact terminals which is similar to contact terminals <NUM>. However, in this embodiment the contact securing portions <NUM> have resilient locking arms <NUM>. The resilient locking arms <NUM> extend from securing portions <NUM> whereby locking surfaces <NUM> are provided at free ends of the locking arms <NUM>. The locking arms <NUM> and the locking surfaces <NUM> cooperate with the locking projections <NUM> and the locking shoulders <NUM> to retain the terminals <NUM> in position in the terminal receiving cavities <NUM>.

A third illustrative embodiment of contact terminals <NUM> is shown in <FIG>. The contact terminals <NUM> have conductor mating portions <NUM>, securing portions <NUM> and substrate mating portions <NUM>. The conductor mating portions <NUM> are configured to terminate conductors <NUM> therein. The conductors <NUM> may be terminated by crimping, insulation displacement, soldering or using other known methods of termination.

The securing portions <NUM> have locking walls <NUM>. The locking walls <NUM> have locking surfaces <NUM>. The securing portions <NUM> are formed by folding planar conductive material into box shaped members with top walls <NUM>, oppositely facing bottom walls <NUM>, first side or locking walls <NUM> and second side walls <NUM>.

The substrate mating portions <NUM> have first arms <NUM> which extend from the top walls <NUM> and second arms <NUM> which extend from the bottom walls <NUM>. The first arms <NUM> extend from the securing portions <NUM> to free ends <NUM>. The first arms <NUM> have a fork like configuration with first resilient arms <NUM> and second resilient arms <NUM>. The first resilient arms <NUM> are formed to have curved portions <NUM> provided proximate the free ends <NUM>. The second resilient arms <NUM> are formed to have curved portions <NUM> provided proximate the free ends <NUM>.

The second arms <NUM> extend from the securing portions <NUM> to free ends <NUM>. The first arms <NUM> have a fork like configuration with first resilient arms <NUM> and second resilient arms <NUM>. The first resilient arms <NUM> are formed to have curved portions <NUM> provided proximate the free ends <NUM>. The second resilient arms <NUM> are formed to have curved portions <NUM> provided proximate the free ends <NUM>. The first arms <NUM> and the second arms <NUM> are provided in line, with the first arms <NUM> being positioned on top of the second arms <NUM> in the illustrative orientation shown in <FIG>.

The curved portions <NUM>, <NUM> are curved such that edges <NUM> of the curved portions <NUM>, <NUM> extend away from the longitudinal axes <NUM> of the substrate mating portions <NUM>. The curved portions <NUM>, <NUM> are curved such that edges <NUM> of the curved portions <NUM>, <NUM> extend away from the longitudinal axes <NUM> of the substrate mating portions <NUM>. The curved portions <NUM>, <NUM> extend in a direction from the longitudinal axes <NUM> in the opposite direction as the curved portions <NUM>, <NUM>.

In use, as the terminals <NUM> are moved into through holes of a substrate (not shown) the curved portions <NUM>, <NUM>, <NUM>, <NUM> engage the walls of the through holes, causing the curved portions <NUM>, <NUM>, <NUM>, <NUM> and the resilient arms <NUM>, <NUM>, <NUM>, <NUM> to be resiliently deformed inward, toward each other, while retaining elastic energy. As the curved portions <NUM>, <NUM>, <NUM>, <NUM> are positioned on different resilient arms <NUM>, <NUM>, <NUM>, <NUM>, the movement of the curved portions <NUM>, <NUM>, <NUM>, <NUM> is independent of the other curved portions. This allows the movement of the curved portions <NUM>, <NUM>, <NUM>, <NUM> to occur with little force, thereby allowing the terminals <NUM> to be inserted onto the substrate with low insertion force. The low insertion force allows the terminals <NUM> to be inserted onto the substrate by a user or operator without the need for additional tooling.

Once inserted and positioned in the through holes of the substrate, the edges <NUM>, <NUM> of the curved portions <NUM>, <NUM>, <NUM>, <NUM> engage the walls of the through holes and exert normal forces on the walls of the through holes, as the resilient arms <NUM>, <NUM>, <NUM>, <NUM> attempt to move back toward their unstressed position. The normal force is sufficient to provide a stable electrical connection while allowing for a low insertion force. The normal force may be, for example, <NUM> Newtons or less. However, other normal forces may be obtained by alterations of the configuration of the resilient arms <NUM>, <NUM>, <NUM>, <NUM>. The use of terminals <NUM> with low normal forces allows the terminals <NUM> to be used over many cycles.

<FIG> illustrates contact terminals which is similar to contact terminals <NUM>. However, in this embodiment the contact securing portions <NUM> have resilient locking arms <NUM>. The resilient locking arms <NUM> extend from securing portions <NUM> whereby locking surfaces <NUM> are provided at free ends of the locking arms <NUM>. The locking arms <NUM> and the locking surfaces <NUM> cooperate with the locking projections and the locking shoulders to retain the terminals <NUM> in position in the terminal receiving cavities.

A fourth illustrative embodiment of contact terminals <NUM> is shown in <FIG>. The contact terminals <NUM> have conductor mating portions <NUM>, securing portions <NUM> and substrate mating portions <NUM>. The conductor mating portions <NUM> are configured to terminate conductors <NUM> therein. The conductors <NUM> may be terminated by crimping, insulation displacement, soldering or using other known methods of termination.

The securing portions <NUM> have locking walls <NUM>. The locking walls <NUM> have locking surfaces <NUM>. The locking walls <NUM> and the locking surfaces <NUM>. The securing portions <NUM> are formed by folding planar conductive material into box shaped members with top walls <NUM>, oppositely facing bottom walls <NUM>, first side or locking walls <NUM> and second side walls <NUM>.

The substrate mating portions <NUM> have first resilient arms <NUM> which extend from the first side walls <NUM> and second resilient arms <NUM> which extend from the second side walls <NUM>. The first resilient arms <NUM> have first planar portions <NUM>, u-shaped portions <NUM> and curved portions <NUM>. The curved portions <NUM> extend from the u-shaped portions <NUM> back toward the securing portions <NUM>. The second resilient arms <NUM> have second planar portions <NUM>, u-shaped portions <NUM> and curved portions <NUM>. The curved portions <NUM> extend from the u-shaped portions <NUM> back toward the securing portions <NUM>.

In use, as the terminals <NUM> are moved into through holes of a substrate (not shown) the curved portions <NUM>, <NUM> engage the walls of the through holes, causing the curved portions <NUM>, <NUM> to be resiliently deformed inward, toward each other, while retaining elastic energy. As the curved portions <NUM>, <NUM> are positioned on different resilient arms <NUM>, <NUM>, the movement of the curved portions <NUM> is independent of the curved portions <NUM>. This allows the movement of the curved portions <NUM>, <NUM> to occur with little force, thereby allowing the terminals <NUM> to be inserted onto the substrate with low insertion force. The low insertion force allows the terminals <NUM> to be inserted onto the substrate by a user or operator without the need for additional tooling.

Once inserted and position in the through holes of the substrate, the projections <NUM> of the curved portions <NUM>, <NUM> engage the walls of the through holes and exert normal forces on the walls of the through holes, as the curved portions <NUM>, <NUM> attempt to move back toward their unstressed position. The normal force is sufficient to provide a stable electrical connection while allowing for a low insertion force. The normal force may be, for example, <NUM> Newtons or less. However, other normal forces may be obtained by alterations of the configuration of the curved portions <NUM>, <NUM>. The use of terminals <NUM> with low normal forces allows the terminals <NUM> to be used over many cycles.

<FIG> illustrates contact terminals which are similar to contact terminals <NUM>. However, in this embodiment the contact securing portions <NUM> have resilient locking arms <NUM>. The resilient locking arms <NUM> extend from securing portions <NUM> whereby locking surfaces <NUM> are provided at free ends of the locking arms <NUM>. The locking arms <NUM> and the locking surfaces <NUM> cooperate with the locking projections and the locking shoulders to retain the terminals <NUM> in position in the terminal receiving cavities.

Claim 1:
A low insertion force contact terminal (<NUM>) comprising:
a conductor mating portion (<NUM>) for terminating a conductor (<NUM>) therein;
a securing portion (<NUM>) for securing the terminal (<NUM>) in a terminal receiving cavity of a housing;
a substrate mating portion (<NUM>) extending from the securing portion (<NUM>), the substrate mating portion (<NUM>) having at least two sections which have curved portions (<NUM>, <NUM>) thereon;
wherein the at least two sections move independently, causing the curved portions (<NUM>, <NUM>) to exert a normal force on walls of through holes of a substrate to which the contact terminal (<NUM>) is mated which is sufficient to provide a stable electrical connection while allowing for a low insertion force, wherein the insertion or normal force is equal to or less than <NUM> Newtons;
wherein the securing portion (<NUM>) is formed by folding planar conductive material into a box shaped member with a top wall (<NUM>), an oppositely facing bottom wall (<NUM>), a first side wall (<NUM>) and a second side wall (<NUM>), a first section of the at least two sections of the substrate mating portion (<NUM>) is a first resilient arm (<NUM>) which extends from the first side wall (<NUM>) and a second section of the at least two sections of the substrate mating portion (<NUM>) is a second resilient arm (<NUM>) which extends from the second side wall (<NUM>); and
wherein the first resilient arm (<NUM>) has a first planar portion (<NUM>), a first u-shaped portion (<NUM>) and a first curved portion (<NUM>), the first curved portion (<NUM>) extends from the first u-shaped portion (<NUM>) back towards the securing portion (<NUM>), the second resilient arm (<NUM>) has a second planar portion (<NUM>), a second u-shaped portion (<NUM>) and a second curved portion (<NUM>), the second curved portion (<NUM>) extends from the second u-shaped portion (<NUM>) back towards the securing portion (<NUM>).