Patent Description:
The need for electrical connectors which are compact in size continues to increase. As the connectors are made smaller, the electrical terminals positioned in the connectors must also be made smaller. The miniaturization of the terminals requires that less material be used in the manufacturer of the terminals, thereby making the terminals vulnerable to damage or deformation when in use or when undergoing testing, qualification or assembly into the connector housing. Patent <CIT> discloses an electrical contact having a mating receptacle contact receiving section and a wire termination section. The contact receiving section has side, top and bottom walls. One side wall extends upwardly to form an erroneous insertion prevention projection having side walls, a top wall and a rear wall which engages the top wall of the contact receiving section.

The problem to be solved is to provide a terminal with improved strength to prevent damage or deformation. It would also be beneficial to provide such a reinforced terminal without increasing the overall size of the terminal.

This problem is solved by a one piece connector, thereby eliminating loose components which can fall during installation or which can come loose during operation.

According to the invention there is provided an electrical contact according to claim <NUM>.

As shown in the illustrative embodiment of <FIG>, a receptacle contact <NUM> including a mating portion <NUM> and a transition portion or region <NUM>. The transition portion <NUM> extends to a termination portion (not shown), such as, but not limited to a crimp portion. The entire receptacle contact <NUM> is formed from a single piece stamped sheet-metal form, which is stamped and formed or bent into the configuration shown in <FIG>.

As shown in <FIG>, the mating portion <NUM> includes a front or mating contact receiving end <NUM> and a back end <NUM> proximate the transition portion <NUM>. The mating portion <NUM> includes a box-shaped contact portion <NUM> for accepting a respective mating contact or mating pin contact (not shown). The box-shaped contact portion <NUM> has a bottom wall <NUM>, a top wall <NUM> and side walls <NUM>, <NUM>.

A respective side wall <NUM> has an upper portion <NUM> which extends beyond the top wall <NUM>. The upper portion <NUM> of the side wall <NUM> is formed to provide a top wall <NUM> and a sloped side wall <NUM>. The upper portion <NUM> of the side wall <NUM>, the top wall <NUM> and the sloped side wall <NUM> form a retention portion <NUM> of the mating portion <NUM> of the contact <NUM>. The retention portion <NUM> extends from the front end <NUM> to the rear end <NUM> of the mating portion <NUM>.

As shown in <FIG>, the upper portion <NUM> of the side wall <NUM>, the top wall <NUM> and the sloped side wall <NUM> have a cavity or opening <NUM> provided therein. The opening <NUM> is configured to receive a locking projection (not shown) of a connector housing (not shown) into which the contact <NUM> is inserted. The locking projection is dimensioned to cooperate with the cavity or opening <NUM> to maintain the receptacle contact <NUM> in position in the housing. The locking projection cooperates with the receptacle contact <NUM> to provide the primary retention of the receptacle contact <NUM> in the housing.

In alternative embodiments, the upper portion <NUM> of the side wall <NUM>, the top wall <NUM> or the sloped side wall <NUM> may have an orientation and/or locking feature or locking projection (not shown) which projects outward therefrom. The locking projection is dimensioned to cooperate with a cavity of a housing (not shown) to maintain the receptacle contact <NUM> in position in the housing. The locking projection cooperates with the housing to provide the primary retention of the receptacle contact <NUM> in the housing. The locking projection may also act as a polarizing means. If a housing into which the receptacle contact <NUM> is to be inserted has a corresponding cavity into which the projection is to be positioned, then it is assured that the receptacle contact <NUM> cannot be improperly inserted into the housing.

As shown in <FIG>, the one-piece receptacle contact <NUM> has a first resilient contact projection <NUM> and a second resilient contact projection or spring arm <NUM>, which are formed integrally from the bottom wall <NUM> and the top wall <NUM>, respectively. Portions of the two resilient contact arms <NUM>, <NUM> extend toward one another. The resilient contact projections <NUM>, <NUM> have respective freely movable contact areas <NUM>, <NUM> (<FIG>) provided proximate thereto. In the embodiment shown, the contact areas <NUM>, <NUM> are rounded and are laterally offset, but are relatively close together, so that even when small contact pins are inserted, a secure and reliable mechanical and electrical connection is assured. At least in the region of the contact areas <NUM>, <NUM>, the resilient contact projections <NUM>, <NUM> are preferably provided with a plating or metalizing layer, such as a gold or tin overlay, thereby providing an enhanced electrical connection with the inserted contact pin. An overstress protection portion <NUM> extends from the side wall <NUM> (as shown in <FIG>) to cooperate with a free end <NUM> the resilient contact arm <NUM> to prevent the overstress of the contact projection <NUM>. The overstress protection portion <NUM> extends essentially parallel to the top wall <NUM>.

As shown in <FIG>, a free end <NUM> of the sloped side wall <NUM> is positioned proximate the top wall <NUM> of the box shaped contact portion <NUM>. The free end <NUM> may be positioned proximate to or in engagement with the top wall <NUM> when no forces are applied to the contact <NUM>. If a force is applied to the upper portion <NUM> of the side wall <NUM>, the top wall <NUM> or the sloped side wall <NUM>, the retention portion <NUM> may be compressed or rotated, causing the free end <NUM> to engage the top wall <NUM>, thereby preventing deformation of the retention portion <NUM>.

As shown in <FIG> and <FIG>, the retention portion <NUM> has a back wall <NUM> which extends from the sloped side wall <NUM>. The back wall <NUM> extends at approximately <NUM> degrees from the sloped side wall <NUM>. The back wall <NUM> is configured to approximate the space provided between the sloped side wall <NUM>, the top wall <NUM> of the box shaped contact portion <NUM>, the upper portion <NUM> of the side wall <NUM>, and the top wall <NUM>. A securing portion <NUM> of the back wall <NUM> extends into a cavity <NUM> formed in the top wall <NUM> of the box shaped contact portion <NUM> proximate the back end <NUM>. The cavity <NUM>, as shown in <FIG> and <FIG>, is a cutout or opening which extends through the top wall <NUM> and which is dimensioned to receive and retain the securing portion <NUM> of the back wall <NUM> therein.

As shown in <FIG>, <FIG>, the retention portion <NUM> has detents <NUM> spaced along the length of the sloped side wall <NUM>. The detents <NUM> extend from the free end <NUM> of the sloped side wall <NUM>. In the illustrative embodiment shown, two detents <NUM> are shown. However, other numbers and configurations of detents may be used. As shown in <FIG>, the detents <NUM> have engagement shoulders <NUM> which are provided proximate the free end <NUM> of the sloped side wall <NUM>.

As shown in <FIG>, detent receiving openings <NUM> are spaced along the length of the top wall <NUM> of the box shaped contact portion <NUM>. The detent receiving openings <NUM> are positioned in alignment with the detents <NUM>. In the illustrative embodiment shown, two detent receiving openings <NUM> are shown. The detent receiving openings <NUM> have engagement shoulders <NUM> which are provided proximate the side wall <NUM> of the box shaped contact portion <NUM>.

In use, the contact <NUM> is inserted into a contact receiving cavity of contact receiving housing (not shown). If the contact <NUM> is not fully or properly inserted, the contact receiving cavity does not fully enclose or encapsulate the contact <NUM>, allowing the contact <NUM>, and in particular, the retention portion <NUM>, to be engaged by a secondary lock or the like from the top or side. In previously known contacts, the force associated with such an engagement could result in the failure of the retention portion, as the top wall <NUM> and sloped side wall <NUM> could be easily moved or deformed. In contrast, the retention portion <NUM> of the present invention is strengthened to prevent damage or deformation without increasing the overall size of the terminal.

Referring to <FIG>, a force F1 applied to the top surface <NUM> of the retention portion <NUM> will cause the securing portion <NUM> of the back wall <NUM> to move further downward (as viewed in <FIG>) into cavity <NUM>. As this occurs, the side wall <NUM> of the back wall <NUM> will engage either the side wall <NUM>. Alternatively, as the force F1 is applied, a side wall <NUM> of the securing projection <NUM> will engage a side wall <NUM> of the cavity <NUM> formed in the top wall <NUM>. In either case, the lateral movement the back wall <NUM> and the retention portion <NUM> relative to the box shaped contact portion <NUM> is prevented.

In addition, as the force F1 is applied to the top surface <NUM> of the retention portion <NUM> , the engagement shoulders <NUM> of the detents <NUM> engage the engagement shoulders <NUM> of the detent receiving openings <NUM> to prevent the downward and the lateral movement the detents <NUM> and the retention portion <NUM> relative to the box shaped contact portion <NUM>. In so doing, the retention portion <NUM> and the contact <NUM> are strengthened to prevent damage or deformation without increasing the overall size of the terminal.

Referring again to <FIG>, a force F2 applied to the side wall <NUM> will cause the securing portion <NUM> of the back wall <NUM> to engage the side wall <NUM> of the cavity <NUM> formed in the top wall <NUM> to prevent the lateral movement the back wall <NUM> and the retention portion <NUM> relative to the box shaped contact portion <NUM>. In addition, the engagement shoulders <NUM> of the detents <NUM> engage the engagement shoulders <NUM> of the detent receiving openings <NUM> to prevent the downward and the lateral movement the detents <NUM> and the retention portion <NUM> relative to the box shaped contact portion <NUM>. In so doing, the retention portion <NUM> and the contact <NUM> are strengthened to prevent damage or deformation without increasing the overall size of the terminal.

Referring again to <FIG>, a force F3 applied to the sloped side wall <NUM> will cause the side wall <NUM> of the back wall <NUM> to engage the side wall <NUM> to prevent the lateral movement the back wall <NUM> and the retention portion <NUM> relative to the box shaped contact portion <NUM>. In so doing, the retention portion <NUM> and the contact <NUM> are strengthened to prevent damage or deformation without increasing the overall size of the terminal.

An alternate embodiment of the contact <NUM> is shown in <FIG>. The contact <NUM> is stamped from a single piece of material and is formed into the configuration shown in <FIG>. In this embodiment, the contact <NUM> has a mating portion <NUM> and a transition portion or region <NUM>. The contact <NUM>, mating portion <NUM> and transition portion <NUM> are similar to that of contact <NUM>, mating portion <NUM> and transition portion <NUM>.

The retention portion <NUM> has a back wall <NUM> which extends from the sloped side wall <NUM>. The back wall <NUM> extends at approximately <NUM> degrees from the sloped side wall <NUM>. The back wall <NUM> is configured to approximate the space provided between the sloped side wall <NUM>, the top wall <NUM> of the box shaped contact portion <NUM>, the upper portion <NUM> of the side wall <NUM>, and the top wall <NUM>. As shown in <FIG>, a securing tab <NUM> which is provided at the distal end of the top wall <NUM>, extends into a cavity <NUM> formed in the side wall <NUM> proximate the back end <NUM>. The cavity <NUM>, as shown in <FIG>, is a cutout or opening which extends through the side wall <NUM> and which is dimensioned to receive and retain the securing tab <NUM> therein.

The retention portion <NUM> has a detent <NUM> provided on the sloped side wall <NUM>. The detent <NUM> extends from the free end <NUM> of the sloped side wall <NUM>. In the illustrative embodiment shown, one detent <NUM> is shown. However, other numbers and configurations of detents may be used. The detent <NUM> has an engagement shoulder <NUM> (<FIG>) which is provided proximate the free end <NUM> of the sloped side wall <NUM>.

As shown in <FIG>, a detent receiving opening <NUM> is provided in the top wall <NUM> of the box shaped contact portion <NUM>. The detent receiving opening <NUM> is positioned in alignment with the detent <NUM>. In the illustrative embodiment shown, one detent receiving opening <NUM> is shown. The detent receiving opening <NUM> has an engagement shoulder <NUM> which is provided proximate the side wall <NUM> of the box shaped contact portion <NUM>.

In use, the contact <NUM> is inserted into a contact receiving cavity of contact receiving housing (not shown). If the contact <NUM> is not fully or properly inserted, the contact receiving cavity does not fully enclose or encapsulate the contact <NUM>, allowing the contact <NUM>, and in particular, the retention portion <NUM>, to be engaged by a secondary lock or the like from the top or side.

Referring to <FIG>, a force F4 applied to the top surface <NUM> of the retention portion <NUM> will cause a bottom wall <NUM> of the back wall <NUM> to engage the top wall <NUM>. As the securing tab <NUM> of the top wall <NUM> is positioned in the cavity <NUM>, the securing tab <NUM> engages a wall <NUM> of the cavity <NUM> to prevent the downward movement of the securing tab <NUM> and the top wall <NUM>. As the top wall <NUM> is prevented from moving downward, the back wall <NUM> is also prevented from moving downward (as viewed in <FIG>).

As the force F4 is applied to the top surface <NUM> of the retention portion <NUM>, the side wall <NUM> of the back wall <NUM> may also engage the side wall <NUM> to prevent the lateral movement the back wall <NUM> and the retention portion <NUM> relative to the box shaped contact portion <NUM>. In addition, the engagement shoulder <NUM> of the detent <NUM> engage the engagement shoulder <NUM> of the detent receiving opening <NUM> to prevent the downward and the lateral movement the detent <NUM> and the retention portion <NUM> relative to the box shaped contact portion <NUM>. In so doing, the retention portion <NUM> and the contact <NUM> are strengthened to prevent damage or deformation without increasing the overall size of the terminal.

Referring again to <FIG>, a force F5 applied to the side wall <NUM> will cause the engagement shoulder <NUM> of the detent <NUM> to engage the engagement shoulder <NUM> of the detent receiving opening <NUM> to prevent the downward and the lateral movement the detent <NUM> and the retention portion <NUM> relative to the box shaped contact portion <NUM>. In so doing, the retention portion <NUM> and the contact <NUM> are strengthened to prevent damage or deformation without increasing the overall size of the terminal.

Referring again to <FIG>, a force F6 applied to the sloped side wall <NUM> will cause the side wall <NUM> of the back wall <NUM> to engage the side wall <NUM> to prevent the lateral movement the back wall <NUM> and the retention portion <NUM> relative to the box shaped contact portion <NUM>. In so doing, the retention portion <NUM> and the contact <NUM> are strengthened to prevent damage or deformation without increasing the overall size of the terminal.

Claim 1:
An electrical contact (<NUM>) comprising:
a mating portion (<NUM>) for mating with a mating contact, the mating portion (<NUM>) having a contact portion (<NUM>) at a front and a retention portion (<NUM>) at a back;
the mating portion (<NUM>) having a mating portion bottom wall (<NUM>), a mating portion top wall (<NUM>) and mating portion side walls (<NUM>, <NUM>), a respective mating portion side wall (<NUM>) having an upper portion (<NUM>) which extends beyond the top wall (<NUM>), the upper portion (<NUM>) extends to form the retention portion (<NUM>);
the retention portion (<NUM>) having a retention portion top wall (<NUM>), a retention portion side wall (<NUM>) and a retention portion back wall (<NUM>), the retention portion back wall (<NUM>) is disposed in the space between the mating portion top wall (<NUM>), the upper portion (<NUM>) of the respective mating portion side wall (<NUM>), the retention portion top wall (<NUM>) and a retention portion side wall (<NUM>);
wherein the retention portion back wall (<NUM>) cooperates with one or more of the mating portion top wall (<NUM>), the upper portion (<NUM>) of the respective mating portion side wall (<NUM>), the retention portion top wall (<NUM>) and a retention portion side wall (<NUM>) to prevent damage or deformation of the retention portion (<NUM>) as a force is applied to the retention portion (<NUM>),
characterised in that a detent (<NUM>) is provided on the retention portion side wall (<NUM>), the detent (<NUM>) extends from a free end (<NUM>) of the retention portion side wall (<NUM>), the detent (<NUM>) has an engagement shoulder (<NUM>) provided proximate the free end (<NUM>) of the retention portion side wall (<NUM>), and a detent receiving opening (<NUM>) is provided on the mating portion top wall (<NUM>), the detent receiving opening (<NUM>) positioned in alignment with the detent (<NUM>).