ELECTRICAL CONTACT ELEMENT AND AN ELECTRICAL CONNECTOR AND AN ELECTRICAL CONNECTOR ASSEMBLY COMPRISING THE CONTACT ELEMENT
United States Patent 3596235
The tines of a uniplanar sheet metal fork receptacle for a tab or post are rectangularly bent so that the effective lever length of each arm exceeds the length or height of a housing in which the receptacle is disposed. The tendency of the housing dimensions to restrict the range of tab and post shapes and sizes that the receptacle can accommodate is thus reduced.
US Patent References:
Combined contact and wire terminal
Daly - March 1962 - 3027440
Terminal blocks and connectors therefor
Ege - July 1965 - 3193794
Electrical connector
Gammel et al. - January 1968 - 3366919
Combined contact and wire terminal
Daly - March 1962 - 3027440
Terminal blocks and connectors therefor
Ege - July 1965 - 3193794
Electrical connector
Gammel et al. - January 1968 - 3366919
Application Number:
04/849402
Publication Date:
07/27/1971
Filing Date:
08/12/1969
View Patent Images:
Export Citation:
Assignee:
AMP Incorporated (Harrisburg, PA)
Primary Class:
Other Classes:
439/80, 439/65, 439/907
International Classes:
H01R12/18; H01R9/08; H05K1/00
Field of Search:
339/176,192,217,218,219,220,243,252,256,258,241,74,262,47,49,17
Primary Examiner:
Calvert, Ian A.
Assistant Examiner:
Hafer, Robert A.
Claims:
I claim
1. An electrical contact element which has been stamped from a single piece of sheet metal stock of uniform thickness so as to be substantially uniplanar, the contact element comprising first and second cantilever contact springs extending in the same direction from a base and being resiliently deformable in the plane of the contact element to grip a male contact member inserted between the contact springs, each of the contact springs comprising a first portion extending from the base and being capable of flexing relative thereto and a second portion which is angled with respect to the first portion and being capable of flexing relative thereto and which is engaged by the male member when the male member is inserted between the contact springs; each said second portion extending in the same general direction from its associated first portion, the first and second portions of the contact springs being so angled and the cross-sectional areas of these portions being so chosen that the second portions are flexed about their junctions with the first portions upon the second portions being engaged by the male member so that the first portions are flexed about their junctions with the base.
2. A contact element according to claim 1, in which the first portions of the contact springs are parallel, the first portion of the first contact spring being shorter than the first portion of the second contact spring, the second portion of the second contact spring extending substantially at right angles to the first portion of that contact spring, and the second portion of the first contact spring being inclined towards the second portion of the second contact spring.
3. A contact element according to claim 2, in which the first contact spring has a third portion extending from the end of the second portion remote from the first portion, the third portion being angled with respect to the second portion to cooperate with an inclined surface on the second portion of the second contact spring to provide a guiding mouth for the male member.
4. A contact element according to claim 1, in which the base extends parallel to the insertion direction of the male member, at least one first post extending from an end of the base, a second post extending from the base in substantial axial alignment with the first portion of the second contact spring.
5. An electrical contact element, which has been stamped from a single piece of sheet metal stock of uniform thickness so as to be substantially uniplanar, the contact element comprising a base member having first and second cantilever contact spring members extending outwardly from one side of said base member in the same direction, said contact spring members being contained in the same plane as said base member and being resiliently movable toward and away from each other in this plane, said contact spring members having first sections extending outwardly from said base member in a substantially parallel manner and second sections extending at an angle with respect to said first sections and in the same general direction and being spaced apart a sufficient distance thereby defining a contact-receiving area therebetween, junctions between said first and second sections and between said first sections and said base member adapted to be flexed when said contact-receiving area receives a contact member therein.
6. An electrical contact element as defined in claim 5 wherein one of said contact spring members is an outer spring member and its second section is disposed substantially at a right angle with respect to its first section while the other of said spring contact members is an inner spring member and its second section is disposed at an acute angle with respect to its first section, and said second section of said inner spring member extends toward but spaced from the second section of said outer spring member.
7. An electrical contact element as defined in claim 6 wherein said second section of said inner spring member has an outer section defining a free end which is disposed at an acute angle with respect to said second section of said inner spring member and extends in a direction away from said second section of said outer spring member, a free end of said second section of said outer spring member has a chamfered area facing said free end of said second section of said inner spring member, said free ends defining guide means.
8. An electrical contact element as defined in claim 5 wherein said base member at one end has first and second contact sections extending outwardly from said base member at a right angle with respect to one another and at the other end a third contact section extending in the same direction as said base member.
9. An electrical contact element as defined in claim 5 where said base member has an extension along a section thereof.
10. An electrical connector comprising in combination a dielectric housing and an electrical contact element, said housing being substantially rectangular and having a cavity therein, an internal wall provided in said housing dividing said cavity into a base-receiving portion and a contact-receiving portion, a wall of said housing having an opening in communication with said contact-receiving portion, another wall of said housing having another opening in communication with said base-receiving and contact-receiving portions through which said electrical contact element is positioned in said cavity, said another opening and said base-receiving and contact-receiving portions cooperating to form a generally C-shaped cavity, said electrical contact element having a base member disposed in said base-receiving portion and cantilever spring contact members extending outwardly from said base member, said spring contact members having first sections extending substantially parallel to one another and disposed in the bight portion of the C-shaped cavity and second sections disposed at an angle with respect to said first sections, said second sections disposed in said contact-receiving portion and having a contact-engaging area in alignment with said first-mentioned opening, and means provided by said housing and said electrical contact element securing the base member of said contact element in said cavity while permitting free flexing movement of said first and second sections of said spring contact members.
11. An electrical connector comprising in combination a dielectric housing and an electrical contact element, said housing being substantially rectangular and having a cavity therein, an internal wall provided in said housing dividing said cavity into a base-receiving portion and a contact-receiving portion, a wall of said housing having an opening in communication with said contact-receiving portion, another wall of said housing having another opening in communication with said base-receiving and contact-receiving portions through which said electrical contact element is positioned in said cavity, said electrical contact element having a base member disposed in said base-receiving portion and cantilever spring contact members extending outwardly from said base member, said spring contact members having first sections extending substantially parallel to one another and second sections disposed at an angle with respect to said first sections, said second sections disposed in said contact-receiving portion and having a contact-engaging area in alignment with said first-mentioned opening, means provided by said housing and said electrical contact element securing said contact element in said cavity, post members extending outwardly from said base member and outwardly beyond said housing through said another opening and a further opening in said first-mentioned wall and spaced apart from said first-mentioned opening therein.
12. An electrical connector comprising an electrical contact element having first and second cantilever contact springs extending in the same direction from a base and being resiliently deformable to grip a male contact member inserted between the contact springs, the contact element being disposed within a cavity in an insulating housing, said housing being substantially rectangular and having an open first side through which the contact element is insertable into the cavity, the housing having a first aperture in a second side thereof opposite to the first side for receiving the male member, a first post projecting from the contact element and extending from the open side of the housing, and a second post also projecting from the contact element and extending from the housing at right angles to the first post, and a third post extending from the base through a second aperture in the second side of the housing, the second aperture also extending through a third wall of the housing adjacent to the second wall.
13. A connector as set forth in claim 12 further including an internal wall in the housing, said wall extending on the opposite side of the base of the contact element from the said third wall, the base being secured between the internal wall and the third wall.
14. A connector as set forth in claim 12 wherein the contact element base has an enlarged portion having a boss which engages a sidewall portion of the housing, the enlarged portion further having opposite flat surfaces for locating the contact element in the cavity between the internal wall and the third wall.
1. An electrical contact element which has been stamped from a single piece of sheet metal stock of uniform thickness so as to be substantially uniplanar, the contact element comprising first and second cantilever contact springs extending in the same direction from a base and being resiliently deformable in the plane of the contact element to grip a male contact member inserted between the contact springs, each of the contact springs comprising a first portion extending from the base and being capable of flexing relative thereto and a second portion which is angled with respect to the first portion and being capable of flexing relative thereto and which is engaged by the male member when the male member is inserted between the contact springs; each said second portion extending in the same general direction from its associated first portion, the first and second portions of the contact springs being so angled and the cross-sectional areas of these portions being so chosen that the second portions are flexed about their junctions with the first portions upon the second portions being engaged by the male member so that the first portions are flexed about their junctions with the base.
2. A contact element according to claim 1, in which the first portions of the contact springs are parallel, the first portion of the first contact spring being shorter than the first portion of the second contact spring, the second portion of the second contact spring extending substantially at right angles to the first portion of that contact spring, and the second portion of the first contact spring being inclined towards the second portion of the second contact spring.
3. A contact element according to claim 2, in which the first contact spring has a third portion extending from the end of the second portion remote from the first portion, the third portion being angled with respect to the second portion to cooperate with an inclined surface on the second portion of the second contact spring to provide a guiding mouth for the male member.
4. A contact element according to claim 1, in which the base extends parallel to the insertion direction of the male member, at least one first post extending from an end of the base, a second post extending from the base in substantial axial alignment with the first portion of the second contact spring.
5. An electrical contact element, which has been stamped from a single piece of sheet metal stock of uniform thickness so as to be substantially uniplanar, the contact element comprising a base member having first and second cantilever contact spring members extending outwardly from one side of said base member in the same direction, said contact spring members being contained in the same plane as said base member and being resiliently movable toward and away from each other in this plane, said contact spring members having first sections extending outwardly from said base member in a substantially parallel manner and second sections extending at an angle with respect to said first sections and in the same general direction and being spaced apart a sufficient distance thereby defining a contact-receiving area therebetween, junctions between said first and second sections and between said first sections and said base member adapted to be flexed when said contact-receiving area receives a contact member therein.
6. An electrical contact element as defined in claim 5 wherein one of said contact spring members is an outer spring member and its second section is disposed substantially at a right angle with respect to its first section while the other of said spring contact members is an inner spring member and its second section is disposed at an acute angle with respect to its first section, and said second section of said inner spring member extends toward but spaced from the second section of said outer spring member.
7. An electrical contact element as defined in claim 6 wherein said second section of said inner spring member has an outer section defining a free end which is disposed at an acute angle with respect to said second section of said inner spring member and extends in a direction away from said second section of said outer spring member, a free end of said second section of said outer spring member has a chamfered area facing said free end of said second section of said inner spring member, said free ends defining guide means.
8. An electrical contact element as defined in claim 5 wherein said base member at one end has first and second contact sections extending outwardly from said base member at a right angle with respect to one another and at the other end a third contact section extending in the same direction as said base member.
9. An electrical contact element as defined in claim 5 where said base member has an extension along a section thereof.
10. An electrical connector comprising in combination a dielectric housing and an electrical contact element, said housing being substantially rectangular and having a cavity therein, an internal wall provided in said housing dividing said cavity into a base-receiving portion and a contact-receiving portion, a wall of said housing having an opening in communication with said contact-receiving portion, another wall of said housing having another opening in communication with said base-receiving and contact-receiving portions through which said electrical contact element is positioned in said cavity, said another opening and said base-receiving and contact-receiving portions cooperating to form a generally C-shaped cavity, said electrical contact element having a base member disposed in said base-receiving portion and cantilever spring contact members extending outwardly from said base member, said spring contact members having first sections extending substantially parallel to one another and disposed in the bight portion of the C-shaped cavity and second sections disposed at an angle with respect to said first sections, said second sections disposed in said contact-receiving portion and having a contact-engaging area in alignment with said first-mentioned opening, and means provided by said housing and said electrical contact element securing the base member of said contact element in said cavity while permitting free flexing movement of said first and second sections of said spring contact members.
11. An electrical connector comprising in combination a dielectric housing and an electrical contact element, said housing being substantially rectangular and having a cavity therein, an internal wall provided in said housing dividing said cavity into a base-receiving portion and a contact-receiving portion, a wall of said housing having an opening in communication with said contact-receiving portion, another wall of said housing having another opening in communication with said base-receiving and contact-receiving portions through which said electrical contact element is positioned in said cavity, said electrical contact element having a base member disposed in said base-receiving portion and cantilever spring contact members extending outwardly from said base member, said spring contact members having first sections extending substantially parallel to one another and second sections disposed at an angle with respect to said first sections, said second sections disposed in said contact-receiving portion and having a contact-engaging area in alignment with said first-mentioned opening, means provided by said housing and said electrical contact element securing said contact element in said cavity, post members extending outwardly from said base member and outwardly beyond said housing through said another opening and a further opening in said first-mentioned wall and spaced apart from said first-mentioned opening therein.
12. An electrical connector comprising an electrical contact element having first and second cantilever contact springs extending in the same direction from a base and being resiliently deformable to grip a male contact member inserted between the contact springs, the contact element being disposed within a cavity in an insulating housing, said housing being substantially rectangular and having an open first side through which the contact element is insertable into the cavity, the housing having a first aperture in a second side thereof opposite to the first side for receiving the male member, a first post projecting from the contact element and extending from the open side of the housing, and a second post also projecting from the contact element and extending from the housing at right angles to the first post, and a third post extending from the base through a second aperture in the second side of the housing, the second aperture also extending through a third wall of the housing adjacent to the second wall.
13. A connector as set forth in claim 12 further including an internal wall in the housing, said wall extending on the opposite side of the base of the contact element from the said third wall, the base being secured between the internal wall and the third wall.
14. A connector as set forth in claim 12 wherein the contact element base has an enlarged portion having a boss which engages a sidewall portion of the housing, the enlarged portion further having opposite flat surfaces for locating the contact element in the cavity between the internal wall and the third wall.
Description:
There is disclosed in U.S. Pat. No. 2,760,176, an electrical contact element which has been stamped from a single piece of sheet metal stock of uniform thickness, so as to be substantially uniplanar, the contact element comprising first and second cantilever contact springs extending in the same direction from a base and being resiliently deformable in the plane of the contact element to grip a male contact member inserted between the contact springs. Upon insertion of the male member, the contact springs are forced apart by the male member so as to flex about their junctions with the base.
The contact element is for disposal in a substantially square insulating housing for mounting on a printed circuit panel, the contact springs being of short effective lever length in view of the shape of the housing with the result that the contact element is mateable only with male members of an undesirably small range of thickness, since the fact that the contact springs are flexed in the plane of the contact element severely limits the extent to which the contact springs may be deflected without being permanently set.
The present invention concerns a contact element which is preferably for use in circuit systems in which male members having a wide variety of different cross-sectional shapes and cross-sectional area may be employed, the male members being in the form, for example, both of flat tabs and square cross-sectional electrical posts. To this end it is essential that the contact springs of the contact element should be spaced by a minimum width corresponding to the minimum male member thickness and yet be capable of receiving the male members of maximum thickness without being permanently set.
According to an object of the invention, in a contact element each of the contact springs comprises a first portion extending from the base and a second portion which is angled with respect to the first portion and which is engaged by the male member when the male member is inserted between the contact springs; the first and second portions of the contact springs being so angled and the cross-sectional areas of these portions being so chosen that the second portions are flexed about their junctions with the first portions upon the second portions being engaged by the male member so that the first portions are flexed about their junction with the base.
A contact element according to another object of the invention may conveniently be received in a substantially rectangular insulating housing which can be secured with various different orientations to a printed circuit panel, the contact element and the housing being such that the contact element is capable of being mated with a male member which is differently positioned with respect to the panel, in each orientation of the housing, at least one post extending from the contact element being positioned to engage in a hole in the printed circuit panel in each orientation of the housing.
Other objects and attainments of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings in which there are shown and described illustrative embodiments of the invention; it is to be understood, however, that these embodiments are not intended to be exhaustive nor limiting of the invention but are given for purposes of illustration in order that others skilled in the art may fully understand the invention and the principles thereof and the manner of applying it in practical use so that they may modify it in various forms, each as may be best suited to the conditions of a particular use.
For a better understanding of the invention, reference will now be made by way of example to the accompanying drawings, in which:
FIG. 1 is a perspective view of a female electrical contact element;
FIG. 2 is an elevational view partly in section of an insulating housing for the contact element;
FIG. 3 is a perspective view of the housing showing the contact element mounted in the housing, the contact element being shown in broken lines;
FIG. 4 is a cross-sectional view of a first electrical connector assembly including the contact element mounted in the housing;
FIG. 5 is an elevational view partly in section of a second electrical connector assembly including the contact element mounted in the housing, the contact element being shown mainly in broken lines;
FIG. 6 is a cross-sectional view of a third electrical connector assembly including the contact element mounted in the housing; and
FIG. 7 is a fragmentary cross-sectional view of a fourth electrical connector assembly comprising a plurality of the contact elements each mounted in its housing.
Reference will now be made to FIG. 1. The contact element which is generally referenced C and which has been stamped from a single piece of sheet metal stock of uniform thickness so as to be substantially uniplanar, comprises a rectilinear base 1 from which extend a pair of cantilever contact springs 2 and 3. The contact spring 2 has a first portion 4 extending substantially at right angles from the base 1 and a second portion 6 extending substantially at right angles from the end of the portion 4 remote from the base 1, the left-hand (as seen in FIG. 1) edge of the free end of the portion 6 having a chamfered surface 8. The contact spring 3 has a first portion 10 extending substantially at right angles from the base 1, a second portion 12 extending from the end of the portion 10 remote from the base 1 and converging upwardly (as seen in FIG. 1) towards the portion 6 of the contact spring 2 and a third portion 14 which diverges upwardly and outwardly (as seen in FIG. 1) from the portion 6 to cooperate with the chamfered surface 8 to provide a mouth 9 for guiding a male electrical contact member between the contact springs 2 and 3 when inserted into the mouth 9 in the direction of the arrow A. Posts 16 and 18 of smaller cross-sectional area than the base 1 extend at right angles to one another from the lower (as seen in FIG. 1) end of the base 1, the post 16 having at its root an essentially triangular-shaped stop 20, the apex of which is directed upwardly (as seen in FIG. 1). The stop 20 has an upper (as seen in FIG. 1) surface 21 which is inclined at a given angle with respect to the vertical front surface (as seen in FIG. 1). A guide portion 22, which may be regarded as a part of and therefore an extension of the base 1, extends from the upper (as seen in FIG. 1) end of the base 1, the guide portion 22 being of greater cross-sectional area than the base 1 and having a flat surface 28 which is offset from the base 1 in the direction of the portion 12 of the spring 3. The portion 22 has one or more rounded bosses 24 (only one of these bosses shown). A further post 26 extends from the upper (as seen in FIG. 1) end of the portion 22 and is of considerably smaller cross-sectional area than the portion 22.
As shown in FIGS. 2 and 3, a rectangular insulating housing H for the contact element C, is square as seen in elevation and comprises broad sidewalls 40 and 42 and narrower walls 44, 46 and 48, the lower (as seen in FIG. 2) side of the housing H being open. The wall 48 has an inwardly-tapered aperture 30 communicating with an internal cavity 32 of the housing H and into which extends an elongate internal wall 34. A further aperture 36 in the wall 48 communicates with the cavity 32 on the opposite side of the wall 34 to the aperture 30. The sidewall 42 has an inclined step portion 52, so that a portion 53 of the sidewall 42 is less widely spaced from the sidewall 40 than the remainder of the sidewall 42. The wall 46 has a rounded-off end portion 54 at its end adjacent the mouth of the aperture 36 and an inclined end surface 56 having the same angle of inclination as the surface 21 of the stop 20.
The contact element C can be mounted in the housing H by inserting it through the open side of the housing H so that the portion 6, 12 and 14 of the contact springs 2 and 3 extend into the cavity 32 between the walls 34 and 44 with the mouth 9 of the contact element C in alignment with the aperture 30 of the housing H, as shown for example in FIG. 4. The contact element C is guided into the housing H by cooperation between the portion 22 of the contact element C and walls 34 and 46. When the contact element C has been fully inserted into the housing H, the portion 22 lies between the walls 34 and 46 so that the post 26 projects through the aperture 36 outwardly of the housing H. The surface 21 of the stop 20 engages the surface 56 of the wall 46 thus limiting the insertion of the contact element within the housing. The boss or bosses 24 engage the portion 53 of the sidewall 42 when the contact element C has been fully inserted into the housing H. The post 18 projects through the open side of the housing, the post 16 extending outwardly of the housing and at right angles to the wall 46.
The electrical connector so formed by the contact element C and housing H may be used in a variety of different ways as will now be described with reference to FIGS. 4 to 7.
As shown in FIG. 4, the housing H has been mounted on a first printed circuit panel P1 with the open side of the housing adjacent the panel P1 and the post 18 extending through a hole in the panel P1 and being secured in the hole by solder to secure the contact element C to a conductive path (not shown) on the panel P1. A male contact element M1 stamped from a single piece of metal stock of uniform thickness has a body 58 from which extend posts 60 projecting through holes in a second printed circuit panel P2 and being secured in these holes by solder which is also employed to connect the posts 60 to one or more printed conductors (not shown) on the panel P2. The contact element M1 has a male contact member 62 extending from the body 58 and mating with the contact element C, as shown in FIG. 4. The lower (as seen in FIG. 4) end surface of the body 58 of the contact element M1 engages the exterior surface of the wall 48 of the housing H, the lower (as seen in FIG. 4) edge portion of the panel P2, which extends at right angles to the panel P1, engaging the exterior surface of the wall 44 of the housing H so that the panel P2 is located in engagement with respect to the housing H.
The member 62 was mated with the contact element C by moving the panel P3 towards the housing H to introduce the member 62 through the aperture 30 and between the portions 6 and 12 of the contact springs 1 and 2 guided by the inwardly-tapering surfaces of the aperture 30 and the mouth 9, the insertion of the male member 62 being limited by the engagement of the body 58 against the wall 48.
As a result of the insertion of the male member 62 between the contact spring portions 6 and 12, the portions 6 and 12 are flexed outwardly about their junctions with the portions 4 and 10 respectively of the contact springs, the portions 10 and 4 of the contact springs 3 and 2 respectively also flexing about their junctions with the base 1. The effective lever length of the contact spring 3 is accordingly approximately equal to the sum of the lengths of the portions 10 and 12 of the contact spring 3. There is sufficient clearance between the panel P1 and the portion 4 of the contact spring 2 to enable the portion 4 also to flex about its junction with the base 1. The effective lever length of the contact spring 2 is accordingly approximately equal to the sum of the lengths of the portions 4 and 6 of the contact spring 2. By virtue of the considerable lever lengths of the contact springs 2 and 3, the receptacle formed by the contact springs 2 and 3 is capable of receiving male members of a wide range of different cross-sectional shapes and cross-sectional areas. The right-hand (as seen in FIG. 4) surface of the wall 34 and the interior surface of the wall 44 of the housing H restrain the contact spring portions 6 and 12 against excessive outward movement during mating, for example as a result of initial misalignment between the male member 62 and the mouth 9. Over-stressing of the contact springs is thus avoided.
The posts 16 and 26 may be employed for connecting leads to the contact element C, a lead being soldered for example to the post 16 or wrapped for example about the post 26. The post 26 may otherwise be employed for example to mate with the electrical receptacle provided, for example by a further electrical contact element C in a further housing H. The post 18 may be soldered to a printed conductor (not shown) on the lower (as seen in FIG. 4) surface of the panel P1. If not required, the posts 16 and 26 may be severed from the contact element C.
As shown in FIG. 5, the housing H is mounted on a first printed circuit panel P3 with the wall 48 of the housing H adjacent the panel P3, the post 26 extending through a hole in the panel P3 and being secured to a conductive path (not shown) by solder. The aperture 30 is aligned with a further hole in the panel P3 and receives the male member 62' of a male contact element M2 similar to the element M1 and being similarly secured to a second printed circuit panel P4 by legs 60', the body 58' of the contact element M2 being, however, somewhat narrower than the body 58 of the contact element M1. The upper (as seen in FIG. 5) edge of the panel P4 which extends at right angles to the panel P2 limits the insertion of the male member 62' between the contact springs 2 and 3. The post 18', corresponding to the post 18 of the contact element C of FIG. 4, has a lead 68 wrapped thereabout, and it is longer than the post 18.
As shown in FIG. 6, the housing H may be mounted on a first printed circuit panel P5 with the wall 46 of the housing H adjacent the panel P5, the post 16 extending through a hole in the panel P5 and being soldered to a printed conductor (not shown) on the panel P5. The post 26 has been bent over the rounded portion 54 of the wall 46 to extend at right angles to the portion 22 of the contact element C and has been inserted through a further hole in the panel P5 and being soldered to a printed conductor (not shown) on the panel P5. Since the cross section of the portion 22 is considerably greater than that of the post 26, the bending operation was readily performed without damage to the contact element C. Since the post 18 is redundant in this example, it was severed near its base from the contact element C. A male contact element M3 has a body 58" secured to a second printed circuit panel P6 in abutting coplanar relationship with the panel P5 by legs 60" extending through holes in the panel P6 and being soldered to printed conductors (not shown) thereon, the contact element M3 having a male member 62" extending through the aperture 30 and mating with the contact element C. The body 58" of the contact element M3 is of considerably greater width than that of either of the contact elements M1 or M2 described above. The insertion of the male member 62" is limited by the engagement of the panels P5 and P6.
As shown in FIG. 7, a plurality of connectors each according to FIG. 5, are arranged in superposed relationship to provide a modular electrical connecting system, the post 18" of one connector mating with the contact springs 2 and 3 of the next connector above (as seen in FIG. 7). The post 18.varies. of each contact element C may (as shown) have a shoulder 70 engaging the next connector above (as seen in FIG. 7) to locate the connectors of the system with respect to one another.
It will, therefore, be appreciated that the aforementioned and other desirable objects have been achieved; however, it should be emphasized that the particular embodiments of the invention, which are shown and described herein, are intended as merely illustrative and not as restrictive of the invention.
The contact element is for disposal in a substantially square insulating housing for mounting on a printed circuit panel, the contact springs being of short effective lever length in view of the shape of the housing with the result that the contact element is mateable only with male members of an undesirably small range of thickness, since the fact that the contact springs are flexed in the plane of the contact element severely limits the extent to which the contact springs may be deflected without being permanently set.
The present invention concerns a contact element which is preferably for use in circuit systems in which male members having a wide variety of different cross-sectional shapes and cross-sectional area may be employed, the male members being in the form, for example, both of flat tabs and square cross-sectional electrical posts. To this end it is essential that the contact springs of the contact element should be spaced by a minimum width corresponding to the minimum male member thickness and yet be capable of receiving the male members of maximum thickness without being permanently set.
According to an object of the invention, in a contact element each of the contact springs comprises a first portion extending from the base and a second portion which is angled with respect to the first portion and which is engaged by the male member when the male member is inserted between the contact springs; the first and second portions of the contact springs being so angled and the cross-sectional areas of these portions being so chosen that the second portions are flexed about their junctions with the first portions upon the second portions being engaged by the male member so that the first portions are flexed about their junction with the base.
A contact element according to another object of the invention may conveniently be received in a substantially rectangular insulating housing which can be secured with various different orientations to a printed circuit panel, the contact element and the housing being such that the contact element is capable of being mated with a male member which is differently positioned with respect to the panel, in each orientation of the housing, at least one post extending from the contact element being positioned to engage in a hole in the printed circuit panel in each orientation of the housing.
Other objects and attainments of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings in which there are shown and described illustrative embodiments of the invention; it is to be understood, however, that these embodiments are not intended to be exhaustive nor limiting of the invention but are given for purposes of illustration in order that others skilled in the art may fully understand the invention and the principles thereof and the manner of applying it in practical use so that they may modify it in various forms, each as may be best suited to the conditions of a particular use.
For a better understanding of the invention, reference will now be made by way of example to the accompanying drawings, in which:
FIG. 1 is a perspective view of a female electrical contact element;
FIG. 2 is an elevational view partly in section of an insulating housing for the contact element;
FIG. 3 is a perspective view of the housing showing the contact element mounted in the housing, the contact element being shown in broken lines;
FIG. 4 is a cross-sectional view of a first electrical connector assembly including the contact element mounted in the housing;
FIG. 5 is an elevational view partly in section of a second electrical connector assembly including the contact element mounted in the housing, the contact element being shown mainly in broken lines;
FIG. 6 is a cross-sectional view of a third electrical connector assembly including the contact element mounted in the housing; and
FIG. 7 is a fragmentary cross-sectional view of a fourth electrical connector assembly comprising a plurality of the contact elements each mounted in its housing.
Reference will now be made to FIG. 1. The contact element which is generally referenced C and which has been stamped from a single piece of sheet metal stock of uniform thickness so as to be substantially uniplanar, comprises a rectilinear base 1 from which extend a pair of cantilever contact springs 2 and 3. The contact spring 2 has a first portion 4 extending substantially at right angles from the base 1 and a second portion 6 extending substantially at right angles from the end of the portion 4 remote from the base 1, the left-hand (as seen in FIG. 1) edge of the free end of the portion 6 having a chamfered surface 8. The contact spring 3 has a first portion 10 extending substantially at right angles from the base 1, a second portion 12 extending from the end of the portion 10 remote from the base 1 and converging upwardly (as seen in FIG. 1) towards the portion 6 of the contact spring 2 and a third portion 14 which diverges upwardly and outwardly (as seen in FIG. 1) from the portion 6 to cooperate with the chamfered surface 8 to provide a mouth 9 for guiding a male electrical contact member between the contact springs 2 and 3 when inserted into the mouth 9 in the direction of the arrow A. Posts 16 and 18 of smaller cross-sectional area than the base 1 extend at right angles to one another from the lower (as seen in FIG. 1) end of the base 1, the post 16 having at its root an essentially triangular-shaped stop 20, the apex of which is directed upwardly (as seen in FIG. 1). The stop 20 has an upper (as seen in FIG. 1) surface 21 which is inclined at a given angle with respect to the vertical front surface (as seen in FIG. 1). A guide portion 22, which may be regarded as a part of and therefore an extension of the base 1, extends from the upper (as seen in FIG. 1) end of the base 1, the guide portion 22 being of greater cross-sectional area than the base 1 and having a flat surface 28 which is offset from the base 1 in the direction of the portion 12 of the spring 3. The portion 22 has one or more rounded bosses 24 (only one of these bosses shown). A further post 26 extends from the upper (as seen in FIG. 1) end of the portion 22 and is of considerably smaller cross-sectional area than the portion 22.
As shown in FIGS. 2 and 3, a rectangular insulating housing H for the contact element C, is square as seen in elevation and comprises broad sidewalls 40 and 42 and narrower walls 44, 46 and 48, the lower (as seen in FIG. 2) side of the housing H being open. The wall 48 has an inwardly-tapered aperture 30 communicating with an internal cavity 32 of the housing H and into which extends an elongate internal wall 34. A further aperture 36 in the wall 48 communicates with the cavity 32 on the opposite side of the wall 34 to the aperture 30. The sidewall 42 has an inclined step portion 52, so that a portion 53 of the sidewall 42 is less widely spaced from the sidewall 40 than the remainder of the sidewall 42. The wall 46 has a rounded-off end portion 54 at its end adjacent the mouth of the aperture 36 and an inclined end surface 56 having the same angle of inclination as the surface 21 of the stop 20.
The contact element C can be mounted in the housing H by inserting it through the open side of the housing H so that the portion 6, 12 and 14 of the contact springs 2 and 3 extend into the cavity 32 between the walls 34 and 44 with the mouth 9 of the contact element C in alignment with the aperture 30 of the housing H, as shown for example in FIG. 4. The contact element C is guided into the housing H by cooperation between the portion 22 of the contact element C and walls 34 and 46. When the contact element C has been fully inserted into the housing H, the portion 22 lies between the walls 34 and 46 so that the post 26 projects through the aperture 36 outwardly of the housing H. The surface 21 of the stop 20 engages the surface 56 of the wall 46 thus limiting the insertion of the contact element within the housing. The boss or bosses 24 engage the portion 53 of the sidewall 42 when the contact element C has been fully inserted into the housing H. The post 18 projects through the open side of the housing, the post 16 extending outwardly of the housing and at right angles to the wall 46.
The electrical connector so formed by the contact element C and housing H may be used in a variety of different ways as will now be described with reference to FIGS. 4 to 7.
As shown in FIG. 4, the housing H has been mounted on a first printed circuit panel P1 with the open side of the housing adjacent the panel P1 and the post 18 extending through a hole in the panel P1 and being secured in the hole by solder to secure the contact element C to a conductive path (not shown) on the panel P1. A male contact element M1 stamped from a single piece of metal stock of uniform thickness has a body 58 from which extend posts 60 projecting through holes in a second printed circuit panel P2 and being secured in these holes by solder which is also employed to connect the posts 60 to one or more printed conductors (not shown) on the panel P2. The contact element M1 has a male contact member 62 extending from the body 58 and mating with the contact element C, as shown in FIG. 4. The lower (as seen in FIG. 4) end surface of the body 58 of the contact element M1 engages the exterior surface of the wall 48 of the housing H, the lower (as seen in FIG. 4) edge portion of the panel P2, which extends at right angles to the panel P1, engaging the exterior surface of the wall 44 of the housing H so that the panel P2 is located in engagement with respect to the housing H.
The member 62 was mated with the contact element C by moving the panel P3 towards the housing H to introduce the member 62 through the aperture 30 and between the portions 6 and 12 of the contact springs 1 and 2 guided by the inwardly-tapering surfaces of the aperture 30 and the mouth 9, the insertion of the male member 62 being limited by the engagement of the body 58 against the wall 48.
As a result of the insertion of the male member 62 between the contact spring portions 6 and 12, the portions 6 and 12 are flexed outwardly about their junctions with the portions 4 and 10 respectively of the contact springs, the portions 10 and 4 of the contact springs 3 and 2 respectively also flexing about their junctions with the base 1. The effective lever length of the contact spring 3 is accordingly approximately equal to the sum of the lengths of the portions 10 and 12 of the contact spring 3. There is sufficient clearance between the panel P1 and the portion 4 of the contact spring 2 to enable the portion 4 also to flex about its junction with the base 1. The effective lever length of the contact spring 2 is accordingly approximately equal to the sum of the lengths of the portions 4 and 6 of the contact spring 2. By virtue of the considerable lever lengths of the contact springs 2 and 3, the receptacle formed by the contact springs 2 and 3 is capable of receiving male members of a wide range of different cross-sectional shapes and cross-sectional areas. The right-hand (as seen in FIG. 4) surface of the wall 34 and the interior surface of the wall 44 of the housing H restrain the contact spring portions 6 and 12 against excessive outward movement during mating, for example as a result of initial misalignment between the male member 62 and the mouth 9. Over-stressing of the contact springs is thus avoided.
The posts 16 and 26 may be employed for connecting leads to the contact element C, a lead being soldered for example to the post 16 or wrapped for example about the post 26. The post 26 may otherwise be employed for example to mate with the electrical receptacle provided, for example by a further electrical contact element C in a further housing H. The post 18 may be soldered to a printed conductor (not shown) on the lower (as seen in FIG. 4) surface of the panel P1. If not required, the posts 16 and 26 may be severed from the contact element C.
As shown in FIG. 5, the housing H is mounted on a first printed circuit panel P3 with the wall 48 of the housing H adjacent the panel P3, the post 26 extending through a hole in the panel P3 and being secured to a conductive path (not shown) by solder. The aperture 30 is aligned with a further hole in the panel P3 and receives the male member 62' of a male contact element M2 similar to the element M1 and being similarly secured to a second printed circuit panel P4 by legs 60', the body 58' of the contact element M2 being, however, somewhat narrower than the body 58 of the contact element M1. The upper (as seen in FIG. 5) edge of the panel P4 which extends at right angles to the panel P2 limits the insertion of the male member 62' between the contact springs 2 and 3. The post 18', corresponding to the post 18 of the contact element C of FIG. 4, has a lead 68 wrapped thereabout, and it is longer than the post 18.
As shown in FIG. 6, the housing H may be mounted on a first printed circuit panel P5 with the wall 46 of the housing H adjacent the panel P5, the post 16 extending through a hole in the panel P5 and being soldered to a printed conductor (not shown) on the panel P5. The post 26 has been bent over the rounded portion 54 of the wall 46 to extend at right angles to the portion 22 of the contact element C and has been inserted through a further hole in the panel P5 and being soldered to a printed conductor (not shown) on the panel P5. Since the cross section of the portion 22 is considerably greater than that of the post 26, the bending operation was readily performed without damage to the contact element C. Since the post 18 is redundant in this example, it was severed near its base from the contact element C. A male contact element M3 has a body 58" secured to a second printed circuit panel P6 in abutting coplanar relationship with the panel P5 by legs 60" extending through holes in the panel P6 and being soldered to printed conductors (not shown) thereon, the contact element M3 having a male member 62" extending through the aperture 30 and mating with the contact element C. The body 58" of the contact element M3 is of considerably greater width than that of either of the contact elements M1 or M2 described above. The insertion of the male member 62" is limited by the engagement of the panels P5 and P6.
As shown in FIG. 7, a plurality of connectors each according to FIG. 5, are arranged in superposed relationship to provide a modular electrical connecting system, the post 18" of one connector mating with the contact springs 2 and 3 of the next connector above (as seen in FIG. 7). The post 18.varies. of each contact element C may (as shown) have a shoulder 70 engaging the next connector above (as seen in FIG. 7) to locate the connectors of the system with respect to one another.
It will, therefore, be appreciated that the aforementioned and other desirable objects have been achieved; however, it should be emphasized that the particular embodiments of the invention, which are shown and described herein, are intended as merely illustrative and not as restrictive of the invention.