EP0880805B1 - Stamped power contact - Google Patents

Abstract

A power port terminal formed by stamping from a blank of conductive material comprises a contact receiving socket portion (12) and an integral mounting portion (14). The socket includes a web with a plurality of beams (20) thereon. The inner surface of the beams on the bends thereof define a substantially continuous cylindrical contact surface at a predetermined point along the reference axis of the terminal. The contact surface has a predetermined constricted dimension (36) measured in a plane perpendicular to the reference axis, this dimension being the most constricted dimension along the reference axis of the terminal. The terminal is thereby able to accomodate a pin of any desired axial length. The trailing mounting portion has a set of mounting legs (46) thereon, that in the preferred instance, extend generally perpendicular to the reference axis of the terminal. Latch tabs (38) may be provided on one or more of the beams. There are lateral projections (62) on the mounting portion, which restrain the terminal from pivoting on its longitudinal axis when it is mounted in a through hole (52) in an insulative housing (50).

Description

Background of the Invention
• 1.Field of the Invention: The present invention relates to asocket-type terminal for use in effecting a relatively high-amperage powerconnection with a male pin of any desired length.
• 2.Brief Description of Prior Developments: A power port terminalfor interconnecting a backplane with a male pin plug may be formed inany one of a variety of ways. U.S. Patent No. 4,702,707 illustrates apower terminal that includes a base to which a mating component havinga socket may be attached. In this terminal the base and a portion of themating component are formed as screw machined parts. U.S. Patent No.4,749,357 shows a power connector in which a socket defined from acrown band of spring contact beams is inserted into a block of conductivematerial. In both of these arrangements the contact beams of theterminal extend around the entire 360° periphery of the male pin.However, since one end of the terminal is closed, the socket may accept apin having only a predetermined limited axial dimension.
• The power terminal shown at page 334, 335 of the Du PontElectronics Interconnect and Packaging Catalog, August 1988, is also amachined part having a socket that may accept a pin having only apredetermined limited axial dimension. This part also includes a snap-ringlatch arrangement which is received about the socket of the terminaland which cooperates with a housing to retain the terminal.
• The terminal shown in U.S. Patent No. 4,002,400, assigned to theassignee of the present invention, is formed from a stamped blank ofconductive material. Again, however, it appears that the socket portion of the terminal is blocked at an axially rearward point by a wire crimp barreland an insulation crimp barrel, effectively limiting the axial dimension ofa pin receivable in the socket.
• The power terminal forming a part of the Du Pont HPC ConnectorSystem, as shown at page 6 of Bulletin 7121, January 1987, is fabricatedfrom a stamped blank of conductive material. Although in this terminalthe length of the pin receivably by the socket is not limited, the socketregion does not fully surround the pin when the same is received therein.
• U.S. Patent 5,376,012, on which the preamble of claim 1 is based,discloses a power port terminal which is formed bystamping from a blank of conductive material. The socket includes a webwith a plurality of beams. The inner surface of the beams define asubstantially continuous cylindrical contact surface. The trailingmounting portion has a set of mounting legs. While this contact providesa socket formed from a stamped conductive material that both surroundsa male pin over substantially 360° of its periphery and does not limit theaxial length of pin receivable therein, it has been found that this contactmay tend to pivot on its longitudinal axis when it is mounted in a throughhole of an insulative housing.
• A need, therefore, exists for a stamped power contact which doesriot pivot on its longitudinal axis. A need also exists for such a stampedpower contact which is not subject to being overextended into the throughhole of the insulative housing in which it is mounted.
Summary of the Invention
• The present invention relates to a power port terminal according to claim 1. The terminal comprises acontact receiving socket portion and an integral mounting portion. The terminal has a reference axis extending therethrough. The contactreceiving socket portion includes a web with a plurality of beams thereon.When the terminal is formed the beams cooperate to form an axiallyextending tubular socket region. The inner surface of the beams on thebends thereof define a substantially continuous cylindrical contactsurface at a predetermined point along the reference axis within thetubular region. The contact surface is interrupted only by the spacingbetween the beams and is thus adapted to surround a male pin over 360°of its periphery. The cylindrical contact surface has a predeterminedconstricted dimension measured in a plane perpendicular to the referenceaxis, this dimension of the substantially continuous cylindrical contactsurface being the most constricted dimension along the reference axis ofthe terminal. The terminal is thereby able to accommodate a pin of anydesired axial length.
• The trailing mounting portion has a set of mounting legs thereon.The mounting legs depend from the lateral flanges of a curved hoodportion. The hood and flanges preferably surround substantially 270° ofthe periphery of the pin. In the preferred instance the mounting legsextend generally perpendicular to the reference axis of the terminal.Lateral projections also depend from the hood to restrain the terminalfrom pivoting about its longitudinal axis.
• One or more of the beams may have a latch tab thereon. The latchtabs engage with ribs provided in the terminal housing to secure theterminal therewithin.
Brief Description of the Drawings
• The invention will be more fully understood from the followingdetailed description thereof taken in connection with the accompanyingdrawings, which form a part of this application and in which:
• Fig. 1 is a side elevational view of a preferred embodiment of theterminal of the present invention;
• Fig. 2 is a top plan view of the terminal shown in Fig. 1;
• Fig. 3 is a front end view of the terminal shown in Fig. 1;
• Fig. 4 is a rear end view of the terminal shown in Fig. 1;
• Fig. 5 is a bottom plan view of the terminal shown in Fig. 1 asinserted in an insulative housing;
• Fig. 6 is a side elevational view of the contact and housing shown in
• Fig. 5 wherein the housing is in vertical cross section; and
• Fig. 7 is a front end view of the housing and contact shown in Fig.5.
Detailed Description of the Preferred Embodiments
• Throughout the following detailed description similar referencenumerals refer to similar elements in all figures of the drawings.
• With reference to Figs. 1 and 2 shown is a power port terminalgenerally indicated byreference character 10 in accordance with thepresent invention. Theterminal 10 is formed by stamping from a blank ofa suitable conductive material, such as beryllium copper material. Adeveloped view of the blank is illustrated in Fig. 6. Theterminal 10includes acontact receiving portion 12 and anintegral mounting portion14. Areference axis 10A extends through theterminal 10.
• Thecontact receiving portion 12 includes aweb 16 from whichextend a plurality of beams, or fingers, 20. The beams are preferably equiangularly arranged about theaxis 10A. In the embodimentillustrated fivebeams 20 are shown, each beam being angularly separatedfrom the angularly adjacent beam by agap 20G . When theterminal 10is fully formed (in a manner to be described) each of thebeams 20 has acurved insidesurface 20S with an inward bend 20B located axiallytherealong.
• Thebeams 20 cooperate to form an axially extendingtubular socketregion 26. Thesocket region 26 is thus adapted to surround a male pinguided therein over 360° of its periphery. Theinner surface 20S of thebeams 20 define a substantially continuouscylindrical contact surface 28lying at a predetermined point 30 along thereference axis 10A within thetubular socket region 26. Thecontact surface 28 is, as may be best seenin Figs. 3 and 4, interrupted only by thegap 20G between angularlyadjacent beams 20.
• Thecylindrical contact surface 28 defined by the bends 20B of eachbeam 20 defines a circle centered on thereference axis 10A of theterminal. Thesurface 28 thus imparts a predetermined constricteddimension 36 (i.e., the diameter of the surface 28) measured in a planeperpendicular to thereference axis 10A. Thisdimension 36 of thesubstantially continuouscylindrical contact surface 28 is the mostconstricted dimension along thereference axis 10A of the terminal. Thethrough bore of thesocket region 26 of the terminal 10 is thus effectivelyunlimited. The terminal 10 is thereby able to accommodate a pin of anydesired axial length.
• In the preferred embodiment two of thebeams 20 are provided withlatch tabs 38. As may be seen in Fig. 3 thetabs 38 extend outwardlybeyond the basic outer diametric dimension of thecontact receiving portion 12. As an alternative it should be understood that only a singlelatch tab or more than two latch tabs may be provided as desired. Thetabs 38 may be conveniently located on any of thebeams 20. In thepreferred arrangement the tab(s) 38 are formed as appendages disposedaxially between the laterally outward beam(s) 20' and the mountingportion 14. Thetabs 38 may be additionally or alternately formed bypunching through the material of theweb 16.
• The trailing mountingportion 14 extends rearwardly from theweb16. The mountingportion 14 includes ahood region 40 melding into apair oflateral flanges 42. As is best seen in Fig. 4 and 5 thehood 40 andtheflanges 42 preferably extend substantially 270° about thereferenceaxis 10A of the terminal 10. A plurality of mountinglegs 46 dependingfrom eachflange 42 defines a set of mounting legs for the terminal 10.The mountinglegs 46 each extend downwardly a substantial distancebelow thecontact receiving portion 12.
• In the preferred embodiment, the mounting legs extend generallyperpendicularly to thereference axis 10A of the terminal. The mountinglegs 46 may be received by plated through bores provided in the surface ofa substrate whereby electrical interconnection may be effected betweenthe terminal 10 and a backplane on the substrate. It should beunderstood that is within the contemplation of the present invention toarrange thelegs 46 such that they align parallel to thereference axis 10Aof the terminal.
• The terminal 10 would preferably be formed from a blank (notshown). The blank is attached to a carrier strip (not shown) by a tail (notshown). The blank is made by a stamping operation and the terminal 10 is formed therefrom by bending the blank over a mandrel, as isunderstood by those skilled in the art.
• With reference to Figs. 5 - 7 the terminal 10 is received within ahousing 50 formed from a block of a suitable insulating material. Thehousing 50 has a throughpassage 52 therein. Locatingguide members54 extend axially along the walls of thepassage 52 to position theterminal 10 within the housing. Lockingribs 56 are disposed about therear end of the throughhole 52. The terminal 10 is inserted into thepassage 52 in thehousing 50 in the direction of thearrow 58. Thelatches 38 on thebeams 20 are resiliently deflected as the terminal 10 isinserted into thehousing 50. Once axially past the lockingribs 56 thelatches 38 snap into locking position behind the lockingribs 56. Thecircumferential extend of the lockingribs 56 is such that thetabs 38 willengage against arib 56 to retain the terminal 10, once inserted, withinthehousing 50.
• Since thedimension 36 of thesurface 28 is the most constricteddimension of the socket, a terminal 10 in accordance with the presentinvention presents no impediment to the axial advance of a male pin.Thus a pin having any desired length may be received coaxially with thereference axis of the terminal. Such a capability is believed advantageouswhen using the terminal of the present invention in a so-called "firstmake-last break" interconnection system.
• Referring to Figs. 1 - 4 and 6, resilientlateral projections 60 extendfrom thehood 40 of the mountingportion 14. To the rear of theselateralprojections 60 there areappendages 62. Referring particularly to Fig. 6, itwill be seen that theresilient lateral projections 60 engage lockingribs 56.It will be understood that thelateral projections 60 on the opposed sides the opposed sides of the terminal 10 each engage a lockingrib 56 so as toprevent or significantly reduce pivotal motion of the terminal 10 in thethroughhole 52 of theinsulative housing 50. It will also be appreciatedthat theappendages 62 extend outwardly from thelateral projections 60so as to abut the rear of the insulative housing and prevent the terminal10 from being overextending into the thoughhole 52.
• It will be appreciated that a stamp power contact has beendescribed which is not subject to undo pivoting motion in the throughhole of an insulative housing in which it is mounted. It will also beappreciated that this stamp power contact is not subject to beingoverextended into the through hole of the insulative housing.
• While the present invention has been described in connection withthe preferred embodiments of the various figures, it is to be understoodthat other similar embodiments may be used or modifications andadditions may be made to the described embodiment for performing thesame function of the present invention without deviating therefrom.Therefore, the present invention should not be limited to any singleembodiment, but rather construed in breadth and scope in accordancewith the recitation of the appended claims.

Claims (4)

1. A female-type power port terminal (10)being receivable within a housing (50) with at least one rib (56) atthe rear end of a through hole (52)for connecting to a male plug of awide range of lengths and cross-sectional dimensions, comprising:

   a contact receiving portion (12) having a web and a plurality of fingers(20) that are unitary with said web (16), said fingers (20) being arranged toform an axially extending socket that is aligned about a reference axis(10A), each of said fingers (20) having a free end and that is distal fromsaid web (16), said free ends being unconnected to each other exceptthrough said web (16), each of said fingers (20) further having a bendtherein proximate said free end said bends together defining a contact surface(28) that is constructed and arranged to contact a male plug that is insertedinto said socket, said contact surface (28) being the most constrictedpoint along said reference axis (10A) in said terminal (10); and

   a mounting portion (14) that is unitary with and extends longitudinallyfrom said contact receiving portion (12) and is formed together with saidcontact receiving portion (12) from a single blank of conductive material,said mounting portion (14) comprising a hood region (40) that is curvedabout said reference axis (10A) by substantially 270 ° to define a spacethat is coextensive and aligned with said socket, said hood region 40 beingopen at least to permit the plug to pass into said space, said mounting portion(14) further comprising a plurality of mounting legs (46) thereon formounting the terminal on a substrate; whereby said terminal (10), as a resultof said unconnected free ends, is constructed to accept the male plugs within a wide range of cross-sectional dimensions, and, as a result of saidopen space defined by said hood region (40), is constructed to accept amale plug of a wide range of lengths (40),characterized in that

   said hood region (40) further comprises a pair of opposed lateral projections(60, 62) extending from said hood region(40) to abut the rear end of the locking ribs (56), for preventing or reducing pivotal and linear motion of said terminal(10) during mating and unmating of a corresponding male plug, and for preventing the terminal from being over extended inthe through hole.
2. The power port terminal (10) of claim 1,characterized in that the mountinglegs (46) have a longitudinal axis extending generally perpendicularly tothe reference axis (10A).
3. The power port terminal (10) of claims 1, and 2,characterized in that atleast one of the fingers (20) has a latch tab (38) thereon or wherein at leasttwo of the fingers (20) have a latch tab (38) thereon.
4. A socket for connecting to a male plug of awide range of lengths and cross-sectional dimensions, having an insulativehousing (50) and a female-type power portterminal (10) according to one of the claims 1-3 insertedtherein.

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