CN113612050A

CN113612050A - Electrical contact having multiple contact points of equal normal force

Info

Publication number: CN113612050A
Application number: CN202110467170.0A
Authority: CN
Inventors: S.D.费尔南德兹
Original assignee: TE Connectivity Services GmbH
Current assignee: TE Connectivity Services GmbH
Priority date: 2020-05-05
Filing date: 2021-04-28
Publication date: 2021-11-05
Anticipated expiration: 2041-04-28
Also published as: CN113612050B; DE102021111433A1

Abstract

The invention relates to an electrical contact having multiple contact points of equal normal force. An electrical connector includes a mating portion for receiving a mating protrusion therein. The mating portion has a first contact arm and a second contact engaging arm. The first contact engagement arm is spaced apart from the second contact engagement arm by a first slot. The first contact arm has a first length that is different from a second length of the second contact arm. A first normal force exerted by the first contact arm on the mating protrusion is equal to a second normal force exerted by the second contact arm.

Description

Electrical contact having multiple contact points of equal normal force

Technical Field

The invention relates to an electrical contact with multiple contact points having equal normal forces. The invention also relates to an electrical contact that can receive a mating projection from multiple directions.

Background

Contacts having multiple contact points facilitate providing redundant contact points to ensure that an electrical connection is established and maintained between the contact and the mating contact. The multiple contact points also help to transfer large currents between the contacts and the mating contacts. When multiple contacts are provided, each contact point has a different normal force. Thus, as the contacts are mated and unmated over multiple cycles, the wear at each contact point may change, thereby causing each contact point to have different electrical characteristics. This can result in an uneven flow of current across the contact points, resulting in poor performance of the contacts.

The contacts are generally configured to mate with the mating contacts in one direction. However, in some applications, it may be beneficial to allow mating contacts to be inserted into the contact from different directions.

Disclosure of Invention

The following provides an overview of certain illustrative embodiments of the 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.

It is desirable to provide a lance-like receiving recess in the contact receiving channel that overcomes the problems of the prior art. It would therefore be advantageous to provide an electrical contact with multiple contact points having equal normal forces. It would also be advantageous to provide an electrical contact that can receive mating projections from multiple directions.

Embodiments relate to an electrical connector for receiving a mating protrusion. The electrical connector has a mating portion for receiving the mating protrusion therein. The mating portion has a first contact arm and a second contact engaging arm. The first contact engagement arm is spaced apart from the second contact engagement arm by a first slot. The first contact arm has a first length that is different from a second length of the second contact arm. A first normal force exerted by the first contact arm on the mating protrusion is equal to a second normal force exerted by the second contact arm.

Embodiments relate to an electrical connector for receiving a mating protrusion. The electrical connector includes a mating portion for receiving the mating protrusion therein. The mating portion has a base portion with a mating portion first wall and a mating portion second wall. The first mating contact engagement portion extends from the mating portion first wall and the second mating contact engagement portion extends from the mating portion second wall. The first and second mating contact engagement portions have first and second contact engagement arms. The first contact engagement arm is spaced apart from the second contact engagement arm by a first slot. The first contact arm has a first length that is different from a second length of the second contact arm. A first normal force exerted by the first contact arm on the mating protrusion is equal to a second normal force exerted by the second contact arm.

The first and second mating contact engagement portions may have third contact engagement arms. The second contact engagement arm is spaced apart from the third contact engagement arm by a second slot. The third contact arm has a third length that is different from the first length of the first contact arm and the second length of the second contact arm. The first slot has a first slot length that is different from a second slot length of the second slot. A third normal force exerted by the third contact arm on the mating protrusion is equal to the first normal force exerted by the first contact arm and the second normal force exerted by the second contact arm.

Embodiments relate to electrical connectors for receiving mating projections from multiple directions. The electrical connector includes a mounting portion for mounting to a substrate or a mating connector and a mating portion for receiving a mating protrusion therein. The mating portion has a base with a first wall and a second wall. The first mating contact engagement portion extends from the first wall and the second mating contact engagement portion extends from the second wall. The first and second mating contact engagement portions have contact arms with first lead-in surfaces disposed at free ends thereof. The projection receiving slot extends between the first wall and the second wall of the base and continues between the first mating contact engagement portion and the second mating contact engagement portion. A second lead-in surface extends from the mating surface of the mating portion, the lead-in surface extending across the base, the first mating contact engagement portion, and the second mating contact engagement portion. The first and second lead-in surfaces allow the mating protrusion to be inserted into the protrusion receiving groove from different directions.

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 those skilled in the art, further embodiments of the present invention are possible without departing from the scope and spirit of the present invention. Accordingly, the drawings and associated descriptions are to be regarded as illustrative in nature and not as restrictive.

Drawings

The accompanying drawings, which are incorporated in and form a part of the specification, schematically illustrate one or more illustrative embodiments of the invention and, together with the general description given above and the detailed description given below, serve to explain the principles of the invention in which:

figure 1 is a perspective view of an illustrative embodiment of an electrical contact according to the present invention.

Figure 2 is a plan view of a first side of the electrical contact of figure 1.

Figure 3 is a plan view of a second side of the electrical contact of figure 1.

Figure 4 is a perspective view of the electrical contact of figure 1 mounted to a substrate.

Fig. 5 is a perspective view of the electrical contact of fig. 1 with a mating protrusion disposed above the electrical contact.

Figure 6 is a perspective view of the electrical contact of figure 1 with a mating protrusion disposed adjacent to the electrical contact.

Fig. 7 is a perspective view of the electrical contact of fig. 1 with a mating protrusion inserted therein.

Fig. 8 is a graph of illustrative normal force at a contact point of an electrical contact versus displacement of a contact arm of the electrical contact.

Figure 9 is a perspective view of an alternative illustrative embodiment of an electrical contact according to the present invention.

Figure 10 is a perspective view of an alternative illustrative embodiment of an electrical contact according to the present invention.

Figure 11 is a perspective view of an alternative illustrative embodiment of an electrical contact according to the present invention.

Detailed Description

The description of illustrative embodiments in accordance with the principles of the invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of the embodiments of the invention disclosed herein, any reference to direction or orientation is merely for convenience of description and does not in any way limit the scope of the invention. Such as "lower," "upper," "horizontal," "vertical," "above," "below," "upper," "lower," "top" and "bottom" as well as derivatives thereof (e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed to indicate an orientation as subsequently described or as illustrated in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly so indicated. Terms such as "attached," "secured," "connected," "coupled," "interconnected," and the like refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Furthermore, the features and benefits of the present invention are described with reference to preferred embodiments. The invention must therefore explicitly not be limited to these preferred embodiments, which show some possible non-limiting combinations of features, which may be present alone or in other combinations of features, the scope of the invention being defined by the appended claims.

Illustrative embodiments of the invention are now described with reference to the drawings. Reference numerals are used throughout the detailed description to refer to various elements and structures. Although the following detailed description contains many specifics for the purpose of illustration, one 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 examples of the present invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.

An illustrative electrical contact 10 according to the present invention is shown in fig. 1-7. The contact 10 has a mounting portion 14 and a male mating portion 16.

In the illustrative embodiment shown, the mounting portion 14 is a generally U-shaped configuration having a mounting portion first wall 18, a mounting portion second wall 20 spaced apart from the mounting portion first wall 18, and a mounting portion third wall 22 extending between the mounting portion first wall 18 and the mounting portion second wall 20. The mounting portion 14 has a substrate engaging surface 24, the substrate engaging surface 24 having mounting legs 26 extending therefrom in a direction away from the mating portion 16. In the illustrative embodiment shown, the mounting legs 26 are configured to be inserted into through holes (not shown) of the substrate 20 (fig. 4). Although an illustrative mounting portion 14 is shown in the drawings, the mounting portion 14 may have different configurations including, but not limited to, socket contacts, pin contacts, or crimp portions.

The mating portion 16 extends from the mounting portion 14. In the illustrative embodiment shown, mating portion 16 extends in a direction away from mounting leg 26. The fitting 16 has a base 28 with a fitting first wall 30, a fitting second wall 32 spaced from the fitting first wall 30, and a third wall fitting 34 extending between the fitting first wall 30 and the fitting second wall 32.

As shown in fig. 1, the first mating contact engagement portion 36a of the mating segment 16 extends from the first wall 30 in a direction away from the third wall 34. The first contact engagement portion 36a has a first curved portion 38a, a first stabilizing portion 40a, and a first tab engagement portion 42 a. The first curved portion 38a extends from the first wall 30 and is integral with the first wall 30.

As shown in fig. 2, the boss engaging portion 42a has a first resilient contact engaging arm 44a, a resilient second contact engaging arm 46a, and a resilient third contact engaging arm 48 a. Although three spring

contact engagement arms

44a, 46a, 48a are provided, other numbers of contact engagement arms may be used. The first spring contact engaging arm 44a is spaced from the second spring contact engaging arm 46a by a first slot 50 a. The second spring contact engaging arm 46a is spaced from the third spring contact engaging arm 48a by a second slot 52 a.

The first resilient contact arm 44a has a straight portion 54a, a contact portion 56a and a lead-in portion 58 a. The first contact arm 44a extends from the stabilizing portion 40a and has a first length L1. The lead-in portion 58a is disposed at a free end of the first contact arm 44a spaced from the stabilizing portion 40 a. The contact portion 56a is disposed between the straight portion 54a and the introduction portion 58 a. The contact portion 56a has a curved configuration.

The second resilient contact arm 46a has a straight portion 64a, a contact portion 66a and a lead-in portion 68 a. The second contact arm 46a extends from the stabilizing portion 40a and has a second length L2. The lead-in portion 68a is disposed at a free end of the second contact arm 46a spaced from the stabilizing portion 40 a. The contact portion 66a is disposed between the straight portion 64a and the introduction portion 68 a. The contact portion 66a has a curved configuration.

The third resilient contact arm 48a has a straight portion 74a, a contact portion 76a and a lead-in portion 78 a. The third contact arm 48a extends from the stabilizing portion 40a and has a third length L3. The lead-in portion 78a is disposed at a free end of the third contact arm 48a spaced from the stabilizing portion 40 a. The contact portion 76a is disposed between the straight portion 74a and the lead-in portion 78 a. The contact portion 76a has a curved configuration.

As shown in fig. 1, the second mating contact engagement portion 36b of the mating segment 16 extends from the second wall 32 in a direction away from the third wall 34. As shown in fig. 3, the second mating contact engagement portion 36b is a mirror image of the first contact engagement portion 36 a. The second contact engagement portion 36b has a second curved portion 38b, a second stabilizing portion 40b, and a second tab engagement portion 42 b. The second curved portion 38b extends from and is integral with the second wall 32.

As shown in fig. 3, the boss engaging portion 42b has a first spring contact engaging arm 44a, a second spring contact engaging arm 46b, and a third spring contact engaging arm 48 b. Although three

contact engagement arms

44b, 46b, 48b are provided, other numbers of contact engagement arms may be used. The first spring contact engaging arm 44b is spaced from the second spring contact engaging arm 46b by a first slot 50 b. The second spring contact engaging arm 46b is spaced from the third spring contact engaging arm 48b by a second slot 52 b.

The first resilient contact arm 44b has a straight portion 54b, a contact portion 56b and a lead-in portion 58 b. The first contact arm 44b extends from the stabilizing portion 40b and has a first length L1. The lead-in portion 58b is disposed at a free end of the first contact arm 44b spaced from the stabilizing portion 40 b. The contact portion 56b is disposed between the straight portion 54b and the introduction portion 58 b. The contact portion 56b has a curved configuration.

The second resilient contact arm 46b has a straight portion 64b, a contact portion 66b and a lead-in portion 68 b. The second contact arm 46b extends from the stabilizing portion 40b and has a second length L2. The lead-in portion 68b is disposed at a free end of the second contact arm 46b spaced from the stabilizing portion 40 b. The contact portion 66b is disposed between the straight portion 64b and the introduction portion 68 b. The contact portion 66b has a curved configuration.

The third resilient contact arm 48b has a straight portion 74b, a contact portion 76b and a lead-in portion 78 b. The third contact arm 48b extends from the stabilizing portion 40b and has a third length L3. The lead-in portion 78b is disposed at a free end of the first contact arm 48b spaced from the stabilizing portion 40 b. The contact portion 76b is disposed between the straight portion 74b and the lead-in portion 78 b. The contact portion 76b has a curved configuration.

As shown in fig. 1, the tab receiving slot 84 extends between the first wall 30 and the second wall 32 of the first mating segment 16. The projection receiving slot 84 continues between the first mating contact engagement portion 36a and the second mating contact engagement portion 36 b. The tab receiving slot 84 has an inclined or lead-in surface 80 extending from the mating surface 82 of the mating portion 16. The lead-in surface 80 extends across the base 28, the first mating contact engagement portion 36a, and the second mating contact engagement portion 36 b.

In use, in the illustrative embodiment, the mounting section 14 of the electrical contact 10 is mounted to a printed circuit board 60, as shown in fig. 4. With the power contact 10 properly installed, the protrusion 86 may be moved into electrical engagement with the mating segment 16 of the power contact 10, either from the top as shown in fig. 5, or from the side as shown in fig. 6.

When inserted from the top (fig. 5), the projections 86 are inserted into the projection-receiving slots 84 through the mating surfaces 82. As the tab 86 is inserted, the tab 86 engages the ramped or lead-in surface 80, which helps to position the tab 86 in the tab receiving slot 84. As the protrusion 86 is inserted, the protrusion 86 initially engages the contact portions 56, 56b of the first

resilient contact arms

44a, 44 b. As insertion continues, the projection 86 engages the

contact portions

66a, 66b of the second resilient contact arms 46a, 46 and then engages the

third contact portions

76a, 76b of the third

resilient contact arms

48a, 48 b.

With the protrusion 86 fully inserted from the top, the mating segment 16 of the power contact 10 is positioned in mechanical and electrical engagement with the protrusion 86 at the

contact portions

56a, 56b of the first

resilient contact arms

44a, 44b, the

contact portions

66a, 66b of the second

resilient contact arms

46a, 46b, and the

third contact portions

76a, 76b of the third

resilient contact arms

48a, 48 b. This provides six points of contact between the power contact 10 and the protrusion 86, thereby providing a high and uniform current flow therebetween.

As shown in fig. 8, the normal force of each contact wall is plotted in newtons, along with the displacement in millimeters. Curve 90 represents the normal force of

contact arms

44a, 44b, curve 92 represents the normal force of

contact arms

46a, 46b, and curve 94 represents the normal force of

contact arms

48a, 48 b. Due to the configuration of the

resilient contact arms

44a, 44b, 46a, 46b, 48a, 48b, the normal force (shown as 90 in fig. 8) applied to the protrusion 86 by the

contact portions

56a, 56b of the first

resilient contact arms

44a, 44b is substantially equal to the normal force (shown as 92 in fig. 8) applied by the

contact portions

66a, 66b of the second

resilient contact arms

46a, 46b and substantially equal to the normal force (shown as 94 in fig. 8) applied by the

contact portions

76a, 76b of the third

resilient contact arms

48a, 48 b. Because the first

resilient contact arms

44a, 44b are surrounded by less material at the stabilizing

portions

40a, 40b, the first

resilient contact arms

44a, 44b have a shorter length L1 to achieve the desired normal force. Since the third

resilient contact arms

48a, 48b are surrounded by more material at the stabilizing

portions

40a, 40b, the third

resilient contact arms

48a, 48b have a longer length L3 to obtain the required normal force.

When inserted from the side (fig. 6), the protrusion 86 is inserted into the protrusion receiving groove 84 through the free ends of the

resilient contact arms

44a, 44b, 46a, 46b, 48a, 48 b. As the tab 86 is inserted, the tab 86 engages the lead-in

surfaces

58a, 58b, 68a, 68b, 78a, 78b, which facilitates positioning the tab 86 in the tab-receiving slot 84.

With the protrusion 86 fully inserted from the side, the mating segment 16 of the power contact 10 is positioned in mechanical and electrical engagement with the protrusion 86 at the

contact portions

56a, 56b of the first

resilient contact arms

44a, 44b, the

contact portions

66a, 66b of the second

resilient contact arms

46a, 46b, and the

third contact portions

76a, 76b of the third

resilient contact arms

Due to the configuration of the

resilient contact arms

contact portions

56a, 56b of the first

resilient contact arms

contact portions

66a, 66b of the second

resilient contact arms

contact portions

76a, 76b of the third

resilient contact arms

48a, 48 b. Because the first

resilient contact arms

44a, 44b are surrounded by less material at the stabilizing

portions

40a, 40b, the first

resilient contact arms

48a, 48b are surrounded by more material at the stabilizing

portions

40a, 40b, the third

resilient contact arms

48a, 48b have a longer length L3 to obtain the required normal force.

Since the normal force is substantially the same at all points of contact, each

contact portion

56a, 56b, 66a, 66b, 76a, 76b will have the same amount of wear when the protrusion 86 is inserted and removed from the power contact 10 over multiple cycles. Since the

contact portions

56a, 56b, 66a, 66b, 76a, 76b exert equal normal forces on the male portion and since the

contact portions

56a, 56b, 66a, 66b, 76a, 76b will have the same amount of wear, the current will remain evenly distributed over the life of the power contact 10 because the electrical connection between each

contact portion

56a, 56b, 66a, 66b, 76a, 76b and the male portion 86 will remain consistent with the

other contact portion

56a, 56b, 66a, 66b, 76a, 76 b.

Having a plurality of

contact portions

56a, 56b, 66a, 66b, 76a, 76b with substantially equal contact or normal forces allows for uniform current flow between the

contact portions

56a, 56b, 66a, 66b, 76a, 76b and the protrusion 86. The uniform current flow prevents any one of the

contact portions

56a, 56b, 66a, 66b, 76a, 76b from overheating due to excessive current flow. Thus, the configuration of the

resilient contact arms

44a, 44b, 46a, 46b, 48a, 48b controls and equalizes the normal force at all contact points, which allows for control and reduction of the maximum temperature rise of the contact 10.

An alternative illustrative electrical contact 110 according to the present invention is shown in fig. 9-11. The contact 110 has a mounting portion 114 and a male mating portion 116. Mounting portion 114 and boss mating portion 116 are similar to mounting portion 14 and boss mating portion 16, with the differences described below.

The mounting portion 114 has a substrate engagement protrusion 124 having a mounting boss 126 passing through the substrate engagement protrusion 124 in a direction away from the mating portion 116. In the illustrative embodiment shown, the mounting bosses 126 are configured to be inserted into through-holes (not shown) of a substrate (not shown). The substrate engagement protrusion 124 engages the substrate to restrict insertion of the mounting projection 126 in the through hole. The substrate engagement protrusion 124 also engages the substrate to help stabilize the contact 110 on the substrate. Other configurations of the mounting portion 114 may be used.

As shown in fig. 10, the boss engaging portion 142a has a first resilient contact engaging arm 144a, a resilient second contact engaging arm 146a, a resilient third contact engaging arm 148a, and a fourth contact engaging arm 149 a. Although the lengths of the first, second and third resilient

contact engagement arms

144a, 146a, 148a are different from the first, second and third resilient

contact engagement arms

44a, 46a, 48a, they operate in the same manner.

The first spring contact engagement arm 144a is spaced from the second spring contact engagement arm 146a by a first slot 150 a. The second spring contact engaging arm 146a is spaced from the third spring contact engaging arm 148a by a second slot 152 a. The third spring contact engagement arm 148a is spaced from the fourth spring contact engagement arm 149a by a third slot 153 a.

The first resilient contact arm 144a has a straight portion 154a, a contact portion 156a and a lead-in portion 158 a. The first contact arm 144a extends from the stabilizing portion 140a and has a first length L4. The lead-in portion 158a is disposed at a free end of the first contact arm 144a spaced from the stabilizing portion 140 a. The contact portion 156a is disposed between the straight portion 154a and the lead-in portion 158 a. The contact portion 156a has a curved configuration.

The second resilient contact arm 146a has a straight portion 164a, a contact portion 166a, and a lead-in portion 168 a. The second contact arm 146a extends from the stabilizing portion 140a and has a second length L5. The lead-in portion 168a is disposed at a free end of the second contact arm 146a spaced from the stabilizing portion 140 a. The contact portion 166a is disposed between the straight portion 164a and the introduction portion 68 a. The contact portion 166a has a curved configuration.

The third resilient contact arm 148a has a straight portion 174a, a contact portion 176a and a lead-in portion 178 a. The third contact arm 148a extends from the stabilizing portion 140a and has a third length L6. The lead-in portion 178a is disposed at a free end of the third contact arm 148a spaced from the stabilizing portion 140 a. The contact portion 176a is disposed between the straight portion 174a and the lead-in portion 178 a. The contact portion 176a has a curved configuration.

The fourth resilient contact arm 149a has a straight portion 175a, a contact portion 177a, and a lead-in portion 179 a. The fourth contact arm 149a extends from the stabilizing portion 140a and has a third length L7. The lead-in portion 170a is disposed at a free end of the fourth contact arm 149a spaced from the stabilizing portion 140 a. The contact portion 177a is disposed between the straight portion 175a and the lead-in portion 179 a. The contact portion 177a has a curved configuration.

As shown in fig. 11, the boss engaging portion 142b has a first spring contact engaging arm 144a, a second spring contact engaging arm 146b, a third spring contact engaging arm 148b, and a fourth spring contact engaging arm 149 b. The first spring contact engagement arm 144b is spaced from the second spring contact engagement arm 146b by a first slot 150 b. The second spring contact engaging arm 146b is spaced from the third spring contact engaging arm 148b by a second slot 152 b. The third spring contact engagement arm 148b is spaced from the fourth spring contact engagement arm 149b by a third slot 153 b.

The first resilient contact arm 144b has a straight portion 154b, a contact portion 156b and a lead-in portion 158 b. The first contact arm 144b extends from the stabilizing portion 140b and has a first length L4. The lead-in portion 158b is disposed at a free end of the first contact arm 144b spaced from the stabilizing portion 140 b. The contact portion 156b is disposed between the straight portion 154b and the lead-in portion 158 b. The contact portion 156b has a curved configuration.

The second resilient contact arm 146b has a straight portion 164b, a contact portion 166b, and a lead-in portion 168 b. The second contact arm 146b extends from the stabilizing portion 140b and has a second length L5. The lead-in portion 168b is disposed at a free end of the second contact arm 146b spaced from the stabilizing portion 140 b. The contact portion 166b is disposed between the straight portion 164b and the lead-in portion 168 b. The contact portion 166b has a curved configuration.

The third resilient contact arm 148b has a straight portion 174b, a contact portion 176b, and a lead-in portion 178 b. The third contact arm 148b extends from the stabilizing portion 140b and has a third length L6. The lead-in portion 178b is disposed at a free end of the first contact arm 148b spaced from the stabilizing portion 140 b. The contact portion 176b is disposed between the straight portion 174b and the lead-in portion 178 b. The contact portion 176b has a curved configuration.

The fourth resilient contact arm 149b has a straight portion 175b, a contact portion 177b, and a lead-in portion 179 b. The fourth contact arm 149b extends from the stabilizing portion 140b and has a third length L7. The lead-in portion 170b is disposed at a free end of the fourth contact arm 149b spaced from the stabilizing portion 140 b. The contact portion 177b is disposed between the straight portion 175b and the lead-in portion 179 b. The contact portion 177b has a curved configuration.

As shown in fig. 9, the tab receiving slot 184 extends between the first wall 130 and the second wall 132 of the first mating portion 116. The tab receiving slot 184 continues between the first mating contact engagement portion 136a and the second mating contact engagement portion 136 b. The tab receiving slot 184 has an inclined or lead-in surface 180 extending from the mating surface 182 of the mating portion 116. The lead-in surface 180 extends across the base 128, the first mating contact engagement portion 136a, and the second mating contact engagement portion 136 b.

In use, in the illustrative embodiment, the mounting portion 114 of the electrical contact 10 is mounted to a substrate (not shown). With the power contact 110 properly installed, the protrusion (similar to the protrusion 86) may be moved from the top into electrical engagement with the mating segment 116 of the power contact 110.

When inserted from the top, the tab is inserted into the tab receiving slot 184 through the mating surface 182. As the tab is inserted, the tab engages the ramped or lead-in surface 180, which helps to locate the tab in the tab receiving slot 184. As the male portion is inserted, the male portion initially engages the

contact portions

156a, 156b of the first

resilient contact arms

144a, 144 b. As insertion continues, the projections engage the

contact portions

166a, 166b of the second

resilient contact arms

146a, 146b, then the

third contact portions

176a, 176b of the third

resilient contact arms

148a, 148b, and finally the

fourth contact portions

177a, 177b of the fourth contact arms 147a, 147 b.

With the male portion fully inserted from the top, the mating segment 116 of the electrical contact 110 is positioned to mechanically and electrically engage the male portion at the

contact portions

156a, 156b of the first

resilient contact arms

144a, 144b, the

contact portions

166a, 166b of the second

resilient contact arms

146a, 146b, the

third contact portions

176a, 176b of the third

resilient contact arms

148a, 148b, and the

fourth contact portions

177a, 177b of the fourth contact arms 147a, 147 b. This provides eight points of contact between the electrical contacts 110 and the male portion, allowing for high and uniform current flow therebetween.

As previously described with respect to fig. 1-8, and due to the configuration of the

resilient contact arms

144a, 144b, 146a, 146b, 148a, 148b, 149a, 149b, the normal force exerted by the

contact portions

156a, 156b of the first

resilient contact arms

144a, 144b is substantially equal to the normal force exerted by the

contact portions

166a, 166b of the second

resilient contact arms

146a, 146b, substantially equal to the normal force exerted by the contact portions 176a, 176 of the third

resilient contact arms

148a, 148b, and substantially equal to the normal force exerted by the

contact portions

177a, 177b of the fourth

resilient contact arms

149a, 149 b.

In the illustrative embodiment shown, the length L5 of the second

resilient contact arms

146a, 146b and the length L6 of the third

resilient contact arms

148a, 148b are approximately equal. The length L4 of the first

resilient contact arms

144a, 144b is approximately equal to, but slightly less than, the length L7 of the fourth

resilient contact arms

149a, 149 b. The length L5 of the second

resilient contact arm

146a, 146b and the length L6 of the third

resilient contact arm

148a, 148b are less than the length L4 of the first

resilient contact arm

144a, 144b and the length L7 of the fourth

resilient contact arm

149a, 149 b. The configuration of the first

resilient contact arm

144a, 144b, the second

resilient contact arm

146a, 146b, the third

resilient contact arm

148a, 148b, and the fourth

resilient contact arm

149a, 149b provides the required normal force for each resilient contact arm.

When inserted from the side, the tabs are inserted into the tab receiving slots 184 through the free ends of the

resilient contact arms

144a, 144b, 146a, 146b, 148a, 148b, 149a, 149 b. As the tabs are inserted, the tabs engage the lead-in

surfaces

158a, 158b, 168a, 168b, 178a, 178b, 179a, 179b, which facilitates positioning of the tabs in the tab receiving slots 184.

With the male portion fully inserted from the side, the mating segment 116 of the electrical contact 110 is positioned to mechanically and electrically engage the male portion at the

contact portions

156a, 156b of the first

resilient contact arms

144a, 144b, the

contact portions

166a, 166b of the second

resilient contact arms

146a, 146b, the

third contact portions

176a, 176b of the third

resilient contact arms

148a, 148b, and the

fourth contact portions

Due to the configuration of the

resilient contact arms

144a, 144b, 146a, 146b, 148a, 148b, 149a, 149b, the normal force exerted by the

contact portions

156a, 156b of the first

resilient contact arms

144a, 144b is substantially equal to the normal force exerted by the

contact portions

166a, 166b of the second

resilient contact arms

148a, 148b, and substantially equal to the normal force exerted by the

contact portions

177a, 177b of the fourth

resilient contact arms

149a, 149 b.

In the illustrative embodiment shown, the length L5 of the second

resilient contact arms

146a, 146b and the length L6 of the third

resilient contact arms

148a, 148b are approximately equal. The length L4 of the first

resilient contact arms

149a, 149 b. The length L5 of the second

resilient contact arm

146a, 146b and the length L6 of the third

resilient contact arm

148a, 148b are less than the length L4 of the first

resilient contact arm

144a, 144b and the length L7 of the fourth

resilient contact arm

149a, 149 b. The configuration of the first

resilient contact arm

144a, 144b, the second

resilient contact arm

146a, 146b, the third

resilient contact arm

148a, 148b, and the fourth

resilient contact arm

149a, 149b provides the required normal force for each resilient contact arm.

Since the normal force is substantially the same at all contact points, each

contact portion

156a, 156b, 166a, 166b, 177a, 177b will have the same amount of wear as the male portion is inserted and removed from the power contact 110 over multiple cycles. Since the

contact portions

156a, 156b, 166a, 166b, 176a, 176b, 177a, 177b exert equal normal forces on the male portions, and since the

contact portions

156a, 156b, 166a, 166b, 176a, 176b, 177a, 177b will have the same amount of wear, the current will remain evenly distributed over the life of the electrical contact 110, since the electrical connection between each

contact portion

156a, 156b, 166a, 166b, 176a, 176b, 177a, 177b and the male portions will be consistent with the

other contact portion

156a, 156b, 166a, 166b, 176a, 176b, 177a, 177 b.

Having a plurality of

contact portions

156a, 156b, 166a, 166b, 176a, 176b, 177a, 177b with substantially equal contact or normal forces allows for uniform current flow between the

contact portions

156a, 156b, 166a, 166b, 176a, 176b, 177a, 177b and the male portion. The uniform current flow may prevent any one of the

contact portions

156a, 156b, 166a, 166b, 176a, 176b, 177a, 177b from overheating due to excessive current flow. Thus, the configuration of the

resilient contact arms

144a, 144b, 146a, 146b, 148a, 148b, 149a, 149b controls and equalizes the normal force at all contact points, which allows for control and reduction of the maximum temperature rise of the contact 110.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention as defined by the appended claims. Those skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, dimensions, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and not limited to the foregoing description or embodiments.

Claims

1. An electrical connector for receiving a mating protrusion, the electrical connector comprising:

a mating portion for receiving the mating protrusion therein, the mating portion having a first contact arm and a second contact engagement arm, the first contact engagement arm being spaced apart from the second contact engagement arm by a first slot, the first contact arm having a first length, the first length being different than a second length of the second contact arm;

wherein a first normal force exerted by the first contact arm on the mating protrusion is equal to a second normal force exerted by the second contact arm.

2. The electrical connector as recited in claim 1, wherein the mating portion has a third contact engagement arm spaced apart from the second contact engagement arm by a second slot, the third contact arm having a third length that is different than a first length of the first contact arm and a second length of the second contact arm, the first slot having a first slot length that is different than a second slot length of the second slot, wherein a third normal force exerted by the third contact arm on the mating protrusion is equal to the first normal force exerted by the first contact arm and the second normal force exerted by the second contact arm.

3. The electrical connector of claim 2, wherein the mating portion has a fourth contact engagement arm, the fourth contact engagement arm being spaced apart from the third contact engagement arm by a third slot, the fourth contact arm having a fourth length, the fourth length is different than the first length of the first contact arm, the second length of the second contact arm, and the third length of the third contact arm, the third slot having a third slot length that is different from the first slot length of the first slot and the second slot length of the second slot, wherein a fourth normal force exerted by the fourth contact arm on the mating protrusion is equal to the first normal force exerted by the first contact arm, the second normal force exerted by the second contact arm, and the third normal force exerted by the third contact arm.

4. The electrical connector of claim 3, wherein the mating portion has a base having a mating portion first wall and a mating portion second wall, a first mating contact junction extending from the mating portion first wall and a second mating contact junction extending from the mating portion second wall, the first mating contact junction having the first contact arm, the second contact arm, the third contact arm, and the fourth contact arm, the second mating contact junction having the second first contact arm, the second contact arm, the second third contact arm, and the second fourth contact arm.

5. The electrical connector of claim 4, wherein the mating portion has a base portion with a mating portion first wall, the mating portion second wall spaced apart from the mating portion first wall, and a mating portion third wall extending between the mating portion first wall and the mating portion second wall.

6. The electrical connector as recited in claim 5, wherein a first mating contact engagement portion of the mating portion extends from the mating portion first wall in a direction away from the mating portion third wall, the first contact engagement portion having a first curved portion extending from and integral with the mating portion first wall, a first stabilizing portion, and a first tab engagement portion.

7. The electrical connector as recited in claim 6, wherein a second mating contact engagement portion of the mating portion extends from the mating portion second wall in a direction away from the mating portion third wall, the second contact engagement portion having a second curved portion extending from and integral with the mating portion second wall, a second stabilizing portion, and a second projection engagement portion.

8. The electrical connector as recited in claim 7, wherein the second mating contact engagement portion is a mirror image of the first contact engagement portion, the first, second, and third contact arms being disposed on the first and second male engagement portions.

9. The electrical connector as recited in claim 8, wherein the first contact arm has a straight portion extending from the stabilizing portion and having a first length, a contact portion disposed at a free end of the first contact arm spaced from the stabilizing portion, and an incoming portion disposed between the straight portion and the incoming portion, the contact portion having a curved configuration.

10. The electrical connector as recited in claim 9, wherein the second contact arm has a straight portion extending from the stabilizing portion and having a second length, a contact portion disposed at a free end of the second contact arm spaced from the stabilizing portion, and an incoming portion disposed between the straight portion and the incoming portion, the contact portion having a curved configuration.

11. The electrical connector as recited in claim 10, wherein the third contact arm has a straight portion extending from the stabilizing portion and having a third length, a contact portion disposed at a free end of the third contact arm spaced from the stabilizing portion, and an incoming portion disposed between the straight portion and the incoming portion, the contact portion having a curved configuration.

12. The electrical connector as recited in claim 11, wherein a tab receiving slot extends between the first wall and the second wall of the base and continues between the first mating contact engagement portion and the second mating contact engagement portion.

13. The electrical connector as recited in claim 12, wherein the projection receiving slot has a lead-in surface extending from a mating surface of the mating portion, the lead-in surface extending across the base, the first mating contact engagement portion, and the second mating contact engagement portion.

14. The electrical connector of claim 13, wherein a mounting portion extends from the mating portion, the mounting portion having a substrate engagement surface with a mounting leg extending therefrom in a direction away from the mating portion.

15. An electrical connector for receiving mating projections from multiple directions, the electrical connector comprising:

a mounting portion for mounting to a substrate or a mating connector;

a mating portion for receiving the mating protrusion therein, the mating portion having a base with a first wall and a second wall, a first mating contact engagement portion extending from the first wall and a second mating contact engagement portion extending from the second wall;

the first and second mating contact engagement portions having contact arms with first lead-in surfaces disposed at free ends thereof;

a projection receiving slot extending between the first wall and the second wall of the base and continuing between the first mating contact engagement portion and the second mating contact engagement portion;

a second lead-in surface extending from the mating surface of the mating portion, the lead-in surface extending across the base, the first mating contact engagement portion, and the second mating contact engagement portion;

wherein the first lead-in surface and the second lead-in surface allow the mating protrusion to be inserted into the protrusion receiving groove from a plurality of directions.

16. The electrical connector as recited in claim 15, wherein the second mating contact engagement portion is a mirror image of the first contact engagement portion.

17. The electrical connector as recited in claim 16, wherein the first and second mating contact engagement portions have first and second contact engagement arms, the first contact engagement arm being spaced apart from the second contact engagement arm by a first slot, the first contact arm having a first length that is different than a second length of the second contact arm, wherein a first normal force exerted by the first contact arm on the mating protrusion is equal to a second normal force exerted by the second contact arm.

18. The electrical connector as recited in claim 17, wherein the first and second mating contact engagement portions have a third contact engagement arm that is spaced apart from the third contact engagement arm by a second slot, the third contact arm having a third length that is different than the first length of the first contact arm and the second length of the second contact arm, the first slot having a first slot length that is different than the second slot length of the second slot, wherein a third normal force exerted by the third contact arm on the mating protrusion is equal to the first normal force exerted by the first contact arm and the second normal force exerted by the second contact arm.

19. The electrical connector as recited in claim 17, wherein the first contact arm has a straight portion extending from the stabilizing portion and having a first length, a contact portion disposed at a free end of the first contact arm spaced from the stabilizing portion, and an incoming portion disposed between the straight portion and the incoming portion, the contact portion having a curved configuration.

20. The electrical connector as recited in claim 19, wherein the second contact arm has a straight portion extending from the stabilizing portion and having a second length, a contact portion disposed at a free end of the second contact arm spaced from the stabilizing portion, and an incoming portion disposed between the straight portion and the incoming portion, the contact portion having a curved configuration.