US3601760A

US3601760A - Electrical connector

Info

Publication number: US3601760A
Application number: US807733A
Authority: US
Inventors: Thomas M Cairns
Original assignee: Ford Motor Co
Current assignee: Ford Motor Co
Priority date: 1969-03-17
Filing date: 1969-03-17
Publication date: 1971-08-24
Anticipated expiration: 1988-08-24
Also published as: DE2005783C3; GB1241157A; DE2005783A1; DE2005783B2

Abstract

An electrical connector includes both a terminal having an annular recess therearound intermediate portions of the terminal of larger cross section and a block of nonconductive material having an aperture therein for receiving the terminal. A flexible wall forms a portion of the terminal block and this wall extends along and defines at least a portion of the length of the block''s terminal receiving aperture. A locating tab, secured to the flexible wall, enters the annular recess of the terminal to position it within the receiving aperture. A locking device is attached to the block to prevent the free flexing of the flexible wall when the tab has positioned the terminal within the aperture.

Description

[54} ELECTRICAL CONNECTOR 7 Claims, 8 Drawing Figs.

[52] US. Cl 339/59, 339/91, 339/217, 339/176 [51] Int. Cl H01! 13/54,

HOlr 9/l6 [50] Field of Search 339/59 M,

64,74, 191 A, 191 M, 191, 192, 195, 195 A, 195 M, 195 8,217,2178, 75 M,62, 63,91 R, 176M UNITED STATES PATENTS 3,101,229 8/1963 Yopp 339/59 3,430,135 2/1969 511216161111. 339/59M U 39 I 4/ Z i /7 3/ United States Patent 1111 3, 1,

[72] inventor ThomasM.Cairns 3,477,061 11/1969 Stephenson 339/59M Dell011,MiCh. 3,487,355 12 1969 Cairns 339/176 1 1 pp 8071733 FORElGN PATENTS 5253 1:413: 933,045 7/1963 GreatBritain 339 192 [73] Assign FordMmrCompany 956,993 4 1964 01661131116111 339/64M Dearborn, Mich. Primary ExaminerMarvin A. Champion Assistant Examiner-Lawrence J. Staab Attorneys-John R. Faulkner and William E. Johnson ABSTRACT: An electrical connector includes both a terminal having an annular recess therearound intermediate portions of the terminal of larger cross section and a block of nonconductive material having an aperture therein for receiving the terminal. A flexible wall forms a portion of the terminal block and this wall extends along and defines at least a portion of the length of the blocks terminal receiving aperture. A locating tab, secured to the flexible wall, enters the annular recess of the terminal to position it within the receiving aperture. A locking device is attached to the block to prevent the free flexing of the flexible wall when the tab has positioned the terminal within the aperture.

PATENTEDAUB24I97I 3,601. 760

SHEET 1 [IF 2 7 39 55 2 39 22 0 0 Z7 E 33 O W) 25 39 O O A;

IE1; is 35 4/ 35 EGA- 55 23 4 54 56 52 FL /0 IN VENTOR.

THOMAS M. CAIRNS Iii; 5

ELECTRICAL CONNECTOR BACKGROUND OF THE INVENTION This invention constitutes an improvement of the type of 5 electrical connectors disclosed and claimed in my copending U.S. Pat. application, Ser. No. 692,822, filed Dec. 22, 1967, now U.S. Pat. No. 3,487,355. This application also discloses and claims an electrical connector which may utilize terminals such as disclosed and claimed in my copending U.S. Pat. application, Ser. No. 719,479, filed Apr. 8, 1968, now U.S. Pat. No. 3,482,207. Briefly the improvement for the electrical connector is found in the fact that individual ones of a plurality of terminals may be inserted into terminal block and temporarily located therein while other individual ones of the plurality of terminals may be inserted into the block. The temporary positioning of the terminals maintains them within the block even though the block is tipped or roughly handled. Once the desired number of terminals have been inserted into the terminal block and temporarily located therein, a single member is then inserted into the block to lock all of the terminals securely therewithin. The locking member cannot be installed fully into position unless each terminal is either properly installed or obviously not installed. This removes operator judgment.

SUMMARY OF THE INVENTION This invention is directed to an electrical connector and, more particularly, the invention is directed to the construction of an electrical connector in which a terminal may be inserted into and temporarily secured within a terminal block, the terminal subsequently being fully secured within the block for use thereof.

The electrical connector of this invention is formed by inserting a terminal of an electrically conductive material into a terminal receiving aperture fonned in a terminal block of nonconductive material. The terminal is formed so as to have an annular recess therearound intermediate portions of the terminal of larger cross section. The improvement in the connector comprises a flexible wall secured to the terminal block. The flexible wall defines at least a portion of the length of the terminal-receiving aperture. A locating tab, associated with the terminal-receiving aperture, enters the annular recess of the terminal to position the terminal properly within the receiving aperture. A locking device is thereafter attached to the terminal block to prevent the free flexing of the flexible wall when the locating tab has positioned a terminal properly within the receiving aperture.

With such a terminal block construction, a first terminal may be initially inserted into one of the apertures formed in the terminal block. Upon insertion of the initial terminal, the locating tab associated with the particular terminal-receiving aperture will enter the recess of the terminal to position the terminal within the aperture. The flexible wall provides sufficient flexing of the terminal-receiving aperture so that the larger portions of an individual terminal may be moved past the locating tab associated with that aperture. Once the locating tab has entered the annular recess of the individual terminal, the lateral movement of the terminal within the aperture is restricted. A locking device is then attached to the terminal block to prevent the free flexing of the flexible wall whereby the confinement of the electric terminal by the locating tab within the terminal-receiving aperture is continued until the locking device is removed.

In greater detail, the locating tab is formed as a portion of the flexible wall. In still greater detail, the electrical connector has at least a pair of terminal-receiving apertures defined in the terminal block. The flexible walls of the pair of terminalreceiving apertures are in juxtaposition with a space therebetween. In this construction, the locking device is formed as a bar and is inserted between the pair of opposed flexible walls. In further detail, the electrical connector has a plurality of pairs of associated terminals receiving apertures aligned in such a manner that the space between the jux taposed flexible walls of each pair of apertures forms a single, continuous passageway. In this construction a single locking bar is inserted into the space between the flexible walls to lock securely all of the terminals which have been inserted within the terminal block.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is an isometric view of a male or plug connector assembled with a female or cap connector, both connectors being formed in accordance with the principles and teachings of a first embodiment of this invention.

FIG. 2 is a view, partly in cross section, along the length of the assembled electrical connectors shown in FIG. I, the view showing the interior structure in greater detail.

FIG. 3 is a view, in enlarged cross section, across the width of the electrical connectors of FIG. 1, the view both showing terminals positioned within the connectors and showing still further details of the structure.

FIG. 4 is an end elevation view of the male connector.

FIG. 5 is a view, partly in cross section, along the length of a second embodiment of assembled electrical connectors constructed in accordance with the teachings of this invention.

FIG. 6 is a view, in cross section, across the width of the electrical connectors of FIG. 5.

FIG. 7 is an end elevation view of the male or plug connector shown in FIGS. 5 and 6.

FIG. 8 is an enlarged view of the locking member utilized in the connector construction shown in FIGS. 5 and 6.

DESCRIPTION OF THE PREFERRED EMBODIMENT Construction for First Embodiment My U.S. Pat. application, Ser. No. 692,882, now U.S. Pat. No. 3,487,355, teaches an electrical connector construction in which electric terminals having annular recesses are locked to a terminal block by use of a locking bar which enters an annular recess of each terminal after the terminal has been positioned in a terminal-receiving aperture of the block. My prior connector construction provides a locating shoulder for initial positioning of each terminal within its aperture so that the locking bar can be directed into the recessed portion of the terminal to secure the terminal to the block. The connector disclosed in this application constitutes an improvement of my prior connector. The new connector includes structure for initially retaining the inserted terminal in the aperture of the terminal block prior to being locked therein. Once initially retained, the terminal cannot be dislodged from the aperture by tipping or shaking the terminal block. Also, after once being retained, the terminal may be later securely locked within the aperture by the insertion of a locking bar.

A first embodiment of the electrical connector of this invention is shown in FIGS. 1 to 4 of the drawings. While the invention is shown and described in conjunction with an electrical connector having both a plurality of terminals and a plurality of terminal-receiving apertures, it is to be understood that the principles and teachings of this invention may be employed with a terminal block having only a single aperture therein.

In FIG. I, a female or cap electrical connector is generally designated by the numeral 10, and a male or plug electrical connector is generally designated by the numeral II. Each of these connectors is formed in accordance with the principles and teachings of this invention. With reference to FIG. 3, it is seen that the plug connector 11 supports therewithin a plurality of female electric terminals 12. On the other hand, the cap connector 10 supports therewithin a plurality of male electric terminals 13. The terminal may be formed in accordance with the principles and teachings of my copending application, Ser. No. 719,479, now U.S. Pat. No. 3,482,207. The only major requirement for the terminals is that each terminal has associated therewith an annular recess intermediate portions of the terminal of larger diameter or cross section. More particularly, with respect to terminal 12, a recess 14 is provided therein intermediate portions of the terminal of larger cross section. Similarly, the terminal 13 is also provided with a recess 16 which is located intermediate areas of the terminal of larger cross section.

The cap connector and plug connector 1 l are formed so as to have a very similar structure. The one major exception in formation of the two connectors is that terminal-receiving apertures 17 of the plug connector extend along the entire length of the terminals 12 located therewithin, best seen in FIG. 3. On the other hand, the terminal-receiving apertures 18 of the cap connector 10 extend only along a portion of the length of the terminal 13 received therewithin.

Now with reference to FIGS. 1, 2 and 3, the construction of the plug connector 11 will be described in detail. The plug or male connector has

exterior sidewalls

21 and 22, as well as a top wall and a bottom wall, respectively designated 23 and 24. A vertical center wall 26 is provided between the sidewalls. A pair of

partition walls

27 and 28 are provided between the top wall and the bottom wall to divide the connector into the plurality of mentioned terminal-receiving apertures 17.

The center wall 26 of the connector 11, as best seen in FIGS. 2 and 3, is bifurcated near one end thereof to form two angularly disposed

walls

31 and 32. In FIG. 2, only the wall 31 is shown. However, it is shown in that figure that there are three of the angularly disposed walls 31 depending from the center wall. Each of the angularly disposed walls is associated with a different terminal-receiving aperture 17. This may be understood by reference to one of the single terminal-receiving apertures shown in FIG. 3. Each of the plurality of angularly disposed

walls

31 and 32 terminate at the beginning of a flexible wall 33 associated therewith. As seen in plan view in FIG. 2, a lateral space 34 is provided between each flexible wall and its associated sidewall or partition wall which were previously designated 23, 24, 27 and 28. The free end 36 of each of theflexible walls 33 terminates at a position beyond the end of the terminal 12 received within associated terminalreceiving aperture 17 of the connector 11.

As best seen in FIG. 3, associated pairs of the flexible walls 33 are in juxtaposition to one another with a space 37 therebetween. Each of the flexible walls 33 defines a portion of the length of one of the terminal-receiving apertures 17 of the connector 11. Each of the flexible walls 33 has associated therewith a locating tab 39. The locating tab is seen in FIG. 3 but not in FIG. 2. As shown in FIG. 3, the locating tabs 39 project inwardly from their associated flexible wall into an associated terminal-receiving aperture 17. FIG. 4 shows how the locating tabs 39 project into the associated annular recesses 14 of the terminals 12. The locating tabs are made to conform to the general configuration of the annular recess of the terminals. Thus, when the locating tab is positioned within a recess of a terminal, the lateral movement of the terminal within the terminal-receiving aperture is substantially restricted. However, the float normal to the terminal axis is not restricted.

Now with references to FIGS. 3 and 4, a locking bar 41 is shown inserted in the space 37 between the juxtaposed flexible walls 33. In particular, this bar occupies the space between the juxtaposed locating tabs 39 provided on the flexible walls. The locking bar engages locating

surfaces

42 and 43 respectively on the

partition walls

27 and 28, see FIG. 2. The extremities of the locking bar engage, respectively, locating surfaces 44 and 46 formed on the top wall 23 and bottom wall 24 of the connector 11. Since the locating surfaces 42 and 43 are opposed to the locating surfaces 44 and 46, the locking bar is held therebetween when the bar is in its fully inserted position. The locking bar also has positioning projections 47 (FIG. 2) thereon which selectively engage either the surface 42 or the surface 43 to stabilize the bar in its inserted position. As best seen in FIG. 4, the locking bar is inserted by being moved laterally along the length of the space 37 between each pair of associated flexible walls 33.

The female or cap connector 10, which houses the terminals 13, is constructed in a manner similar to the construction of the plug connector 11. As seen in FIG. 1, the cap connector 10 has the front portion 51 thereof formed so as to receive internally the front portion of the plug connector. The upper surface 52 of the front portion 51 has a recess 53 therein which terminates at a crossbar 54. The crossbar cooperates with a detent 56 formed on the upper surface 23 of the plug connector. When the two connectors are assembled, the crossbar and detent cooperate to lock the two connectors together into a single unit. When the two connectors are locked together, the

terminals

12 and 13 are brought into electrical connection with one another.

Operation of the First Embodiment With reference to FIGS. 3 and 4 of the drawings, a terminal 12 may be inserted into a terminal aperture 17 of the connector 11 by the following steps. During the insertion of the terminal into its aperture, the locking bar 41 is not positioned in the space 37 between the juxtaposed pairs of flexible walls 33. Thus, as the terminal is inserted into its aperture, the front of the terminal will engage the locating tab 39 formed on the flexible wall. The front of the terminal will act on the locating tab to flex the wall 33 into the free space 37 between it and the opposed wall. The flexing of the wall permits the larger front portion of the terminal to move past the locating tab until such time as the annular recess 14 is aligned with the tab. At this time the tab enters the recess as the flexible wall returns to its normal position with respect to the remainder of the terminalreciving aperture.

The terminal, now inserted into its aperture, is properly located in the connector. The connector may be shaken or otherwise moved or tipped without dislodging the inserted terminal. However, since the locking bar is not inserted, one may still remove the terminal from the aperture. The removal is effected by applying a sufficient force on the lead of the terminal whereby the locating tab once again will be caused to act on the flexible wall to cam the wall into the free space.

Once the desired number of tenninals have been inserted into the connector 11, the locking bar 41 is inserted into the space 37 between the associated pairs of flexible walls 33. The locking bar moves down the full length of the space between each of the three spaced pairs of terminal-receiving apertures and is positioned in its proper position by engagement of the positioning projections 47 with the partition wall 27. When the locking bar 41 is in its fully inserted position, the flexible walls and, in particular, the locating tabs 39, thereof, are not free to flex from their normal position. In other words, any force applied along the axis of the terminal 12 does not cause a camming of the flexible wall into the space 37 permitting easy extraction of the terminal because movement of the wall is restricted. Thus, once the locking bar 41 has been inserted into the connector 11, the individual terminals are securely held within the terminal block. However, when the locking bar is removed, it is a simple matter to remove any terminals from the connector by applying a proper force thereto.

As an alternate construction, the locating tab 39 may be positioned on the wall of the termnal-receiving aperture opposite the flexible wall 33. This particular construction would require the tipping or canting of the terminal during insertion thereof to apply a force against the flexible wall to move the wall out of position.

Construction for Second Embodiment In the construction of the electrical connectors, in accordance with the second embodiment of this invention, the major change is in the design of the locking bar inserted between the opposed flexible walls of the connector. Since many similar details of construction are utilized in the two embodiments, all similar details will be identified by the same names and reference numerals as utilized in the description of the first embodiment structure. Also, since both the plug and cap connectors are similar in construction, description this section will be undertaken only of the plug connector.

In the second embodiment structure, a locking bar 61, shown in isometric view in FIG. 8, is utilized to enter the space 37 between the flexible walls 33. The locking bar is provided with a notch 62 and a detent 63 for purposes which will be described in greater detail hereafter.

The connector 11, as shown in FIG. 7, is modified with respect to the connector shown in FIG. 4 in that the top wall 23 and the bottom wall 24 have

recesses

64 and 66 respectively therein. These recesses are for the purpose of receiving for movement therealong the lateral side edges of the locking bar 61. Also, a portion of the partition wall 28 of the connector is modified so as to extend into the space 37 provided between the opposed flexible walls 33. The extending portion 67 of the partition wall 28 is received within the notch 62 of the locking bar to guide the bar during its insertion into the connector.

The bottom wall 24 of the connector, as best seen in FIG. 5, has at the leading portion thereof an opening 68. The opening is terminated by a portion 69 of the bottom wall 24 which extends across the whole bottom thereof. The detent 63 of the locking bar 61 is received behind this portion of the bottom wall to position the bar in its fully inserted position within the connector.

Operation of the Second Embodiment The operation of the second embodiment structure is similar to the first embodiment structure in the manner in which the terminals are inserted within their respective terminal-receiving apertures. As an individual terminal is inserted, the leading portion thereof engages the locating tab 39 on the flexible wall 33 and causes the wall to be cammed into the space 37 between the juxtaposed walls. After the terminal has been moved along the length of its aperture, the locating tab 39 enters the recess 14 to position and locate the terminal within its aperture. After all of the terminals 12 are inserted within their associated apertures, the locking bar is inserted from right to left as viewed in FIG. 6. In order to accomplish this insertion operation, the notch 62 of the locking bar 61 is aligned with and positioned on the extending portion 67 of the partition wall 28. The locking bar is then moved to the left as viewed in FIG. 6 until the detent 63 slides over the portion 69 of the bottom wall 24. When the locking bar is in its fully inserted position, the terminals are held securely within the connector 11.

I claim:

1. In an electrical connector which includes at least a plurality of pairs of cylindrical, electrical terminals, each terminal having an annular recess therein about the circumference thereof intermediate portions of the terminal of larger diameter, and a block of nonconductive material having a plurality of pairs of apertures for receiving the terminals therein, the improvement comprising:

a first flexible wall associated with one of each pair of apertures and secured to the block of nonconductive material and defining at least a portion of the length of the one terminal-receiving aperture of each pair of apertures;

a second flexible wall associated with the other of each pair of apertures and secured to the block of nonconductive material and defining at least a portion of the length of the other terminal-receiving aperture of each pair of apertures, said first flexible wall and said second flexible wall of each pair of apertures being in juxtaposition with one another with a space therebetween and the pairs of terminal-receiving apertures being aligned in a side by side relationship with said space between each pair of apertures being aligned;

locating means secured to each of said flexible walls and extending into its associated terminal-receiving aperture, said locating means for entering the annular recess of the terminal inserted into the associated aperture for positiqning the terminal properly within that aperture and locking means comprising a single member msertable within said aligned spaces between said flexible walls of said pairs of apertures for preventing the free flexing of said flexible walls when terminals have been located within their associated terminal-receiving apertures.

2. The improved electrical connector as defined in claim 1 wherein said locating means on each of said flexible walls is a projection which extends into its associated terminal-receiving cavity; and wherein said block of nonconductive material is provided with means for aligning said locking means in said space between said pairs of associated apertures in such a position that the locking means is adjacent said inwardly directed projections formed on said flexible walls.

3. The improved electrical connector as defined in claim 2 wherein said aligning means on the nonconductive block consist of both surfaces formed between adjacent pairs of associated terminal-receiving apertures and surfaces at both extremities of the associated pairs of apertures, said surfaces at said extremities and said surfaces between each pair of apertures being positioned on opposite sides of said locking means when said locking means is inserted in its position between said flexible walls; and wherein said locking means is a bar of nonconductive material which is insertable into said space between said associated pairs of apertures by being moved laterally across said space from one extremity of said associated pairs of apertures to said other extremity of said associated pairs of apertures.

4. The improved electrical connector as defined in claim 3 further comprising: projecting portions on said locking bar for engagement with at least one of said surfaces between adjacent pairs of associated terminal-receiving apertures for stabilizing said locking bar in a prescribed attitude within the connector after being inserted therein.

5. The improved electrical connector as defined in claim 2 wherein said locking bar comprises a piece of nonconductive material insertable between said flexible walls by movement inwardly along the length of the space between said pairs of associated walls.

6. The improved electrical connector as defined in claim 5 wherein one of the sidewalls of the block of nonconductive material is provided with an aperture; and wherein said locking bar is provided with a detent which enters said aperture when said locking bar is in a fully inserted position whereby said locking bar is held in a fixed position relative to said flexible walls after insertion.

7. The improved electrical connector as defined in claim 6 wherein one of the walls between an associated pair of terminal-receiving apertures extends into the space between said flexible walls to provide a guide; and wherein said locking bar has a notch along the length thereof, said notch and said projecting wall cooperating to properly position said locking member during its movement into and along said space between said associated pairs of flexible walls.

Claims

1. In an electrical connector which includes at least a plurality of pairs of cylindrical, electrical terminals, each terminal having an annular recess therein about the circumference thereof intermediate portions of the terminal of larger diameter, and a block of nonconductive material having a plurality of pairs of apertures for receiving the terminals therein, the improvement comprising: a first flexible wall associated with one of each pair of apertures and secured to the block of nonconductive material and defining at least a portion of the length of the one terminal-receiving aperture of each pair of apertures; a second flexible wall associated with the other of each pair of apertures and secured to the block of nonconductive material and defining at least a portion of the length of the other terminal-receiving aperture of each pair of apertures, said first flexible wall and said second flexible wall of each pair of apertures being in juxtaposition with one another with a space therebetween and the pairs of terminal-receiving apertures being aligned in a side by side relationship with said space between each pair of apertures being aligned; locating means secured to each of said flexible walls and extending into its associated terminal-receiving aperture, said locating means for entering the annular recess of the terminal inserted into the associated aperture for positioning the terminal properly within that aperture; and locking means comprising a single member insertable within said aligned spaces between said flexible walls of said pairs of apertures for preventing the free flexing of said flexible walls when terminals have been located within their associated terminal-receiving apertures.