WO1998038698A1

WO1998038698A1 - Electrical connector

Info

Publication number: WO1998038698A1
Application number: PCT/US1998/003596
Authority: WO
Inventors: Hiroshi Shirai; Hiroyuki Okazaki; Masaki Uchida; Susumu Nagao
Original assignee: The Whitaker Corporation
Priority date: 1997-02-28
Filing date: 1998-02-24
Publication date: 1998-09-03
Also published as: JPH10302857A; DE19882143T1; AU6666198A; JP2002512728A

Abstract

The present invention provides an electrical connector which makes it possible to obtain highly reliable electrical connections with slender electrical wires such as coil-winding wires, and which is easy to manufacture. The electrical connector is constructed from a housing (60) which has first and second cavities (62, 66) that communicate with each other, a first member (10) which has a base portion (12) that is press-fitted inside the first cavity (62), and an arcuate contact portion (16) that protrudes toward an electrical wire-receiving surface (82) of the first cavity (62), and a second member (40) which is press-fitted inside the second cavity (66). When the electrical wire (1) is disposed between the electrical wire receiving surface (82) and the contact portion (16), and the second member (40) is press-fitted within the second cavity (66), pressing section (46) of the second member (40) presses arcuate portion (30) located in the vicinity of a free end of the first member (10) toward the electrical wire-receiving surface (82), so that sawtooth-shaped serrations (26) of the contact portion (16) makes resilient electrical engagement with the electrical wire (1).

Description

ELECTRICAL CONNECTOR

The present invention relates to an electrical connector, and more specifically relates to an electrical connector which is used to terminate slender electrical wires such as coil windings.

Pressing-contact electrical connections for insulated electrical wires are press-fitted in U-shaped slots by pressing electrical contacts against the electrical wires. Such electrical connections are universally known as a technique for terminating insulated electrical wires without stripping the insulation from the wires beforehand. However, in cases where slender coil-winding wires, such as A G No. 50 wires, are to be terminated, the coil-winding wires tend to break. Furthermore, it is extremely difficult to form a pressing contact with narrow slots that correspond to the diameter of the coil-winding wires. Accordingly, an electrical connector 200 of the type shown in Figures 21 to 23 has been proposed as disclosed in Japanese Patent Application No. 60-28108. The electrical connector 200 comprises an integral contact 210 which has mutually facing first and second sections 212, 214 connected by a third section 216, and a connector housing 230 which has a cavity 232 that accommodates contact 210. The first and second sections 212, 214 of the contact 210 are in a relationship which is such that the two sections converge in the direction of insertion (i.e., toward the left in Figure 22) prior to insertion into the cavity 232. Accordingly, the insertion of the contact 210 into the cavity 232 is facilitated. An electrical wire 202 is wrapped around the periphery of the wall 234 of the housing 230 that faces the cavity 232. A sawtooth-shaped contact surface 218 is located on the second section 214 of the contact 210, and the electrical wire 202 is clamped between the wall 234 of the housing 230 and the contact surface 218 of the contact 210. A bent portion 220, which is bent at a an acute angle, is formed between the second section 214 and the third section 216.

The connection of the contact 210 and the electrical wire 202 is accomplished by means of the following process. First, with the bent portion 220 as the tip end, the contact 210 is initially inserted into the cavity 232 of the housing 230. Next, a pair of rams 204,206 push the free end 214a of the second section 214 and the end portion 212a of the first section 212 toward the left in Figure 22. When the amount of pushing performed by the ram 204 reaches a prescribed amount, pushing by the ram 204 is interrupted, and the pushing of the end portion 212a of the first section by the ram 206 is continued until the third section 216 is parallel to and in contact with the bottom surface 236 of the cavity 232 as shown in Figure 23. As a result of the third section 216 being oriented parallel to the bottom surface 236 of the cavity 232, the first and second sections 212,214 are oriented parallel to each other, and the contact surface 218 of the second section 214 engages with the electrical wire 202 so that the contact 210 and electrical wire 202 are electrically connected.

The contact 210 described above does not have a pressing-contact slot; accordingly, contact 210 can also handle connections with slender electrical wires such as AWG No. 50 wires. However, the following problem arises from the fact that the bent portion 220 is bent at an acute angle, i.e., from the fact that the angle formed by the second section 214 and the third section 216 (which is subjected to the greatest stress) is an acute angle: specifically, the angle formed by the second section 214 and third section 216, which is an acute angle in the initial state, is forced into a right angle in the connected state; accordingly, the portions of the second section 214 that are removed from the bent portion 220 (especially the free end 214a of the second section 214 and the intermediate portion of the bent portion 220) are subjected to a moment in the direction away from the electrical wire 202 as a result of the rigidity of the second section 214 and third section 216, so that there is a possibility that the connection of the contact surface 218 and electrical wire 202 may become disconnected. Furthermore, since the bent portion 220, which is at an acute angle, is forced into a right angle, cracking tends to occur on the inside of the bent portion 220 thereby creating a probability of failure.

Accordingly, one feature of the present invention is to provide an electrical connector which solves the problems described above, i.e., an electrical connector which provides an effective electrical connection with the electrical wire. Furthermore, another feature of the present invention is to provide an electrical connector in which the retaining force of the electrical contact with respect to the insulating housing is high.

The electrical connector of the present invention comprises an insulating housing which has a first cavity in which an electrical wire-receiving surface is formed, and a second cavity which communicates with the first cavity, a first metal member having an external-connecting portion at one end, a substantially arcuate contact portion in which a surface facing the electrical wire- receiving surface forms a protruding part at the other end, and a base portion which is press-fitted inside the first cavity between the connecting portion and contact portion, and a second member which is press-fitted inside the second cavity; so that when an electrical wire is disposed between the electrical wire receiving surface and the facing surface of the contact portion, a pressing section of the second member presses against an arcuate portion in the vicinity of the free end of the contact portion on an opposite side thereof from the facing surface so that the contact portion is caused to make resilient engagement with the electrical wire.

It is desirable that the arcuate portion, which protrudes in the opposite direction from the surface facing the electrical wire-receiving surface, be formed in the vicinity of the free end of the contact portion of the first member. Moreover, it is even more desirable that the pressing section of the second member have a pressing surface which is offset from a base section of the second member, and that the pressing section has resiliency.

Furthermore, it is desirable that a base portion of the first member have a lance, which is cut and caused to protrude toward the inside wall of the insulating housing located on the opposite side of the housing from the electrical wire-receiving surface, and a protruding ridge, which extends in a direction of thickness of the lance from the free end of the lance and bites into the inside wall. Alternatively, it is desirable that the contact portion of the first member have press-fitting projections which extend from both sides in the vicinity of the free end and bite into an inside wall of the insulating housing.

An electrical connector comprises a dielectric housing having a wire-receiving surface along which an electrical wire extends, a first cavity provided in the housing, an electrical contact member movable along the first cavity and having a serrated-contact portion for engagement with the electrical wire, a second cavity provided in the housing, a member movable along the second cavity including a section for moving the serrated-contact portion into electrical connection with the electrical wire between the wire-receiving surface and the serrated- contact portion, wherein the serrated-contact portion has an arcuate shape, and the section is a resilient pressing section. Embodiments of the present invention will now be described by way of example with reference to the accompanying drawings in which:

Figure 1 is an isometric view which illustrates a first member used in an electrical connector of the present invention.

Figure 2 is an isometric view which illustrates a second member used in the electrical connector of the present invention. Figure 3 is a part cross-sectional isometric view which illustrates both the housing and the electrical wire used in the electrical connector of the present invention. Figure 4 is a cross-sectional view which illustrates the connection process of the electrical wire showing the first member press-fitted in the housing.

Figure 5 is a cross-sectional view which illustrates the connection process of the electrical wire showing the second member initially inserted into the housing.

Figure 6 is a cross-sectional view which shows the completed connection of the electrical wire with the electrical connector shown in Figure 4.

Figure 7 is an isometric view which shows another embodiment of the second member.

Figure 8 is an isometric view which illustrates another embodiment the first member used in the electrical connector of the present invention.

Figures 9 and 10 are plan and side views of the first member shown in Figure 8.

Figure 11 is an enlarged view of area A in Figure 10, showing the press-fitted state inside the insulating housing.

Figure 12 is an isometric view which illustrates a further embodiment of the first member of the present invention. Figure 13 is a plan view of the first member shown in Figure 12. Figure 14 is an enlarged view of area B in Figure 13. Figure 15 is a side view of the first member shown in Figure 12.

Figure 16 is an enlarged view of area C in Figure 15. Figure 17 is a cross-sectional view which illustrates the connection process of the electrical wire of the electrical connector of the present invention, showing the first member of Figures 12 to 16 prior to insertion into the housing. Figure 18 is a cross-sectional view which illustrates the connection process of the electrical wire with the electrical connector shown in Figure 17 showing the second member prior to insertion into the housing.

Figure 19 is a cross-sectional view which illustrates the connection process of the electrical wire with the electrical connector shown in Figure 17 showing the second member during insertion into the housing.

Figure 20 is a cross-sectional view which shows the completed connection of the electrical wire with the electrical connector shown in Figure 17.

Figure 21 is an exploded isometric view of a conventional electrical connector.

Figure 22 is a cross-sectional view which shows a contact of the electrical connector of Figure 21 during insertion into a housing.

Figure 23 is a cross-sectional view which shows the completed insertion of the contact into the housing of the electrical connector shown in Figure 21.

In Figures 1 to 3, the electrical connector of the present invention comprises a first member 10, which engages an electrical wire 1, a second member 40 that presses the first member 10 against the wire, and a housing 60 that accommodates a length of wire 1 and the first and second members 10,40. The first member 10 shown in Figure 1 is ideally formed by stamping and forming a copper alloy sheet which possesses resiliency, e.g., a sheet comprising phosphor bronze or beryllium-copper. The first member 10 has a base section 12 in the form of a plate, an external- connecting portion 14 that is located at one end of base portion 12 and that is used to make electrical connection with an external contact or conductor, and a contact portion 16 that is located at the other end of the base portion 12 and that is used to make electrical connection with electrical wire 1. First member 10 constitutes an electrical contact member.

One surface 12a of the base portion 12 is formed so that it is flat throughout. The other surface 12b is formed so that one portion located toward the contact portion 16 is thinner as a result of a portion 18 where the plate thickness varies. A pair of barbs 20 are formed at roughly central positions on both side surfaces of the base portion 12; barbs 20 bite into the inside walls 64 of a first cavity 62 of the housing 60 when the first member 10 is inserted thereinto. A pair of shoulders 22 are formed at one end of the base portion 12 on both sides of the external-connecting portion 14. As will be described later, the shoulders 22 are used to make contact with a pressing tool 90 (Figure 4) when the first member 10 is press-fitted inside the first cavity 62 of the housing 60. The external-connecting portion 14 is a post with a rectangular cross section. However, any universally-known means of making an external electrical connection to portion 14 can be utilized.

The contact portion 16 is offset from the surface 12a of the base portion 12 by a first bent portion 24, which has a shallow reverse S-shape in longitudinal section (see Figure 4) . Contact portion 16 is formed substantially in the shape of a circular arc thereby having an arcuate shape. The first bent portion 24 is formed so that it is narrower than the other portions of the contact portion 16 in order to increase the flexibility thereof. A plurality of sawtooth-shaped serrations 26 are formed on surface 16a of the contact portion 16. Furthermore, the size of the sawtooth-shaped serrations 26 is shown as being exaggerated. Thus, contact portion 16 is a serrated- contact portion. A second bent portion 28, which has substantially a reverse S-shape in longitudinal section, is formed adjacent a free end of the contact portion 16 (see Figure 4) . Arcuate portion 30 on the side of the other surface 16b of the second bent portion 28 is formed in a circular arc shape which protrudes in the opposite direction from the surface 16a. As will be described later, this forms a point which is pressed by the second member 40. A U-shaped cut-out 32 is formed in a free end of the second bent portion 28; cut-out 32 guides the electrical wire 1 during the press-fitting of the first member 10 and second member 40 in the housing 60. Furthermore, the cut-out 32 may also be V-shaped.

As a result of the formation of the portion 18 where the thickness of the plate varies in the base portion 12, the thickness of the contact portion 16 is smaller than the thickness of the external-connecting portion 14. Alternatively, depending on the configuration of the external-connecting portion 14, the first member 10 may be formed with a constant thickness throughout. The second member 40 shown in Figure 2 is formed by stamping and forming a copper alloy metal sheet similar to that used for the first member 10. Furthermore, since the second member 40 does not participate directly in the conduction of electricity, the second member 40 may also be formed from a metal sheet of stainless steel, which has a higher resiliency. The second member 40 has a base section 42 in the form of a plate, and a pressing section 46, which is bent approximately 180 degrees by a bent portion 44 at one end of the base section 42 and which extends substantially parallel to the base section 42 thereby having a C-shape. Accordingly, the pressing section 46 is offset from a main surface 42a of the base section 42. A pair of shoulders 48, which are engaged by pressing tool 92 (Figure 5) when the second member 40 is press-fitted inside a second cavity 66 of the housing 60 (as will be described later) , are located on the other end of the base section 42. A pair of barbs 50 are located at roughly central positions on both side surfaces of the base section 42; these barbs 50 bite into inside walls 68 of the second cavity 66 of the housing 60 when the second member 40 is inserted thereinto. The pressing section 46 is formed with a narrower width than the base section 42. A free end 52 of the pressing section 46 is bent toward the base section 42 to prevent excessive deformation of the bent portion 44. The housing 60 shown in Figure 3 is ideally formed from an insulating material such as a polybutylene terephthalate (PBT) containing glass fibers. Housing 60 is formed as an integral part of the housing of a motor or coil bobbin (not shown) . The overall shape of the housing 60 is roughly that of a rectangular parallelepiped and has first cavity 62 which accommodates the first member 10, second cavity 66 which accommodates the second member 40, and a narrow intermediate cavity 70 via which the first and second cavities 62, 66 communicate with each other. Furthermore, a first electrical wire-accommodating slot 76 and a second electrical wire-accommodating slot 78 are respectively formed in side wall 72 located on the side of the first cavity 62 and side wall 74 located on the side of the second cavity 66 of housing 60. The second slot 78 is deeper than the first slot 76. Furthermore, a post 80 around which any excess length of the electrical wire 1 is wrapped is formed so that post 80 protrudes outward from end wall 74 in the vicinity of the lower end (right end in Figure 3) of the second slot 78. Inside wall 82 of the side wall 72 forms an electrical wire-receiving surface, while inside wall 84 of the side wall 74 forms a receiving surface for the second member 40.

Next, the process by which the first member 10 and the electrical wire 1 are connected with each other will be described with reference to Figures 4 through 6. First, the tip end portion of the electrical wire 1 extending from a coil bobbin (not shown) is wrapped around the circumference of the post 80 of the housing 60 so that the electrical wire 1 is fastened to the housing 60. Next, the first member 10 is provisionally inserted into the first cavity 62 of the housing 60, after which the first member 10 is inserted by means of the first pressing tool 90 to a position where second shoulders 34 of the first member 10 engage stop surfaces 86 of the housing 60 (i. e., the position shown in Figure 4). In this case, the electrical wire 1 is guided by the cut-out 32 of the first member 10, and is caused to conform substantially to the arcuate shape of the contact portion 16. Furthermore, in this state, as a result of the offset of the first bent portion 24 of the first member 10, the contact portion 16 is separated from the electrical wire-receiving surface 82 of the housing 60 by a distance greater than the diameter of the electrical wire 1, and the sawtooth-shaped serrations 26 apply no load to the electrical wire 1. Accordingly, there is no cutting of the electrical wire 1 by the first member 10.

Next, the second member 40 is inserted into the second cavity 66 of the housing 60 as far as the position shown in Figure 5; then, the second member 40 is inserted by means of the second pressing tool 92. The second pressing tool 92 is equipped with a cutting blade 94, which cuts the post 80 and the electrical wire 1 immediately before the second member 40 engages the first member 10. Accordingly, the electrical wire 1 is not cut by the first member 10. When the pushing of the second member 40 by the second pressing tool 92 is continued, the bent section 44 of the second member 40 engages the second surface 16b of the contact portion 16 of the first member 10, so that the second bent portion 28 of the first member 10 is pushed toward the electrical wire-receiving surface 82 of the housing 60. When the pushing of the second member 40 is continued even further, the bent section 44 of the second member 40 rides over the arcuate portion 30 of the first member 10, so that arcuate portion 30 and the pressing section 46 of the second member 40 are engaged as shown in Figure 6. In this state, the first bent portion 24 of the first member 10, which has an increased flexibility as a result of being formed with a narrow width, undergoes resilient deformation, and the contact portion 16 of the first member 10 is resiliently deformed into a substantially linear configuration. As a result, the electrical wire 1 is clamped between the contact portion 16 of the first member 10 and the electrical wire- receiving surface 82 of the housing 60. Viewing the lower end of the base portion 12 of the first member 10 as a supporting point, and the arcuate portion 30 as a force point, the sawtooth-shaped serrations 26 of the contact portion 16 may be viewed as action points. Accordingly, the load applied to the electrical wire 1 (i. e., the amount by which the sawtooth-shaped serrations bite in) is greatly increased by the lever principle. Thus, the reliability of the electrical connection is high.

Furthermore, although a reaction force from the first member 10 is applied to the pressing section 46 and bent section 44 of the second member 40, deformation of the bent section 44 of the second member 40 is prevented by the free end 52 which prevents excessive deformation of pressing section 46. Moreover, the height to which the sawtooth-shaped serrations 26 protrude from the surface

16a of the contact portion 16 is considerably smaller than the diameter of the electrical wire 1, and the contact portion 16 moves in a direction which is substantially perpendicular to the axis of the electrical wire 1; accordingly, there is no danger that the electrical wire 1 will be cut by the deformation of the first member 10.

Furthermore, in cases where the electrical wire 1 pressed by the sawtooth-shaped serrations 26 is partly embedded in the electrical wire-receiving surface 82 of the housing 60, the height to which the sawtooth-shaped serrations 26 protrude may be greater than the diameter of the electrical wire 1. Moreover, since the end portion of the electrical wire 1 which is cut by the cutting blade 94 is guided by the cut-out 32 in the first member 10, the end portion of the electrical wire 1 following cutting is finally positioned in an appropriate manner between the electrical wire-receiving surface 82 and the contact portion 16. In the present invention, little deformation in either the first member 10 or second member 40 takes place, so that no bending exceeding the resilient limit is applied to either member. Accordingly, a highly reliable electrical connection is obtained. Furthermore, both members have relatively simple shapes, and are therefore easy to manufacture; consequently, productivity is high. Moreover, since the pressing section 46 of the second member 40 is endowed with resiliency by the bent section 44, fluctuations in the dimensions of the housing 60 and first member 10 can be absorbed.

Figure 7 is a perspective view which illustrates another shape of second member 40'. Here, the pressing section 46' of the second member 40' is offset from the base section 42' between the base section 42' and the free end 52' without being bent 180 degrees. Pressing section 46' has an exaggerated U-shape. As a result, no bending process requiring a large amount of bending such as a 180 degree bend is necessary. As a result, the stamping and forming die is not complicated, so that manufacture is easy; furthermore, there tends not to be any concentration of stress, and the setting of dimensions is easily facilitated.

Like the first member 10, the first member 110 as shown in Figures 8-11 is basically formed by stamping and forming a copper alloy sheet which possesses resiliency. First member 110 has a base portion 112, an external- connecting portion 114 and a contact portion 116. The first member 110 differs from the first member 10 in the press-fitting structure of the base portion 112.

Specifically, the base portion 112 has a pair of barbs 120 which are formed on both side surfaces near the contact portion 116, and it also has a pair of lances 113 which extend toward the external-connecting portion 114 from the vicinity of the barbs 120. Lances 113 are formed by being cut and caused to protrude from the base portion 112 toward the opposite surface 112b thereof. A space 115 is formed between a free end 113a of each lance 113 and a corresponding shoulder 122. A protruding ridge 117, which extends in the direction of thickness of the lance 113, is formed on the side of the opposite surface 112b of the free end 113a of each lance 113. As shown most clearly in Figure 11, the protruding ridges 117 bite into the inside wall 163 of the first cavity 162 of the housing 160, thus reinforcing the retaining force of the first member 110 with respect to the housing 160. In the embodiment illustrated in Figures 1-6, even if the dimensions of the barbs 20 of the first member 10 are set at large values, the housing 60 opens in the direction of width of the first member 10 as a result of the presence of the first and second slots 76, 78; accordingly, it is difficult to increase the retaining force of the first member 10 with respect to the housing 60. In the case of the first member 110, on the other hand, the protruding ridges 117 bite into the inside wall 163 of the housing with the orientation of the protruding ridges 117 differing from that of the barbs 120 by approximately 90 degrees. Consequently, the first and second slots 76,78 have no deleterious effect. Accordingly, in conjunction with the barbs 120, the protruding ridges 117 make it possible to increase the retaining force of the first member 110 with respect to the housing 160. Furthermore, during press- fitting, the lances 113 flex toward the surface 112a of the base portion 112; accordingly, there is no great resistance to the insertion of the first member 110 into the first cavity 162 of housing 160.

It is desirable that the protruding ridges 117 be formed during the stamping process of the first member 110. Specifically, stamping ridges are deliberately generated when the spaces 115 are stamped out using the surface 112a of the base portion 112 as a pressing surface. The protruding ridges 117 may be formed by deliberately increasing the clearance between the punch and die (not shown) , or by forming a bevel of a prescribed angle in the punch-insertion opening of the die. The latter method is advantageous in that the dimensions of the protruding ridges can be more easily controlled. The first member 110' shown in Figures 12 to 16 differs from the first member 110 in that barbs as press- fitting projections 121' are added on both sides in the vicinity of the free end of the contact portion 116' . As shown in Figure 16, barbs 121' have points which narrow toward the side of the surface 116a' of the contact portion 116'. The reason for this will be described later. First member 110' is otherwise the same as first member 110.

Next, the process by which the first member 110' and the electrical wire 1 are connected to each other will be described with reference to Figures 17 through 20. First, in Figure 17, the tip end portion of the electrical wire 1 extending from a coil bobbin (not shown) is wrapped around the circumference of the post 180' of the housing 160' so that the electrical wire 1 is fastened to the housing 160'. Next, the first member 110' is inserted into the housing 160' by means of the first pressing tool 190' to a position where the second shoulders 134' of the first member 110' engage stop surfaces 186' of the housing 160'. Then, as shown in Figure 18, the second member 140' is inserted into the housing 160' by means of the second pressing tool 192'. Afterward, as shown in Figure 19, the electrical wire 1 is cut, more or less simultaneously with the engagement of the second member 140' against the first member 110', by the cutting blade 194' which moves in linkage with the second pressing tool 192'.

When the pushing of the second pressing tool 192' is continued, the bent section 144' of the second member 140' rides over the arcuate portion 130' of the first member

110', so that the arcuate portion 130' of the first member 110' and the pressing section 146' of the second member 140' are engaged, as shown in Figure 20. At the same time, the cutting of the post 180' by the cutting blade 194' is completed.

As is clear from Figures 18 to 20, the arcuate portion 130' of the contact portion 116' of the first member 110' located in the vicinity of the free end of the contact portion 116' is caused to move along a substantially arcuate path from left to right as a result of being pushed by the second member 140'. Consequently, the barbs 121' formed on both sides of the contact portion 116' in the vicinity of the free end of the contact portion 116' are constantly engaged with the inside walls 181', which are not used for the press-fitting of the first member 110' within the housing 160'. Accordingly, as a result of the press-fitting engagement of the barbs 121' with the inside walls 181', a relatively large retaining force of the first member 110' with respect to the housing 160' is produced. Furthermore, as was described above, the barbs 121' are shaped with a point that narrows toward the side of the surface 116a' of the contact portion 116'; accordingly, the resistance offered by the barbs 121' when the barbs 121' move from the position shown in Figure 18 to the position shown in Figure 20 is extremely small. As a result, the barbs 121' can move smoothly to the position shown in Figure 20.

Preferred embodiments of the present invention were described above; however, the present invention is not limited thereto; if necessary, various modifications and alterations may be made. For example, the pressing section of the second member may also be formed by embossing; alternatively, the second member may be formed by a part which has absolutely no resiliency, such as a round rod, etc. Furthermore, since the second member does not require conductivity, the second member may also be constructed from an insulating material such as a resin. Moreover, in the embodiments described above, the first members 10, 110 and 110' and the second members 40, 40' and 140' were all formed as separate members; however, it would also be possible to form these members as integral units, and to separate them into separate members by cutting the portion connecting the first and second members following insertion into the housing. In such a case, the number of parts that must be manufactured can be reduced, and a single pressing tool can be used. Furthermore, sawtooth-shaped serrations were formed by applying dragging to the contact portion 16 of the first member 10; however, it would also be possible to form projecting ridges by stamping, and to use these ridges as contact points.

Accordingly, the following advantages of the invention are obtained: there is no rebounding of the contact portion from the electrical wire, and the electrical connection therebetween is secure so that a highly reliable electrical connection is effected. Since no sharp bends such as acute-angle bends are formed in the first member, manufacture is facilitated. Moreover, since the first member is in resilient engagement with the electrical wire, no large internal stresses which might cause cracking are generated. The pressing of the pressing section of the second member against the free end of the contact portion of the first member is smoothly performed. The retaining force of the first member with respect to the insulating housing can be reinforced without causing any great resistance to the insertion of the first member into the insulating housing. The press- fitting projections of the contact portion of the first member are constantly engaged by press-fitting with the inside walls of the housing so that the retaining force of the first member with respect to the insulating housing is reinforced.

Claims

1. An electrical connector comprising a dielectric housing (60,160,160') having a wire-receiving surface (82,182') along which an electrical wire (1) extends, a first cavity (62,162,162') provided in the housing, an electrical contact member (10,110,110') movable along the first cavity and having a serrated-contact portion (16,116,116') for engagement with the electrical wire, a second cavity (66,166') provided in the housing, a member (40, 40' , 140' ) movable along the second cavity including a section (46, 46' , 146' ) for moving the serrated-contact portion into electrical connection with the electrical wire between the wire-receiving surface and the serrated- contact portion, characterized in that: the serrated-contact portion (16,116,116') has an arcuate shape, and the section (46, 46' , 146' ) is a resilient pressing section.

2. An electrical connector as claimed in claim 1, wherein said electrical contact member includes a base portion (12,112,112') and a connection portion (14,114,114') .

3. An electrical connector as claimed in claim 2, wherein a bent portion (24) is located between said serrated-contact portion and said base portion and is narrower than said serrated-contact portion and said base portion to increase the flexibility of said serrated- contact portion.

4. An electrical connector as claimed in claim 3, wherein another bent portion (28) is located at a front end of said serrated-contact portion and includes an arcuate portion (30,130').

5. An electrical connector as claimed in claim 4, wherein said bent portion includes a U-shaped cut-out

(32) .

6. An electrical connector as claimed in claim 2, wherein barbs (20) extend outwardly from side surfaces of said base portion that bite into walls (64) of said first cavity.

7. An electrical connector as claimed in claim 6, wherein said base portion (112,112') has lances (113,113') provided with ridges (117) that bite into wall (163) of the first cavity (162) .

8. An electrical connector as claimed in claim 4, wherein a free end of said contact portion (116') has press-fitting projections (121') extending outwardly from both sides thereof.

9. An electrical connector as claimed in claim 1, wherein the resilient pressing section (46) has a C-shape.

10. An electrical connector as claimed in claim 1, wherein the resilient pressing section (46') has an exaggerated U-shape.