WO2007009486A1 - Connector contact with separate clamping beams provided with arcuate sections - Google Patents

Connector contact with separate clamping beams provided with arcuate sections Download PDF

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Publication number
WO2007009486A1
WO2007009486A1 PCT/EP2005/009207 EP2005009207W WO2007009486A1 WO 2007009486 A1 WO2007009486 A1 WO 2007009486A1 EP 2005009207 W EP2005009207 W EP 2005009207W WO 2007009486 A1 WO2007009486 A1 WO 2007009486A1
Authority
WO
WIPO (PCT)
Prior art keywords
wire
connector
clamping
contact
arcuate section
Prior art date
Application number
PCT/EP2005/009207
Other languages
French (fr)
Inventor
Ben Paagman
Ludwig Lange
Original Assignee
Fci
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fci filed Critical Fci
Priority to PCT/EP2005/009207 priority Critical patent/WO2007009486A1/en
Priority to TW095126561A priority patent/TW200729630A/en
Publication of WO2007009486A1 publication Critical patent/WO2007009486A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • H01R13/42—Securing in a demountable manner
    • H01R13/428—Securing in a demountable manner by resilient locking means on the contact members; by locking means on resilient contact members
    • H01R13/432—Securing in a demountable manner by resilient locking means on the contact members; by locking means on resilient contact members by stamped-out resilient tongue snapping behind shoulder in base or case
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/188—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping having an uneven wire-receiving surface to improve the contact
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • H01R4/203—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve having an uneven wire-receiving surface to improve the contact

Definitions

  • the invention relates to the field of electrical connectors and contacts for such connectors. More particularly, the invention may relate to high current cable connectors and contacts for such connectors.
  • Electrical connectors typically comprise a housing accommodating a plurality of connector contacts. These connector contacts typically are arranged such that on a cable side of the connector, wires of a cable can be attached, while on the mating side of the electrical connector, the contacts are capable of receiving counter contacts of a mating connector. In particular, in the case of high current cable connectors, used e.g. for power supply purposes, the connector contacts may be capable of carrying a current of over 40 amps or more for certain electronic equipment .
  • the connector contacts have a mating portion comprising blades, pins or sockets capable of receiving corresponding counter contacts.
  • the connector contacts typically comprise a metallic portion connected to the mating portion.
  • a male or female crimp contact also referred to as Faston ®
  • the metallic portion comprises a central base that is connected to the mating portion. Clamping fingers, e.g. constituting U-shaped cups, extend from the central base at various locations along the base in order to clamp onto an exposed portion of a conduc- tor of a cable or wire.
  • the proposed connector contact has multiple separate clamping beams each in direct electrical contact with the mating portion. Consequently, current density distribution over the connector contact is improved.- In case each of the beams extends from a different leg of a U-shaped mating portion, clamping of the beams onto a wire assists the legs of the mating portion to retain its shape and accordingly to improve the electrical contact with a counter connector contact .
  • Wire clamping beams may comprise arcuate sections being arranged for clamping said wire. These arcuate sections provide suitable crimping means for direct clamping of the contacts onto the wires, in particular conductors of said wires, without needing additional female crimp contacts and accordingly space and components are saved.
  • the overlapping parts of the arcuate sections enable crimping of the contacts on wires of different diameters. Further, the overlap ensures an appropriate distribution of the current density over the connector contact .
  • first and second arcuate sections comprise cooperating structures capable of providing a friction force between said first and second arcuate sections and conductor portions on motion on these sections, these structures, e.g. provided on overlapping parts of the arcuate sections, prevent or hinder the first and second wire clamping beam to be forced away from each other and accordingly reduce the chance of a reduced performance or disconnection of the contact with the wire.
  • the connector contact further comprises a locking latch for mounting said connector contact in said electrical connector it allows easy mounting of the connector contact within a housing of an electrical connector and to prevent that the connector contact moves from its intended location after mounting.
  • the connector contact may comprise jacket clamping means, which preferably comprise arcuate, possibly overlapping, jacket clamping sections. Accordingly, an electrical connector does not necessarily comprise means for clamping of the wire jacket.
  • a cable connector comprising a connector contact as described above.
  • This cable connector may comprise a cable connector housing structured so as to prevent walls of the mating portion and/or the clamping beams from moving apart .
  • a method for attaching a connector contact of an electrical connector to a wire comprising a mating portion capable of receiving a counter contact and a clamping portion comprising a first wire clamping beam and a second wire clamping beam each extending separately from said mating portion and wherein said first wire clamping beam comprises a first arcuate section and said second wire clamping beam comprises a second arcuate section capable of clamping said wire, said method comprising the steps of: exposing a portion of a conductor of said wire, and crimping said first and second arcuate section of said clamping portion onto said exposed conductor portion.
  • the arcuate sections of the wire clamping beams provide suitable crimping means for direct clamping of the contacts onto the wires without needing additional female crimp contacts and accordingly space and components are saved in this method.
  • cooperating structures are provided on said arcuate sections during said crimping step, said structures be- ing capable of providing a friction force between said first and second arcuate sections and conductor portions on motion on these sections.
  • These structures e.g. provided as indents on overlapping parts of the arcuate sections with a crimping tool, prevent or hinder the first and second wire clamping beam to be forced away from each other.
  • FIGS. IA and IB illustrate a front view and rear view of an electrical cable connector according to an embodiment of the invention
  • Figs. 2A and 2B illustrate the electrical cable connector of Figs. IA and IB without the top housing part
  • Figs. 3A-3E respectively illustrate a side view, a bot- torn view, a front view and two three-dimensional views of a connector contact according to a first embodiment of the invention.
  • Figs. 4A and 4B illustrate three-dimensional views of a connector contact including a wire jacket clamping section ac- cording to a second embodiment of the invention.
  • Figs . IA and IB illustrate a front view and a rear view of a high current electrical cable connector 1, hereinafter also referred to as cable connector 1, capable of carrying a current of over 40 amps for power supply purposes in e.g. telecom applications.
  • the cable connector 1 comprises an integral first housing part 2 with openings to accommodate rotatable latches 3 for connecting the cable connector 1 to a counter part.
  • a second housing part or top housing part 4 is mounted on the first housing part 2 by means of a fastener 5.
  • the cable connector 1 may also be provided with one or more than two wires.
  • a further housing part 9 is shown with openings 10 exposing a portion of a connector contact according to an embodiment of the invention as will be described next with reference to Figs. 2A, 2B and Figs. 3A-3E.
  • Figs. 2A and 2B illustrate the electrical cable connec- tor 1 of Figs. IA and IB without the top housing part 4.
  • the cable connector 1, or more specifically the housing parts 2, 4, are structured to accommodate connector contacts 20 connected to the conductors 7 of the wires 6 according to an embodiment of the invention.
  • the connector contacts 20 are described into more detail with reference to Figs. 3A-3E.
  • the housing parts 2, 4 determine a wire entry structured to cooperate with the jacket 8 of the wires 6 for strain relief.
  • the wire entry has a relief structure constituted by a series of ribs and recesses 21.
  • a receiving opening 22 for the fastener 5 is shown, enabling mounting of the top housing part 4 onto the first housing part 2 after application of the connector contacts 20 being connected to the wires 6.
  • Mounting of the top housing part 4 completes the wire entry and clamps the wire jacket 8 by means of the ribs and recesses 21.
  • Figs. 3A-3E respectively illustrate a side view, a bottom view, a front view and two three-dimensional views of a connector contact 20 according to a first embodiment of the invention.
  • the connector contact 20 has a mating portion 23 capable of receiving a counter contact and a clamping portion 24 capable of attaching the connector contact 20 to the wire 6, more specifically to an exposed portion of the conductor 7 of the wire S.
  • the clamping portion 24 comprises a first wire clamping beam 25 and a second wire clamping beam 26 each extending separately from the mating portion 23.
  • the connector contact is a female mating portion 23 which has a set of substantially parallel blades 27 for receiving blades of a counter male connector contact in between.
  • the connector contact of the invention may as well be a male blade connector contact, a pin contact, a socket contact or any other connector contact.
  • the connector contact 20 is par- ticularly suitable for carrying high currents in excess of 10 amps, preferably 30 amps or 40 amps. In these high current connector contacts typically sufficient mass/area is present for carrying the high current .
  • the mating portion 23, in particular the parallel blades 27, are exposed in the cable connector 1 in the further housing part 9 through openings 10.
  • the connector contacts 20 are mounted in the further housing part 9 by means of latches 28.
  • Each of the wire clamping beams 25, 26 separately ex- tends from the mating portion 23 and terminates into a first arcuate section Rl and a second arcuate section R2 which are arranged for clamping onto an exposed portion of the conductor 7 of the wire 6.
  • the arcuate sections Rl, R2 of the beams 25, 26 are connected to the blades 27 via intermediate curved portions 29.
  • the semi-circular arcuate sections Rl, R2 partly overlap in region 0 and are concentric.
  • the arcuate sections Rl, R2 may be driven away from each other, e.g. by a resilient force exerted by the intermediate portions 29, the overlapping parts O of the arcuate section may be structured such that they clamp on each other when attached to a wire 6.
  • the U-shaped mating portion 23 formed by the blades 27 has an improved ability to retains its shape as a result of the separate extending beams extending from the legs of the U crimped on the wire 6 providing a higher contact normal force . Consequently, an improved and more reliable electrical contact can be made with a counter contact . .
  • the connector contact 20 may be manufactured from sheet metal by stamping and bending. In contrast with the prior art wherein the blades 27 had a metal extension over which an additional crimped female contact connected to a wire is applied, the connector contact 20 of the invention is directly applied to a wire 6.
  • the wire clamping beams 25, 26 are manufactured from the material used for the metal extension in case a crimped female contact connection is applied.
  • the cable connector 1 shown in Figs . IA and IB may be manufactured as follows. First, the jacket 8 of the wires 6 may be stripped to expose a portion of the conductor 7. As mentioned previously, a sleeve may be applied as well. Subsequently, the exposed portion of the wire 6 is inserted between the arcuate sections Rl, R2 of the connector contact 20. Then, the arcuate sections are crimped onto the exposed conductor portions with a tool (not shown) until the conductor is firmly attached to the connector contact 20, dependent on the diameter of the conductor.
  • structures, such as indents may be formed by a crimping tool in the arcuate sections Rl, R2, preferably in the overlapping region O, that are capable of providing a friction force between the first and second arcuate sections Rl, R2 and a conductor portion on motion on these sections.
  • the connector contact 20 is applied into the further housing part 9 of the electrical cable connector 1 in which the connector contact 20 locks by means of the latch 28.
  • the top housing part 4 is mounted on the first housing part 2 by means of the fastener 5 cooperating with the receiving opening 22 such that the jacket 8 is firmly clamped between the housing parts 2, 4 by means of the ribs and recesses 21.
  • the connector contact fits into the cable connector housing so as to prevent the parallel blades of the mating portion and the clamping beams from moving apart
  • FIGs. 4A and 4B show a connector contact 20 according to a second embodiment the invention.
  • identical reference numerals have been applied to indicate identical or similar features of the connector contact 20 as shown in Figs. 3A-3E.
  • the connector contact 20 of Figs. 4A and 4B has an additional wire jacket clamping section 30 for clamp- ing on the wire jacket 8 of the wire 6.
  • the wire jacket clamping section has additional concentric arcuate sections R3 , R4, separated by a recess 31 from the arcuate sections Rl, R2 of the clamping portion 24 for the conductor 7 of the wire 6. Consequently, the ribs and recesses 21 shown in Figs. 2A and 2B may be omitted.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Multi-Conductor Connections (AREA)

Abstract

The invention relates to a connector contact for an electrical connector (20) comprising a mating portion (23) capa­ble of receiving a counter contact and a clamping portion (24) capable of attaching said connector contact to a wire. The clamping portion comprises at least a first wire clamping beam (25) and a second wire clamping beam (26) and wherein said first wire clamping beam and said second wire clamping beam separately extend from said mating portion. The invention further relates to a cable connector comprising such a connector contact and a method of attaching a wire to such a connector contact.

Description

Connector contact with separate clamping beams provided with arcuate sections
FIELD OF THE INVENTION
Generally, the invention relates to the field of electrical connectors and contacts for such connectors. More particularly, the invention may relate to high current cable connectors and contacts for such connectors.
BACKGROUND OF THE INVENTION
Electrical connectors typically comprise a housing accommodating a plurality of connector contacts. These connector contacts typically are arranged such that on a cable side of the connector, wires of a cable can be attached, while on the mating side of the electrical connector, the contacts are capable of receiving counter contacts of a mating connector. In particular, in the case of high current cable connectors, used e.g. for power supply purposes, the connector contacts may be capable of carrying a current of over 40 amps or more for certain electronic equipment .
In the art, the connector contacts have a mating portion comprising blades, pins or sockets capable of receiving corresponding counter contacts. On the other side, the connector contacts typically comprise a metallic portion connected to the mating portion. A male or female crimp contact (also referred to as Faston®) is attached to the cable or wire on the one hand and to the metallic portion of the connector contact on the other hand. Alternatively, connector contacts are known wherein the metallic portion comprises a central base that is connected to the mating portion. Clamping fingers, e.g. constituting U-shaped cups, extend from the central base at various locations along the base in order to clamp onto an exposed portion of a conduc- tor of a cable or wire.
However, several problems .affect the performance, utility and/or manufacturability of the known connector contacts. For example, the use of crimp contacts requires additional com- ponents and accommodates a considerable amount of space in the electrical connector. Further, connector contacts having a central current carrying base from which U-shaped cups extend set high requirements to the construction of the connector element . Still further, U-shaped cups may prove difficult in accommodating wires of different diameter.
Consequently, there is a need for an improved connector contact .
SUMMARY OF THE INVENTION
In an aspect of the invention, a connector contact according to claims 1-6 is provided.
In contrast to the prior art connector contacts having a single central base from which clamping fingers extend, the proposed connector contact has multiple separate clamping beams each in direct electrical contact with the mating portion. Consequently, current density distribution over the connector contact is improved.- In case each of the beams extends from a different leg of a U-shaped mating portion, clamping of the beams onto a wire assists the legs of the mating portion to retain its shape and accordingly to improve the electrical contact with a counter connector contact .
Wire clamping beams may comprise arcuate sections being arranged for clamping said wire. These arcuate sections provide suitable crimping means for direct clamping of the contacts onto the wires, in particular conductors of said wires, without needing additional female crimp contacts and accordingly space and components are saved.
The overlapping parts of the arcuate sections enable crimping of the contacts on wires of different diameters. Further, the overlap ensures an appropriate distribution of the current density over the connector contact .
In yet another aspect of the invention, a high current connector contact for an electrical cable connector according to claims 7.
When first and second arcuate sections comprise cooperating structures capable of providing a friction force between said first and second arcuate sections and conductor portions on motion on these sections, these structures, e.g. provided on overlapping parts of the arcuate sections, prevent or hinder the first and second wire clamping beam to be forced away from each other and accordingly reduce the chance of a reduced performance or disconnection of the contact with the wire.
When the connector contact further comprises a locking latch for mounting said connector contact in said electrical connector it allows easy mounting of the connector contact within a housing of an electrical connector and to prevent that the connector contact moves from its intended location after mounting.
In an embodiment of the invention, the connector contact may comprise jacket clamping means, which preferably comprise arcuate, possibly overlapping, jacket clamping sections. Accordingly, an electrical connector does not necessarily comprise means for clamping of the wire jacket.
In a further aspect of the invention a cable connector is proposed comprising a connector contact as described above. This cable connector may comprise a cable connector housing structured so as to prevent walls of the mating portion and/or the clamping beams from moving apart .
In a further aspect of the invention a method for attaching a connector contact of an electrical connector to a wire is proposed, said connector contact comprising a mating portion capable of receiving a counter contact and a clamping portion comprising a first wire clamping beam and a second wire clamping beam each extending separately from said mating portion and wherein said first wire clamping beam comprises a first arcuate section and said second wire clamping beam comprises a second arcuate section capable of clamping said wire, said method comprising the steps of: exposing a portion of a conductor of said wire, and crimping said first and second arcuate section of said clamping portion onto said exposed conductor portion.
The arcuate sections of the wire clamping beams provide suitable crimping means for direct clamping of the contacts onto the wires without needing additional female crimp contacts and accordingly space and components are saved in this method.
Preferably, cooperating structures are provided on said arcuate sections during said crimping step, said structures be- ing capable of providing a friction force between said first and second arcuate sections and conductor portions on motion on these sections. These structures, e.g. provided as indents on overlapping parts of the arcuate sections with a crimping tool, prevent or hinder the first and second wire clamping beam to be forced away from each other.
The invention will be further illustrated with reference to the attached drawings, which schematically show a preferred embodiment according to the invention. It will be understood that the invention is not in any way restricted to this specific and preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings :
Figs . IA and IB illustrate a front view and rear view of an electrical cable connector according to an embodiment of the invention;
Figs. 2A and 2B illustrate the electrical cable connector of Figs. IA and IB without the top housing part;
Figs. 3A-3E respectively illustrate a side view, a bot- torn view, a front view and two three-dimensional views of a connector contact according to a first embodiment of the invention, and
Figs. 4A and 4B illustrate three-dimensional views of a connector contact including a wire jacket clamping section ac- cording to a second embodiment of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
Figs . IA and IB illustrate a front view and a rear view of a high current electrical cable connector 1, hereinafter also referred to as cable connector 1, capable of carrying a current of over 40 amps for power supply purposes in e.g. telecom applications. The cable connector 1 comprises an integral first housing part 2 with openings to accommodate rotatable latches 3 for connecting the cable connector 1 to a counter part. A second housing part or top housing part 4 is mounted on the first housing part 2 by means of a fastener 5. Two wires 6, having a conductor 7 and a jacket 8, enter the cable connector 1. It should be appreciated that a sleeve (not shown) may accommodate both wires 6 and be attached to the cable connector 1. It should further be appreciated that the cable connector 1 may also be provided with one or more than two wires. Finally, a further housing part 9 is shown with openings 10 exposing a portion of a connector contact according to an embodiment of the invention as will be described next with reference to Figs. 2A, 2B and Figs. 3A-3E.
Figs. 2A and 2B illustrate the electrical cable connec- tor 1 of Figs. IA and IB without the top housing part 4. The cable connector 1, or more specifically the housing parts 2, 4, are structured to accommodate connector contacts 20 connected to the conductors 7 of the wires 6 according to an embodiment of the invention. The connector contacts 20 are described into more detail with reference to Figs. 3A-3E. The housing parts 2, 4 determine a wire entry structured to cooperate with the jacket 8 of the wires 6 for strain relief. In the present embodiment, the wire entry has a relief structure constituted by a series of ribs and recesses 21. Finally, a receiving opening 22 for the fastener 5 is shown, enabling mounting of the top housing part 4 onto the first housing part 2 after application of the connector contacts 20 being connected to the wires 6. Mounting of the top housing part 4 completes the wire entry and clamps the wire jacket 8 by means of the ribs and recesses 21. Figs. 3A-3E respectively illustrate a side view, a bottom view, a front view and two three-dimensional views of a connector contact 20 according to a first embodiment of the invention. The connector contact 20 has a mating portion 23 capable of receiving a counter contact and a clamping portion 24 capable of attaching the connector contact 20 to the wire 6, more specifically to an exposed portion of the conductor 7 of the wire S. The clamping portion 24 comprises a first wire clamping beam 25 and a second wire clamping beam 26 each extending separately from the mating portion 23.
More particularly, the connector contact is a female mating portion 23 which has a set of substantially parallel blades 27 for receiving blades of a counter male connector contact in between. It should however be appreciated that the connector contact of the invention may as well be a male blade connector contact, a pin contact, a socket contact or any other connector contact. Preferably, the connector contact 20 is par- ticularly suitable for carrying high currents in excess of 10 amps, preferably 30 amps or 40 amps. In these high current connector contacts typically sufficient mass/area is present for carrying the high current .
The mating portion 23, in particular the parallel blades 27, are exposed in the cable connector 1 in the further housing part 9 through openings 10. The connector contacts 20 are mounted in the further housing part 9 by means of latches 28.
Each of the wire clamping beams 25, 26 separately ex- tends from the mating portion 23 and terminates into a first arcuate section Rl and a second arcuate section R2 which are arranged for clamping onto an exposed portion of the conductor 7 of the wire 6. The arcuate sections Rl, R2 of the beams 25, 26 are connected to the blades 27 via intermediate curved portions 29. The semi-circular arcuate sections Rl, R2 partly overlap in region 0 and are concentric. As the arcuate sections Rl, R2 may be driven away from each other, e.g. by a resilient force exerted by the intermediate portions 29, the overlapping parts O of the arcuate section may be structured such that they clamp on each other when attached to a wire 6.
The U-shaped mating portion 23 formed by the blades 27 has an improved ability to retains its shape as a result of the separate extending beams extending from the legs of the U crimped on the wire 6 providing a higher contact normal force . Consequently, an improved and more reliable electrical contact can be made with a counter contact . . The connector contact 20 may be manufactured from sheet metal by stamping and bending. In contrast with the prior art wherein the blades 27 had a metal extension over which an additional crimped female contact connected to a wire is applied, the connector contact 20 of the invention is directly applied to a wire 6. The wire clamping beams 25, 26 are manufactured from the material used for the metal extension in case a crimped female contact connection is applied.
The cable connector 1 shown in Figs . IA and IB may be manufactured as follows. First, the jacket 8 of the wires 6 may be stripped to expose a portion of the conductor 7. As mentioned previously, a sleeve may be applied as well. Subsequently, the exposed portion of the wire 6 is inserted between the arcuate sections Rl, R2 of the connector contact 20. Then, the arcuate sections are crimped onto the exposed conductor portions with a tool (not shown) until the conductor is firmly attached to the connector contact 20, dependent on the diameter of the conductor. Simultaneously with crimping the arcuate sections Rl, R2 on the exposed conductor, structures, such as indents may be formed by a crimping tool in the arcuate sections Rl, R2, preferably in the overlapping region O, that are capable of providing a friction force between the first and second arcuate sections Rl, R2 and a conductor portion on motion on these sections.
Afterwards, the connector contact 20 is applied into the further housing part 9 of the electrical cable connector 1 in which the connector contact 20 locks by means of the latch 28. Finally, the top housing part 4 is mounted on the first housing part 2 by means of the fastener 5 cooperating with the receiving opening 22 such that the jacket 8 is firmly clamped between the housing parts 2, 4 by means of the ribs and recesses 21. Further, the connector contact fits into the cable connector housing so as to prevent the parallel blades of the mating portion and the clamping beams from moving apart
Figs. 4A and 4B show a connector contact 20 according to a second embodiment the invention. In Figs. 4A and 4B, identical reference numerals have been applied to indicate identical or similar features of the connector contact 20 as shown in Figs. 3A-3E.
In addition, the connector contact 20 of Figs. 4A and 4B has an additional wire jacket clamping section 30 for clamp- ing on the wire jacket 8 of the wire 6. The wire jacket clamping section has additional concentric arcuate sections R3 , R4, separated by a recess 31 from the arcuate sections Rl, R2 of the clamping portion 24 for the conductor 7 of the wire 6. Consequently, the ribs and recesses 21 shown in Figs. 2A and 2B may be omitted.
It should be appreciated that, in contrast to what is shown in Figs. 4A and 4B, the arcuate sections Rl and R2 of the clamping portion 24 may alternatively overlap contrary to the arcuate sections R3, R4 of the wire jacket clamping portion 30. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word "comprising" does not exclude the presence of elements or steps other than those listed in a claim. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

Claims

1. A connector contact (2Oj for an electrical connector comprising a mating portion (23) capable of receiving a counter contact and a clamping portion (24) capable of attaching said connector contact to a wire (6) , wherein said clamping portion comprises at least a first wire clamping beam (25) and a second wire clamping beam (26) and wherein said first wire clamping beam and said second wire clamping beam separately extend from said mating portion.
2. A connector contact (20) for an electrical connector comprising a mating portion (23) capable of receiving a counter contact and a clamping portion (24) capable of attaching said connector contact to a wire (6) , wherein said clamping portion comprises a first wire clamping beam (25) and a second wire clamping beam (26) each extending separately from said mating portion and wherein said first wire clamping beam comprises a first arcuate section (Rl) and/or said second wire clamping beam comprises a second arcuate section (R2) , said arcuate sections being arranged for clamping said wire.
3. The connector contact (20) according to claim 2, wherein said first arcuate section (Rl] is structured to at least partly overlap said second arcuate section (R2) on clamping said wire.
4. The connector contact (20) according to claim 2 or 3, wherein said first arcuate section (Rl) and second arcuate section (R2) are concentric sections.
5. The connector contact (20) according to one or more of claims 2-4, wherein said first arcuate section (Rl) and second arcuate section (R2) are substantially semi-circular sections .
6. The connector contact (20) according to one or more of the preceding claims, wherein said first wire clamping beam (25) and second wire clamping beam (26) further have, preferably arcuate, wire jacket clamping sections (R3,R4).
7. A high current connector contact (20) for an elec- trical cable connector comprising a mating portion (23) with at least one blade (27) capable of receiving a counter contact in contact with said at least one blade and a clamping portion (24) capable of attaching said connector contact to a wire (6) , wherein said clamping portion comprises a first wire clamping beam (25) and a second wire clamping beam (26) each extending separately from said mating portion and wherein said first wire clamping beam terminates with a first arcuate section (Rl) and said second wire clamping beam terminates with a second arcuate section (R2) , said first arcuate section being structured to at least partly overlap said second arcuate section on clamping said wire .
8. The connector contact (20) according to one or more of the preceding claims, wherein said first and/or second first wire clamping beams (25, 26) comprise cooperating structures ca- pable of providing a friction force between said first and second clamping beams (25, 26) and a conductor portion on motion on these sections.
9. The connector contact (20) according to one or more of the preceding claims, wherein said connector contact further comprises a locking latch (28) for mounting said connector contact in said electrical connector.
10. A cable connector (1) comprising a connector contact (20) with a mating portion (23) capable of receiving a counter contact of a counter connector and a clamping portion (24) capable of attaching said connector contact to a wire (6) , wherein said clamping portion comprises at least a first wire clamping beam (25) and a second wire clamping beam (26) and wherein said first wire clamping beam and said second wire clamping beam separately extend from said mating portion.
11. The cable connector (1) according to claim 10, wherein said first wire clamping beam (25) comprises a first arcuate section (Rl) and/or said second wire clamping beam (26) comprises a second arcuate section (R2) capable of clamping said wire .
12. The cable connector (1) according to claim 11, wherein said first wire clamping beam (25) terminates with said first arcuate section (Rl) and said second wire clamping beam (26) terminates with said second arcuate section (R2) and wherein said first arcuate section is capable of partly overlapping said second arcuate section on clamping said cable.
13. The cable connector (1) according to one or more of the claims 10-12, wherein said cable connector comprises a cable connector housing (2,4) structured so as to prevent walls of the mating portion and/or the clamping beams from moving apart.
14. A method for attaching a connector contact (20) of an electrical connector (1) to a wire (6) , said connector con- tact comprising a mating portion (23) capable of receiving a counter contact and a clamping portion (24) comprising a first wire clamping beam (25) and a second wire clamping beam (26) each extending separately from said mating portion, said method comprising the steps of: - exposing a portion of a conductor (7) of said wire, and
- crimping said first wire clamping beam (25) and said second wire clamping beam (26) onto said exposed conductor portion.
15. The method according to claim 14, wherein said first and second wire clamping beams (25, 26) comprise respec- tively first and second arcuate sections (Rl, R2) , said first arcuate section being capable of partly overlapping said second arcuate section (R2) on crimping said section onto said exposed conductor portion, further comprising the step of providing cooperating structures on said arcuate sections during said crimping step, said structures being capable of providing a friction force between said first and second arcuate sections and a conductor portion on motion on these sections.
PCT/EP2005/009207 2005-07-22 2005-07-22 Connector contact with separate clamping beams provided with arcuate sections WO2007009486A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/EP2005/009207 WO2007009486A1 (en) 2005-07-22 2005-07-22 Connector contact with separate clamping beams provided with arcuate sections
TW095126561A TW200729630A (en) 2005-07-22 2006-07-20 Connector contact with separate clamping beams provided with arcuate sections

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2005/009207 WO2007009486A1 (en) 2005-07-22 2005-07-22 Connector contact with separate clamping beams provided with arcuate sections

Publications (1)

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WO2007009486A1 true WO2007009486A1 (en) 2007-01-25

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2115830B1 (en) * 2007-02-23 2019-11-20 Amphenol Fci Asia Pte. Ltd. Contact for electrical connector

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Publication number Priority date Publication date Assignee Title
TWI393295B (en) * 2010-07-01 2013-04-11 Alltop Technology Co Ltd Power connector
TWI393301B (en) * 2010-07-01 2013-04-11 Alltop Technology Co Ltd Power connector

Citations (5)

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DE705325C (en) * 1938-06-17 1941-04-24 Bosch Gmbh Robert Cable lug
EP0373675A1 (en) * 1988-12-16 1990-06-20 The Whitaker Corporation Electrical contact terminal
US6129565A (en) * 1999-08-24 2000-10-10 Hon Hai Precision Ind. Co., Ltd. Cable connector having a grounding device
US20040214472A1 (en) * 2003-04-28 2004-10-28 Irish Kenneth G. Connector
DE10345202A1 (en) * 2003-09-29 2005-04-28 Electro Terminal Gmbh & Co Kg Method of configuring circuit boards for contacting circuit boards with wires, involves mechanically fixing and electrically contacting conductor by terminal connection or insulation-piercing contact

Patent Citations (5)

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Publication number Priority date Publication date Assignee Title
DE705325C (en) * 1938-06-17 1941-04-24 Bosch Gmbh Robert Cable lug
EP0373675A1 (en) * 1988-12-16 1990-06-20 The Whitaker Corporation Electrical contact terminal
US6129565A (en) * 1999-08-24 2000-10-10 Hon Hai Precision Ind. Co., Ltd. Cable connector having a grounding device
US20040214472A1 (en) * 2003-04-28 2004-10-28 Irish Kenneth G. Connector
DE10345202A1 (en) * 2003-09-29 2005-04-28 Electro Terminal Gmbh & Co Kg Method of configuring circuit boards for contacting circuit boards with wires, involves mechanically fixing and electrically contacting conductor by terminal connection or insulation-piercing contact

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2115830B1 (en) * 2007-02-23 2019-11-20 Amphenol Fci Asia Pte. Ltd. Contact for electrical connector

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