Electrical connectors

• US 5,569,039 A
• Filed: 01/12/1995
• Issued: 10/29/1996
• Est. Priority Date: 01/14/1994
• Status: Expired due to Term

• Current Assignee: Cinch Connectors Incorporated (Bel Connector Incorporated)
• Original Assignee: Labinal Components and Systems, Inc.
• Inventors: Bailey, William R., Garay, Antonio A., Rosborough, Keith A.
• Primary Examiner(s): Abrams, Neil
• Application Number:
  US08/372,011
• Time in Patent Office: 656 Days
• Field of Search: 439/66, 439/76.1, 439/91, 439/700, 439/824
• US Class Current: 439/76.1
• CPC Class Codes: B60R 16/02 electric constitutive elements
• CPC Class Codes: H01R 12/714 with contacts abutting directly the printed circuit; Button contacts therefore provided on the printed circuit
• CPC Class Codes: H01R 13/2471 pin shaped

Abstract

Electrical connector devices are provided for interconnecting external conductors with a connecting member such as a circuit which has upwardly projecting components that are adjacent contact areas on an exposed surface. The connector device comprises an insulator body for supporting a plurality of conductor elements in spaced relation to one another. The insulator body includes a plurality of cantilever hollow projections which have a length that exceeds the height of the components above the contact surfaces. The projections extend from the conductor sites generally parallel to one another and are disposed to mate the contact surfaces while providing spaces therearound to receive and accommodate the components. The insulator body preferably is a unitary molded body which includes the projections. An axially compressible conductive means extends through each of the hollow projections from the respective conductor site to an exposed end at the distal end of the respective projection. Preferably each compressible conductive means includes a wadded wire contact button and an exposed end plunger.

Claims

1. An electrical connector device for connecting with a mating connector member that has, on one side thereof, generally planar conductive contact surfaces and outwardly projecting circuit components, said connector device comprising:

an electrical insulator body which has a mounting side that includes a support surface for supporting such a connector member and a recess which extends inward of said body relative to said support surface for receiving said outwardly protruding circuit components of such connector member;

electrical conductors extending within said insulator body;

said insulator body defining an opening extending from each of said electrical conductors to an open distal end closely adjacent the position of a conductive contact surface of such a mating connector member supported on said support surface;

a resilient electrically conductive contact disposed in each of said openings and retained and supported in said insulator body, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end exposed through said distal end of the respective opening and being resiliently compressible axially of the respective opening for compressive engagement with a contact surface of such a mating connector member supported on said surface

each of said openings has an inner side wall and said resilient conductive contact is retained and supported by the inner side wall of the respective opening.

2. A connector device as in claim 1 wherein said insulator body includes an outwardly facing external surface which faces such a mating connector body mounted on said body, and said electrical conductor elements are embedded in said body adjacent said external surface.

3. A connector device as in claim 2 wherein said electrical conductor elements are elongated elements which extend generally parallel to said external surface.

4. A connector device as in claim 2 wherein said external surface is a surface of a wall of said body which forms the bottom of said recess whereby said circuit components are accommodated between said connector member and said external surface.

5. A connector as in claim 1 wherein each of said resilient conductive contacts includes a wadded wire element.

6. A connector as in claim 1 wherein each of said resilient conductive contacts includes a plurality of elements and at least one of said elements is a wadded wire element.

7. A connector as in claim 1 wherein each of said resilient conductive contacts includes a wadded wire element which has one end abutting the respective conductor and a plunger element abutting the other end of said wadded wire element, said plunger element being resiliently reciprocable axially of the respective opening by the respective wadded wire element.

8. A connector as in claim 1 wherein said insulator body includes an externally exposed socket, a plurality of prong elements extending within said socket and a corresponding plurality of electrical conductors connected to said prong elements and extending within said insulator body.

9. A connector as in claim 8 wherein said electrical conductors are integral with the respective prong element.

10. A connector as in claim 1 wherein said body is a unitary molded body.

11. A connector as in claim 10 wherein said body is molded of a thermoplastic material.

12. A connector as in claim 1 wherein said distal end of said opening is modified to retain said contact.

13. A connector as in claim 12 wherein said distal end is staked.

14. A connector as in claim 1 wherein said body includes registering portions to position a mating connector member.

15. A connector as in claim 14 wherein said registering portions are pins.

16. A connector device for interconnecting external circuits with a mating connector member which includes electrical conductors and has a mating face that includes at least one exposed generally planar conductive contact surface, said connector device comprising:

an electrical insulator body for supporting at least one conductor element and having an external surface for receiving such a mating connector member thereover with said planar conductive contact surface exposed toward said electrical insulator body,

at least one electrical conductor element which includes a portion disposed within said insulator body and a prong extending externally of said body for engagement by a conductor of an external circuit,

said insulator body defining an opening extending from each said electrical conductor element therein to an open distal end closely adjacent the position of such a mating connector member supported on said device, and

a resilient electrically conductive contact disposed in each of said openings and retained and supported in said insulator body, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end exposed through said distal end of the respective opening and being resiliently compressible axially of the respective opening for compressive engagement with a contact surface of such a mating connector member mounted on said device

each of said openings has an inner side wall and said resilient conductive contact is retained and supported by the inner side wall of the respective opening.

17. A connector device as in claim 16 wherein each of said resilient conductive contacts includes a wadded wire button element.

18. A connector device as in claim 16 wherein each of said resilient conductive contacts includes a plurality of elements and at least one of said elements is a wadded wire button element.

19. A connector device as in claim 16 wherein each of said resilient conductive contacts includes a wadded wire button element which has one end abutting the respective conductor element and a plunger element abutting the other end of said wadded wire button element, said plunger element being resiliently reciprocable axially of the respective opening by the respective wadded wire button element.

20. A connector device as in claim 16 for interconnecting with such a mating connector member which also has outwardly projecting circuit components on the same side thereof as said planar conductive contact surface, wherein said insulator body includes portions for supporting such a mating connector member in spaced relation to said external surface to accommodate said circuit components between said connector member and said external surface.

21. A connector device as in claim 20 wherein said electrical conductor element is embedded in said body adjacent said external surface.

22. A connector device as in claim 21 wherein said electrical conductor element is an elongated element which extends generally parallel to said external surface.

23. A connector as in claim 16 wherein said insulator body includes an externally exposed socket, said prong element extending within said socket and a corresponding electrical conductor connected to said prong element and extending within said insulator body.

24. A connector as in claim 23 wherein said electrical conductor is integral with the respective prong element.

25. A connector as in claim 16 wherein said body is a unitary molded body.

26. A connector as in claim 25 wherein said body is molded of a thermoplastic material.

27. A connector as in claim 16 wherein said distal end of said opening is modified to retain said contact.

28. A connector as in claim 27 wherein said distal end is staked.

29. A connector device as in claim 16 wherein said body includes registering portions to position a mating connector member.

30. A connector as in claim 29 wherein said registering portions are pins.

31. A connector device for interconnecting external circuits with a mating connector member which includes electrical conductors and has a mating face that includes generally planar conductive contact surfaces, said connector device comprising:

an electrical insulator body having one wall with an external surface for receiving such a mating connector member thereover,

at least one externally prong element exposed for engagement by a conductor of an external circuit connector,

an electrical conductor joined to each of said prong elements and extending within said insulator body adjacent said wall,

said insulator body defining openings extending from said electrical conductors through said wall surface, and

a resilient electrically conductive contact disposed in each of said openings and retained and supported in said insulator body, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end exposed through said wall surface and being resiliently compressible axially of the respective opening for compressive engagement with a contact surface of such a mating connector member disposed over said wall surface

each of said openings has an inner side wall and said resilient conductive contact is retained and supported by the inner side wall of the respective opening.

32. A connector device as in claim 31 wherein said electrical conductor is an elongated conductor disposed within said insulator body generally parallel to said external surface.

33. A connector device as in claim 31 wherein each of said resilient conductive contacts includes a wadded wire button element.

34. A connector device as in claim 31 wherein each of said resilient conductive contacts includes a plurality of elements and at least one of said elements is a wadded wire button element.

35. A connector device as in claim 31 wherein each of said resilient conductive contacts includes a wadded wire button element which has one end abutting the respective conductor and a plunger element abutting the other end of said wadded wire button element, said plunger element being resiliently reciprocable axially of the respective opening by the respective wadded wire button element.

36. A connector device as in claim 31 wherein said insulator body includes an externally exposed socket, a plurality of said prong elements extending within said socket and a corresponding plurality of electrical conductors connected to said prong elements and extending within said insulator body.

37. A connector device as in claim 36 wherein said electrical conductors are integral with the respective prong element.

38. A connector as in claim 31 wherein said body is a unitary molded body.

39. A connector as in claim 38 wherein said body is molded of a thermoplastic material.

40. A connector as in claim 31 wherein said distal end of said opening is modified to retain said contact.

41. A connector as in claim 40 wherein said distal end is staked.

42. A connector device as in claim 31 wherein said body includes registering portions to position a mating connector member.

43. A connector as in claim 42 wherein said registering portions are pins.

44. An electrical connector assembly comprising:

a connector member that has, on one side thereof, generally planar conductive contact surfaces and outwardly projecting circuit components;

an electrical insulator body which has a mounting side that includes a support surface, said connector member being supported on said support surface, said body having a recess which extends inward of said body relative to said support surface and in which said outwardly protruding circuit components of such connector member are disposed;

electrical conductors extending within said insulator body;

said insulator body including portions which extend from adjacent said electrical connectors to adjacent said conductive contact surfaces of said connector member and define an opening extending from each of said electrical conductors to an open distal end closely adjacent the position of a respective one of said conductive contact surfaces; and

a resilient electrically conductive contact disposed in each of said openings, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end engaging the respective contact surface, said conductive contact elements being resiliently compressible axially of the respective opening for compressive engagement with the respective contact surface of said mating connector member

each of said openings has an inner side wall and said resilient conductive contact is retained and supported by the inner side wall of the respective opening.

45. An electrical connector assembly as in claim 44 in which said connector member includes a heat sink and a circuit mounted on said heat sink, said circuit including said generally planar contact surfaces and said outwardly protruding circuit components.

46. A connector device as in claim 44 wherein each of said resilient conductive contacts includes a plurality of elements and at least one of said elements is a wadded wire button element.

47. A connector device as in claim 44 wherein each of said resilient conductive contacts includes a wadded wire button element which has one end abutting the respective conductor element and a plunger element abutting the other end of said wadded wire button element, said plunger element being resiliently reciprocable axially of the respective opening by the respective wadded wire button element.

48. A connector as in claim 44 wherein said insulator body includes an externally exposed socket, a plurality of prong elements extending within said socket and a corresponding plurality of electrical conductors connected to said prong elements and extending within said insulator body.

49. A connector as in claim 48 wherein said electrical conductors are integral with the respective prong element.

50. A connector as in claim 44 wherein each of said resilient conductive contacts includes a wadded wire element.

51. A connector as in claim 44 wherein a gasket material is located between said support surface and said connector member.

52. A connector as in claim 44 wherein a potting material is located in said recess.

53. A connector as in claim 45 wherein said circuit is an engine control circuit.

54. A connector as in claim 44 wherein said body is a unitary molded body.

55. A connector as in claim 54 wherein said body is molded of a thermoplastic material.

56. A connector as in claim 44 wherein said distal end of said opening is modified to retain said contact.

57. A connector as in claim 56 wherein said distal end is staked.

58. A connector device as in claim 44 wherein said body includes registering portions to position a mating connector member.

59. A connector as in claim 58 wherein said registering portions are pins.

60. A connector device for interconnecting external circuits with a mating connector member which includes electrical conductors and has a mating face that includes at least one exposed generally planar conductive contact surface, said connector device comprising:

an electrical insulator body for supporting at least one conductor element and having an external surface for receiving such a mating connector member thereover with said planar conductive contact surface exposed toward said electrical insulator body,

at least one electrical conductor element which includes a portion disposed within said insulator body and a prong extending externally of said body for engagement by a conductor of an external circuit,

said insulator body defining an opening extending from each said electrical conductor element therein to an open distal end closely adjacent the position of such a mating connector member supported on said device, and

a resilient electrically conductive contact disposed in each of said openings and retained and supported in said insulator body, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end exposed through said distal end of the respective opening and being resiliently compressible axially of the respective opening for compressive engagement with a contact surface of such a mating connector member mounted on said device

each of said resilient conductive contacts includes a wadded wire button element which has one end abutting the respective conductor element and a plunger element abutting the other end of said wadded wire button element, said plunger element being resiliently reciprocable axially of the respective opening by the respective wadded wire button element.

61. A connector device for interconnecting external circuits with a mating connector member which includes electrical conductors and has a mating face that includes generally planar conductive contact surfaces, said connector device comprising:

an electrical insulator body having one wall with an external surface for receiving such a mating connector member thereover,

at least one externally prong element exposed for engagement by a conductor of an external circuit connector,

an electrical conductor -joined to each of said prong elements and extending within said insulator body adjacent said wall,

said insulator body defining openings extending from said electrical conductors through said wall surface, and

a resilient electrically conductive contact disposed in each of said openings and retained and supported in said insulator body, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end exposed through said wall surface and being resiliently compressible axially of the respective opening for compressive engagement with a contact surface of such a mating connector member disposed over said wall surface

each of said resilient conductive contacts includes a wadded wire button element which has one end abutting the respective conductor and a plunger element abutting the other end of said wadded wire button element, said plunger element being resiliently reciprocable axially of the respective opening by the respective wadded wire button element.

62. An electrical connector assembly comprising:

a connector member that has, on one side thereof, generally planar conductive contact surfaces and outwardly projecting circuit components;

an electrical insulator body which has a mounting side that includes a support surface, said connector member being supported on said support surface, said body having a recess which extends inward of said body relative to said support surface and in which said outwardly protruding circuit components of such connector member are disposed;

electrical conductors extending within said insulator body;

said insulator body including portions which extend from adjacent said electrical connectors to adjacent said conductive contact surfaces of said connector member and define an opening extending from each of said electrical conductors to an open distal end closely adjacent the position of a respective one of said conductive contact surfaces; and

a resilient electrically conductive contact disposed in each of said openings, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end engaging the respective contact surface, said conductive contact elements being resiliently compressible axially of the respective opening for compressive engagement with the respective contact surface of said mating connector member

each of said resilient conductive contacts includes a wadded wire button element which has one end abutting the respective conductor element and a plunger element abutting the other end of said wadded wire button element, said plunger element being resiliently reciprocable axially of the respective opening by the respective wadded wire button element.

63. An electrical connector device for connecting with a mating connector member that has, on one side thereof, generally planar conductive contact surfaces and outwardly projecting circuit components, said connector device comprising:

an electrical insulator body which has a mounting side that includes a support surface for supporting such a connector member and a recess which extends inward of said body relative to said support surface for receiving said outwardly protruding circuit components of such connector member;

electrical conductors extending within said insulator body;

said insulator body defining an opening extending from each of said electrical conductors to an open distal end closely adjacent the position of a conductive contact surface of such a mating connector member supported on said support surface;

a resilient electrically conductive contact disposed in each of said openings and retained and supported in said insulator body, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end exposed through said distal end of the respective opening and being resiliently compressible axially of the respective opening for compressive engagement with a contact surface of such a mating connector member supported on said surface

each of said resilient conductive contacts includes a wadded wire button element which has one end abutting the respective conductor and a plunger element abutting the other end of said wadded wire button element, said plunger element being resiliently reciprocable axially of the respective opening by the respective wadded wire button element.

64. An electrical connector device for connecting with a mating connector member that has, on one side thereof, generally planar conductive contact surfaces and outwardly projecting circuit components, said connector device comprising:

an electrical insulator body which has a mounting side that includes a support surface for supporting such a connector member and a recess which extends inward of said body relative to said support surface for receiving said outwardly protruding circuit components of such connector member;

electrical conductors extending within said insulator body;

said insulator body defining an opening extending from each of said electrical conductors to an open distal end closely adjacent the position of a conductive contact surface of such a mating connector member supported on said support surface;

a resilient electrically conductive contact disposed in each of said openings and retained and supported in said insulator body, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end exposed through said distal end of the respective opening and being resiliently compressible axially of the respective opening for compressive engagement with a contact surface of such a mating connector member supported on said surface

each of said resilient conductive contacts includes a wadded wire element.

65. A connector device for interconnecting external circuits with a mating connector member which includes electrical conductors and has a mating face that includes at least one exposed generally planar conductive contact surface, said connector device comprising:

an electrical insulator body for supporting at least one conductor element and having an external surface for receiving such a mating connector member thereover with said planar conductive contact surface exposed toward said electrical insulator body,

at least one electrical conductor element which includes a portion disposed within said insulator body and a prong extending externally of said body for engagement by a conductor of an external circuit,

said insulator body defining an opening extending from each said electrical conductor element therein to an open distal end closely adjacent the position of such a mating connector member supported on said device, and

a resilient electrically conductive contact disposed in each of said openings and retained and supported in said insulator body, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end exposed through said distal end of the respective opening and being resiliently compressible axially of the respective opening for compressive engagement with a contact surface of such a mating connector member mounted on said device

each of said resilient conductive contacts includes a wadded wire element.

66. A connector device for interconnecting external circuits with a mating connector member which includes electrical conductors and has a mating face that includes generally planar conductive contact surfaces, said connector device comprising:

an electrical insulator body having one wall with an external surface for receiving such a mating connector member thereover,

at least one externally prong element exposed for engagement by a conductor of an external circuit connector,

an electrical conductor joined to each of said prong elements and extending within said insulator body adjacent said wall,

said insulator body defining openings extending from said electrical conductors through said wall surface, and

a resilient electrically conductive contact disposed in each of said openings and retained and supported in said insulator body, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end exposed through said wall surface and being resiliently compressible axially of the respective opening for compressive engagement with a contact surface of such a mating connector member disposed over said wall surface

each of said resilient conductive contacts includes a wadded wire element.

67. An electrical connector assembly comprising:

a connector member that has, on one side thereof, generally planar conductive contact surfaces and outwardly projecting circuit components;

an electrical insulator body which has a mounting side that includes a support surface, said connector member being supported on said support surface, said body having a recess which extends inward of said body relative to said support surface and in which said outwardly protruding circuit components of such connector member are disposed;

electrical conductors extending within said insulator body;

said insulator body including portions which extend from adjacent said electrical connectors to adjacent said conductive contact surfaces of said connector member and define an opening extending from each of said electrical conductors to an open distal end closely adjacent the position of a respective one of said conductive contact surfaces; and

a resilient electrically conductive contact disposed in each of said openings, each of said resilient electrically conductive contacts having a proximal end engaging the respective conductor and a distal end engaging the respective contact surface, said conductive contact elements being resiliently compressible axially of the respective opening for compressive engagement with the respective contact surface of said mating connector member

each of said resilient conductive contacts includes a wadded wire element.