Low cost electrical connector

Claim 2

An electrical connector comprising: a dielectric body member including a main body portion having first and second exterior surfaces adapted to be positioned in cooperative juxtaposition with associated members having electrically conductive elements, said main body portion having a plurality of spaced-apart, contact-receiving apertures extending therethrough between said surfaces; each aperture having a narrow cavity region extending inwardly from said first exterior surface, a shoulder cavity region wider than said narrow cavity region and extending inwardly from said narrow cavity region toward said second exterior surface, and a wide cavity region wider than said shoulder cavity region and extending from said shoulder cavity region to said second exterior surface; said shoulder cavity region communicating with said narrow cavity region and cooperating therewith to define an offset shoulder surface disposed substantially normal to the longitudinal axis of said narrow cavity region; and a plurality of electrical contacts disposed in respective ones of said apertures, each contact including a terminal portion, a shoulder portion and an active contact portion, each said terminal portion being shaped complementary to and disposed snugly in said narrow cavity region of said aperture and extending outwardly beyond said first exterior surface for connection to another electrically conductive element; each said shoulder portion being shaped complementary to and disposed in a water-tight fit in said shoulder cavity region of said aperture in mating engagement with said shoulder surface, each said shoulder portion having at least one ridge on opposite faces thereof isolated from said narrow cavity region and said wide cavity region and extending in a direction substantially normal to the longitudinal axis of said aperture; said active contact portion extending into said wide cavity region for connection to another electrical component; whereby said snug fit of said terminal portion, said water-tight fit of said shoulder portion, said offset shoulder surface and said ridge together define a substantially irregular and constricted path through said aperture to thereby provide an essentially liquid impervious juncture which prevents seepage to said active contact portion.

Claim 3

The electrical connector set forth in claim 1, wherein each of said electrical contacts comprises a relatively flat unitary metal member and the terminal and shoulder portions of each said aperture is generally rectangular in cross section in a plane perpendicular to the aperture axis.

Claim 4

The electrical connector set forth in claim 2, wherein said contacts are cold-formed from sheet metal stock.

Claim 5

The electrical connector set forth in claim 2, wherein the active contact portion of each of said electrical contact comprises a pair of spaced parallel prongs connected at said shoulder portion, said contact being substantially configurated in the shape of a tuning fork with said prongs serving to releasably grasp an associated male mating member inserted therebetween and to provide electrical contact therewith, whereby said connector serves as a female receptacle adapted to receive a plurality of male mating members therein.

Claim 6

The electrical connector set forth in claim 4, wherein said body member includes an upper body portion through which said apertures extend, said second exterior surface being disposed on said upper body portion, the portion of each said apertures contained by said upper body portion defining said wide cavity region therein so that said upper body portion is spaced from the prongs of said contact so as to permit limited outward flexing of said prongs when an associated male mating contact member is inserted therebetween, said upper body portion thereby providing an insulating barrier between adjacent ones of said contacts.

Claim 7

The electrical connector set forth in claim 5, wherein said active contact portion defined by said spaced prongs is recessed below the second exterior surface of said upper body portion.

Claim 8

The electrical connector set forth in claim 5, wherein said wide cavity region in said upper body portion surrounding said parallel prongs includes oppositely disposed semi cylindrical regions extending from said shoulder cavity region throughout said wide cavity region, thereby to accommodate a generally cylindrical male mating member inserted between said prongs.

Claim 9

The electrical connector set forth in claim 7, wherein each said aperture is provided with a generally conical entryway at said second exterior surface, to thereby guide a mating male member into position in said aperture.

Claim 10

The electrical connector set forth in claim 5, wherein said upper body portion in the area surrounding said active contact portion of said electrical contacts is generally trapezoidal in cross section so as to provide polarizing engagement with an associated complementary electrical component.

Claim 11

The electrical connector set forth in claim 1, wherein at least a portion of each of said aperture is generally rectangular in cross section in a plane perpendicular to the longitudinal axis of each aperture, and said apertures are arranged in at least two parallel rows with said apertures in one said row being spaced approximately midway between the apertures of the second said row.

Claim 12

The electrical connector set forth in claim 10, wherein each said rectangular aperture has a major dimension and a minor dimension, the major dimension being perpendicular to the plane defined by the row of parallel apertures, thereby to permit closer spacing of the electrical contacts disposed in said apertures along each said parallel row.

Claim 13

The electrical connector set forth in claim 1, wherein said body member is formed of a thermoplastic material.

Claim 14

The electrical connector set forth in claim 1, wherein said body member is formed of a glass-filled polyester.

Claim 15

The electrical connector set forth in claim 1, wherein said body member further includes a pair of fastening flanges integrally formed therewith and extending outwardly from opposite ends thereof, and means for releasably securing said connector to an associated circuit board.

Claim 16

The electrical connector set forth in claim 1, wherein said main body portion further includes a pair of flanges disposed at opposite ends thereof and extending outwardly from said first exterior surface so that the area of said first exterior surface containing said apertures is spaced from an associated underlying circuit board, thereby reducing engagement of said apertures with insulative material on the printed circuit board.

Claim 17

An electrical connector comprising: a body member formed of a dielectric material and including a main body portion having first and second exterior surfaces adapted to be positioned in cooperative juxtaposition with associated members having electrically conductive elements, said main body portion having a plurality of spaced-apart, contact-receiving apertures extending therethrough between said surfaces; each aperture having a narrow cavity region extending inwardly from said first exterior surface, a shoulder cavity region wider than said narrow cavity region and extending inwardly from said narrow cavity region toward said second exterior surface, and a wide cavity region wider than said shoulder cavity region and extending from said shoulder cavity region to said second exterior surface, said shoulder cavity region communicating with said narrow cavity region and cooperating therewith to define an offset shoulder surface disposed substantially normal to the longitudinal axis of said narrow cavity region; and a plurality of electrical contacts disposed in respective ones of said apertures, each contact including a terminal portion, a shoulder portion and an active contact portion, each said terminal portion being shaped complementary to and disposed in press-fit relationship within said narrow cavity region of said aperture and extending outwardly beyond said first exterior surface for connection to another electrically conductive element; each said shoulder portion being shaped complementary to and disposed in press-fit relationship within said shoulder cavity region of said aperture, each said shoulder portion having at least one raised ridge on opposite faces thereof isolated from said narrow cavity region and said wide cavity region and disposed substantially normal to the longitudinal axis of said aperture; said active contact portion extending into said wide cavity region for connection to another electrically conductive element; said press-fit of said terminal portion, said shoulder portion, said offset shoulder surface and said raised ridge together defining a substantially irregular and constricted path through said aperture to provide an essentially liquid impervious juncture which prevents seepage to said active contact portion, said active contact portion comprising a pair of spaced parallel prongs connected at said shoulder portion and serving to releasably engage a male contact member inserted therebetween, said wide cavity region being spaced from said prongs to permit limited outward flexing of said prongs when said male contact member is inserted therebetween.

Claim 18

An electrical connector comprising: a body member formed of a dielectric material and including a main body portion having first and second exterior surfaces adapted to be positioned in cooperative juxtaposition with associated members having electrically conductive elements, said main body portion having a plurality of spaced-apart, contact-receiving apertures extending therethrough between said surfaces; each aperture having a narrow cavity region extending inwardly from said first exterior surface, a shoulder cavity region wider than said narrow cavity region and extending inwardly from said narrow cavity region toward said second exterior surface, and a wide cavity region wider than said shoulder cavity region and extending from said shoulder cavity region to said second exterior surface, said shoulder cavity region communicating with said narrow cavity region and cooperating therewith to define an offset shoulder surface disposed substantially normal to the longitudinal axis of said narrow cavity region; and a plurality of electrical contacts disposed in respective ones of said apertures, each contact including a terminal portion, a shoulder portion and an active contact portion, each said terminal portion being shaped complementary to and disposed in press-fit relationship within said narrow cavity region of said aperture and extending outwardly beyond said first exterior surface for connection to another electrically conductive element; each said shoulder portion being shaped complementary to and disposed in press-fit relationship within said shoulder cavity region of said aperture, each said shoulder portion having at least one raised ridge on opposite faces thereof isolated from said narrow cavity region and said wide cavity region and disposed substantially normal to the longitudinal axis of said aperture; said active contact portion extending into said wide cavity region for connection to another electrically conductive element; said press-fit of said terminal portion, said shoulder portion, said offset shoulder surface and said raised ridge together defining a substantially irregular and constricted path through said aperture to provide an essentially liquid impervious juncture which prevents seepage to said active contact portion, said active contact portion comprising a pair of spaced parallel prongs connected at said shoulder portion and serving to releasably engage a male contact member inserted therebetween, said wide cavity region being spaced from said prongs to permit limited outward flexing of said prongs when said male contact member is inserted therebetween.

Claim 19

The electrical connector set forth in claim 16, wherein said wide cavity region in said upper body portion surrounding said parallel prongs includes generally semi cylindrical opposed regions extending from said shoulder cavity region throughout said wide cavity region, thereby to accommodate a generally cylindrical male mating member inserted between said prongs.

Claim 20

The electrical connector set forth in claim 17, wherein each said aperture is provided with a generally conical entryway at said second exterior surface, thereby to guide a mating male member into position in said aperture.

Claim 21

An electrical connector comprising: a body member formed of a dielectric material and including a main body portion having first and second exterior surfaces adapted to be positioned in cooperative juxtaposition with associated members having electrically conductive elements, said main body portion having a plurality of spaced-apart, contact-receiving apertures extending therethrough between said surfaces; each aperture having a narrow cavity region extending inwardly from said first exterior surface, a shoulder cavity region wider than said narrow cavity region and extending inwardly from said narrow cavity region toward said second exterior surface, and a wide cavity region wider than said shoulder cavity region and extending from said shoulder cavity region to said second exterior surface, said shoulder cavity region communicating with said narrow cavity region and cooperating therewith to define an offset shoulder surface disposed substantially normal to the longitudinal axis of said narrow cavity region, and each said aperture being generally rectangular in cross section; and a plurality of electrical contacts disposed in respective ones of said apertures, each contact being generally rectangular in cross section and including a terminal portion, a shoulder portion and an active contact portion, each said terminal portion being shaped complementary to and disposed in press-fit relationship within said narrow cavity region of said aperture and extending outwardly beyond said first exterior surface for connection to another electrically conductive element, each said shoulder portion being shaped complementary to and disposed in press-fit relationship within said shoulder cavity region of said aperture, each said shoulder portion having at least one raised ridge on opposite faces thereof isolated from said narrow cavity region and said wide cavity region and extending in a direction substantially normal to the longitudinal axis of said aperture; said active contact portion extending from said shoulder cavity region into said wide cavity region for connection to another electrical conductive element; whereby said press-fit of said terminal, said shoulder portion, said offset shoulder surface and said raised ridge together define a substantially irregular and constricted path through said aperture to thereby provide an essentially liquid impervious juncture which prevents seepage to said active contact portion.

Claim 22

An electrical connector comprising: a body member formed of a dielectric material and including a main body portion having first and second exterior surfaces adapted to be positioned in cooperative juxtaposition with associated members having electrically conductive elements, said main body portion having a plurality of spaced-apart, contact-receiving apertures extending therethrough between said surfaces; each aperture having a narrow cavity region extending inwardly from said first exterior surface, a shoulder cavity region wider than said narrow cavity region and extending inwardly from said narrow cavity region toward said second exterior surface, and a wide cavity region wider than said shoulder cavity region and extending from said shoulder cavity region to said second exterior surface, said shoulder cavity region communicating with said narrow cavity region and cooperating therewith to define an offset shoulder surface disposed substantially normal to the longitudinal axis of said narrow cavity region, and each said aperture being generally rectangular in cross section; and a plurality of electrical contacts disposed in respective ones of said apertures, each contact being generally rectangular in cross section and including a terminal portion, a shoulder portion and an active contact portion, each said terminal portion being shaped complementary to and disposed in press-fit relationship within said narrow cavity region of said aperture and extending outwardly beyond said first exterior surface for connection to another electrically conductive element, each said shoulder portion being shaped complementary to and disposed in press-fit relationship within said shoulder cavity region of said aperture, each said shoulder portion having at least one raised ridge on opposite faces thereof isolated from said narrow cavity region and said wide cavity region and extending in a direction substantially normal to the longitudinal axis of said aperture; said active contact portion extending from said shoulder cavity region into said wide cavity region for connection to another electrical conductive element; whereby said press-fit of said terminal, said shoulder portion, said offset shoulder surface and said raised ridge together define a substantially irregular and constricted path through said aperture to thereby provide an essentially liquid impervious juncture which prevents seepage to said active contact portion.

Claim 23

The electrical connector set forth in claim 19, wherein said contacts are arranged in at least two parallel rows with said contacts in one said row being spaced approximately midway between the contacts of the second said row.

Claim 24

The electrical connector set forth in claim 20, wherein each said rectangular contact has a major dimension and a minor dimension, the major dimension being perpendicular to the plane defined by the row of parallel contacts, to thereby permit closer spacing of the electrical contacts disposed along each said parallel row.

Claim 25

An electrical connector comprising: a body member including a main body portion having first and second exterior surfaces adapted to be positioned in cooperative juxtaposition with associated members having electrically conductive elements, said main body portion having a plurality of spaced-apart, contact-receiving apertures extending therethrough substantially between said surfaces and being arranged in at least one row thereof; each aperture having a narrow cavity region extending inwardly from said first exterior surface and a wider cavity region extending from said narrow cavity region toward said second exterior surface, said wider cavity region being elongated in cross section so as to have a long dimension extending generally transversely of said row and a short dimension extending generally parallel to said row and oppositely disposed semi-cylindrical regions intermediate the ends of said long dimension extending generally from said narrow cavity region toward said second exterior surface to accommodate a generally cylindrical male contact member inserted into said aperture; and a plurality of electrical contacts disposed in respective ones of said apertures, each contact including a terminal portion disposed in said narrow cavity region of said aperture and an active contact portion disposed in said wide cavity region of said aperture, said active contact portion comprising a pair of spaced parallel prongs disposed in a common plane generally transversely of said row and within the long dimension of said wide cavity region of said aperture for receiving either said cylindrical contact member or a rectangular contact member sized for termination between said prongs, said semi-cylindrical regions of said aperture being disposed in alignment with the spacing between said prongs so as to position and guide said cylindrical male contact member for acceptance between said prongs.

Claim 26

An electrical connector comprising: a body member including a main body portion having first and second exterior surfaces adapted to be positioned in cooperative juxtaposition with associated members having electrically conductive elements, said main body portion having a plurality of spaced-apart, contact-receiving apertures extending therethrough substantially between said surfaces and being arranged in at least one row thereof; each aperture having a narrow cavity region extending inwardly from said first exterior surface and a wider cavity region extending from said narrow cavity region toward said second exterior surface, said wider cavity region being elongated in cross section so as to have a long dimension extending generally transversely of said row and a short dimension extending generally parallel to said row and oppositely disposed semi-cylindrical regions intermediate the ends of said long dimension extending generally from said narrow cavity region toward said second exterior surface to accommodate a generally cylindrical male contact member inserted into said aperture; and a plurality of electrical contacts disposed in respective ones of said apertures, each contact including a terminal portion disposed in said narrow cavity region of said aperture and an active contact portion disposed in said wide cavity region of said aperture, said active contact portion comprising a pair of spaced parallel prongs disposed in a common plane generally transversely of said row and within the long dimension of said wide cavity region of said aperture for receiving either said cylindrical contact member or a rectangular contact member sized for termination between said prongs, said semi-cylindrical regions of said aperture being disposed in alignment with the spacing between said prongs so as to position and guide said cylindrical male contact member for acceptance between said prongs.

Claim 27

The electrical connector of claim 22 wherein each of said apertures has a shoulder cavity region extending between said narrow cavity region and said wide cavity region and each of said electrical contacts includes a shoulder portion between said terminal portion and said active contact portion disposed snugly in said shoulder cavity region of said aperture.

Claim 28

The electrical connector of claim 22 wherein each said apertures are provided with a generally conical entryway at said second exterior surface, to thereby guide a mating male member into position in said aperture.

Claim 29

The electrical connector of claim 22 wherein each of said electrical contacts comprises a relatively flat unitary metal member and said terminal portion is generally rectangular in cross section in a plane generally perpendicular to the aperture axis.

Claim 30

The electrical connector of claim 22 wherein said electrical contacts are cold formed from sheet metal stock.

Claim 31

In combination with the electrical connector of claim 22, a second electrical connector having a body member with a plurality of spaced-apart, contact-receiving apertures extending therethrough along at least one row, and a plurality of electrical contacts disposed in respective ones of said apertures, each contact including a generally rectangular terminal portion protruding from said body member for termination within said slot defined by the prongs of a respective one of said first electrical contacts.

Claim 32

The combination of claim 27 wherein each of the electrical contacts for said second electrical connector is cold formed from sheet metal stock.

Claim 33

The electrical connector of claim 22 wherein said wide cavity region is spaced from said prongs to permit limited outward flexing thereof sufficient to accommodate said cylindrical male contact member.