Electrical connector and insulation-piercing contact member

Abstract

An electrical connector comprising two dielectric contact mounts, one a plug and the other a receptacle, fitting together to engage a plurality of conductive contact members carried by one contact mount with similar contact members mounted in the other. Each contact member is formed from a single piece of thin, conductive sheet metal, with a contact element at one end and a terminal element at the other; the terminal element is channel-shaped with two terminal flanges each struck from a channel wall and bent across the channel, preferably into interlocking relation with another channel wall. Each terminal flange has a notch with thin converging walls affording a cutting section to cut the insulation on a conductor inserted into the notch, a transition section with tapered walls to spread the insulation, and a terminal section with thick, smooth walls to engage the conductor in wiping electrical contact. The contact mounts include resilient retention slots for holding the electrical conductors in the terminal elements of the contact members.

I claim: 
     
       1. A unitary contact member formed from a single piece of thin, conductive sheet metal, comprising: an active contact element;   and an integral terminal element, comprising side and bottom walls forming an elongated channel of U-shaped cross-sectional configuration with inner and outer end portions,   said terminal element including at least one terminal flange, formed by at least one flange element struck from one of said walls of said channel and bent to extend transversely of said channel, said flange extending completely across said channel and interlocked with at least one other wall of said channel,   said flange having an upwardly open notch for receiving an insulation-covered electrical conductor, the upper portion of said notch converging downwardly and having thin edges to afford a cutting section for shearing through the insulation on the conductor,   the medial portion of said notch having gradually thickened edges constituting a transition section for spreading the insulation on the conductor,   and the lower portion of said notch having smooth, curved thickened edges affording a terminal section with a resilient pressure jaw engaging the electrical conductor in wiping contact.   
     
     
       2. A unitary contact member, according to claim 1, in which said terminal element includes two of said terminal flanges and inner and outer end portions, one terminal flange being located adjacent the outer end portion of said terminal element and the other terminal flange being located adjacent the inner end portion of said terminal element, each terminal flange having a conductor-receiving notch affording said cutting, transition, and terminal sections. 
     
     
       3. A unitary contact member, according to claim 1 in which said terminal flange is struck from one of said side walls of said channel, extends completely across said channel, and projects into a retaining slot in the other side wall of said channel. 
     
     
       4. A unitary contact member, according to claim 1, in which said terminal flange is struck from the bottom wall of said channel and projects into retaining slots in both side walls of said channel. 
     
     
       5. A unitary contact member, formed from a single piece of thin, conductive sheet metal, comprising: an active contact element;   and an integral terminal element, comprising side and bottom walls forming an elongated channel of U-shaped crosssectional configuration with inner and outer end portions;   said terminal element including at least one terminal flange, formed by at least one flange element struck from one of said walls of said channel and bent to extend transversely of said channel,   said flange having an upwardly open notch for receiving an insulation-covered electrical conductor, the upper portion of said notch converging downwardly and having thin edges to afford a cutting section for shearing through the insulation on the conductor,   the medial portion of said notch having gradually thickened edges constituting a transition section for spreading the insulation on the conductor,   and the lower portion of said notch having smooth, curved thickened edges affording a terminal section with a resilient pressure jaw engaging the electrical conductor in wiping contact, said transition and terminal sections of each terminal flange notch being formed by flaps folded away from the center of the notch and coined or swedged into the recited shape at said transition section.   
     
     
       6. A unitary contact member, according to claim 5, in which the terminal section of said terminal flange notch has downwardly diverging walls which are spread during insertion of an electrical conductor and which apply a retaining force to hold the conductor in said notch. 
     
     
       7. A unitary contact member according to claim 5, in which the side walls of the terminal section of said terminal flange notch terminate in a smooth, arcuate bottom wall. 
     
     
       8. A unitary contact member, formed from a single piece of thin, conductive sheet metal, for an electrical connector of the kind comprising a first dielectric contact mount and a second dielectric contact mount having a plurality of contact mounting passages, the two contact mounts fitting together to align the inner ends of the contact passages in the first mount one-for-one with the inner ends of the contact passages in the second mount, said contact member comprising: an active contact element for positioning in the inner end of a given passage in one mount and for engaging a mating active contact element positioned in the inner end of the aligned passage in the other mount; and an integral terminal element, comprising an elongated channel of U-shaped cross-sectional configuration for positioning in the outer end of said given passage,   said terminal element including at least one integral terminal flange struck from one wall of said channel, said flange extending completely across said channel, and being interlocked with at least one other wall of said channel,   said flange having an upwardly opening notch for receiving an insulation-covered electrical conductor, said notch having a upper portion converging downwardly and having thin edges to afford a cutting section for shearing through the insulation on the conductor,   a medial portion of said notch having gradually thickened edges constituting a transition section for spreading the insulation on the conductor,   and a lower portion of said notch having smooth, thickened edges affording a terminal section with a resilient pressure jaw engaging an electrical conductor in wiping contact.   
     
     
       9. A contact member for interconnection to an insulation-covered electrical conductor, comprising a longitudinally extending terminal element formed of thin, conductive sheet metal with at least one pair of opposed, transverse flange elements forming an upwardly open notch for receiving said conductor, said notch including an upper portion having thin flat edges converging downwardly to afford an insulation cutting section with said thin flat edges extending across at least a major portion of a thickness of said sheet metal, a lower portion having smooth, curved, thickened edges to afford a conductor engaging terminal section, and an insulation-spreading medial portion between said upper and lower portions with edges having a thickness greater than the thickness of said thin edges, said flange element including portions of multiple thicknesses of said sheet metal, said thin sheet metal being bent to form said thickened edges, and said thickened edges being resiliently spread during insertion of the electrical conductor and bearing against the conductor in pressure engagement.   
     
     
       10. A contact member according to claim 9 including an active element for connection to a circuit element and in which said terminal element includes a pair of said notches with said notches being longitudinally displaced and having upper ends forming an entrance to said lower portion, and an insulation-spreading medial portion between said upper and lower portions with edges having a thickness greater than the thickness of said thin edges and extending to said upper ends of said lower portions. 
     
     
       11. A contact member according to claim 9 in which said terminal element includes walls forming a channel open to receive said conductor, with at least one of said walls integrally supporting said flange elements. 
     
     
       12. A contact member for interconnection to an insulation-covered metallic conductor, comprising, a longitudinally extending terminal element formed of thin, conductive sheet metal with at least one pair of opposed, transverse flange elements forming an upwardly open notch for receiving said conductor, said notch including an upper portion having thin edges converging downwardly to afford an insulation cutting section and a lower portion having smooth, curved, thickened edges to afford a conductor engaging terminal section, said flange elements including portions of multiple thicknesses of such sheet metal forming thickened edges, said thickened edges being downwardly diverging and being spread during insertion of said conductor to apply a retaining force to hold the conductor in said notch.   
     
     
       13. An electrical connector unit comprising: insulating means including a plurality of parallel longitudinally extending passages with inner and outer end portions each outer end portion having an upper longitudinal side open for receiving an insulation-covered electrical conductor, and a plurality of contact members mounted in said passages, including terminal elements disposed in said outer end portions, each of said terminal elements including at least one pair of opposed, transverse flange elements forming an upwardly opening notch for receiving said conductor, said notch including an upper portion having thin edges converging downwardly to afford an insulation cutting section and a lower portion having smooth, curved thickened edges to afford a conductor engaging terminal section, said flange elements being formed of thin, conductive sheet metal and including portions of multiple thicknesses of said sheet metal forming said thickened edges.   
     
     
       14. An electrical connector unit, according to claim 13, in which said insulating means includes: conductor retention means including a dielectric extension disposed across the outer end portions of said contact passages, said extension including a plurality of longitudinally elongated conductor support surfaces individually aligned with individual outer end portions and means for releasably retaining the individual conductors extending longitudinally away from the passages from upward movement in a direction out of the lower terminal sections of the notches.   
     
     
       15. An electrical connector unit, according to claim 14, in which said end extension includes a plurality of elongated retainer grooves, one for each contact passage, each retainer groove including a wide entrance section leading to a narrow retainer section which in turns leads to a substantially wider receptacle section large enough to accommodate an insulation-covered conductor. 
     
     
       16. An electrical connector unit, according to claim 14, wherein said outer end portion of each of said passages is of elongated U-shaped configuration with side walls and said terminal element includes an elongated channel with said flange elements and side and bottom walls, the side walls of the terminal element affording a close fit with the side walls of the outer end of the contact passage in which the contact member is mounted, so that the insulating means prevents excessive distortion of each terminal element when a conductor is inserted in the terminal flange notch thereof. 
     
     
       17. An electrical connector unit, according to claim 14, in which each terminal flange is struck from one wall of said terminal element channel and bent inwardly across said channel into interlocking relation with at least one additional wall thereof. 
     
     
       18. An electrical connector unit according to claim 13 in which said contact members include active elements for connection to circuit elements and said notch includes an insulation-spreading medial portion between said upper and lower portions. 
     
     
       19. An electrical connector unit according to claim 13 in which said terminal elements include channel-forming walls of said sheet metal with at least one of said walls being integral with at least one of said flange elements, and in close fit with said insulating means to prevent excessive distortion of said terminal flange elements when said conductor is inserted in the notch thereof. 
     
     
       20. An electrical connector unit according to claim 19 in which said insulation of said conductor is substantially disposed within said channel. 
     
     
       21. An electrical connector unit according to claim 19 in which said contact members include active elements disposed in said inner end portions, said terminal elements each include a pair of said notches, even including an insulation-spreading medial portion between said upper and lower portions. 
     
     
       22. An electrical connector unit according to claim 13 in which said terminal element includes channel forming side walls with said pair of flange elements being disposed between said walls and integral therewith. .Iadd. 23. An electrical contact member including a longitudinally extending terminal element formed of conductive sheet metal with at least one pair of opposed transversely disposed flange elements and an upwardly opening, insulation-spreading notch with a downwardly converging portion and formed by said flange elements for receiving an insulation-covered metallic conductor inserted downwardly into the notch, the notch including an upwardly disposed portion for spreading the insulation on the conductor and a lower portion with wiping surfaces for electrically engaging the conductor, said lower portion being constructed of said sheet metal bent to form smooth, thickened surfaces as said wiping surfaces for engaging said conductor. .Iaddend. .Iadd. 24. The contact member of claim 23, wherein said notch further includes a coined or swedged medial portion having gradually thickened edges constituting a transition section between said upper and lower portions. .Iaddend. .Iadd. 25. The contact member of claim 23 wherein said terminal element includes at least one wall and said flange element includes a portion bent from said wall with an additional bend to form said thickened surface along said additional bend. .Iaddend..Iadd. 26. The contact member of claim 25 including said conductor disposed in said notch, said wiping surfaces extending through said insulation and providing a pressure jaw engaging said metallic conductor. .Iaddend..Iadd. 27. The contact member of claim 26 wherein said terminal element is constructed of said sheet metal and includes two opposed, longitudinally extending channel walls and two pairs of said flange elements with each of said pairs being separated longitudinally and each flange element being carried by one of said walls. .Iaddend. .Iadd. 28. The contact member of claim 26 wherein at least one of said walls includes a conductor retaining tab integrally joined to one of said walls for retaining said conductor from upward movement in said terminal element. .Iaddend. .Iadd. 29. The structure of claim 26 wherein the said curved surfaces comprise said sheet metal folded upon itself. .Iaddend. .Iadd. 30. An electrical connector including insulating means with a plurality of parallel, longitudinally-extending passages with upwardly open portions and a plurality of contact members comprising terminal elements including channel walls of conductive sheet metal each formed with pairs of opposed flange elements and upwardly opening, insulation-piercing notches formed by said flange elements disposed in said passages for receiving insulation-covered metallic conductors, the notches including upwardly disposed portions for spreading the insulation on the conductors and lower portions with wiping surfaces for electrically engaging the conductors, said lower portions being constructed of said sheet metal bent to form smooth, thickened surfaces providing said wiping surfaces for engaging said conductors. .Iaddend..Iadd. 31. The connector of claim 30 wherein said sheet metal is formed in a reverse band with at least two thicknesses of said sheet metal forming said smooth, thickened surfaces along a longitudinal portion of said conductors. .Iaddend..Iadd. 32. The connector of claim 31 including a plurality of said conductors disposed in said notches with said wiping surfaces extending through said insulation and providing pressure jaws engaging said metallic conductors. .Iaddend. .Iadd. 33. An electrical contact member including a longitudinally-extending terminal element formed of conductive sheet metal with at least one pair of opposed and transversely disposed flange elements and an upwardly opening notch formed by said flange elements for receiving an insulation-covered metallic conductor inserted transversely of its longitudinal axis downwardly into the notch, the notch including a lower portion with wiping surfaces for electrically engaging the conductor, said lower portion being constructed of said sheet metal bent to form smooth, thickened surfaces providing said wiping surfaces for engaging said conductor. .Iaddend..Iadd. 34. The contact member of claim 33 wherein said terminal element includes at least one wall and said flange element includes a portion bent from said wall with an additional bend to form said thickened surface along said additional bend. .Iaddend..Iadd. 35. The contact member of claim 34 including said conductor disposed in said notch, said wiping surfaces extending through said insulation and providing a pressure jaw engaging said metallic conductor. .Iaddend..Iadd. 36. In combination, an electrical contact member comprising a terminal element constructed of conductive sheet metal including a pair of transversely disposed and opposed pressure jaws projecting inwardly between said walls and an upwardly opening notch formed by said jaws with a portion including upwardly-extending smooth, thickened wiping surfaces, said sheet metal being bent to form said surfaces, and an insulation-covered metallic conductor disposed longitudinally in said notch, said surfaces including portions extending through said insulation and engaging said conductor. .Iaddend..Iadd. 37. The combination of claim 36 wherein each of said pressure jaws include a first bend of said sheet metal joined to one of said walls and a second bend providing one of said smooth, thickened wiping surfaces. .Iaddend..Iadd. 38. An electrical contact terminal element formed of conductive sheet metal to provide a longitudinal channel with at least one pair of opposed transversely disposed flange elements integral therewith forming an upwardly open notch for receiving a conductor of greater width than the width of said notch inserted downwardly into the notch by movement of said conductor transversely of its own longitudinal axis, the flange elements each including a portion with a wiping surface for electrically engaging and maintaining engagement with the conductor, said flange elements being deformed from said sheet metal to provide a smooth curved surface having an axis of curvature transverse to the longitudinal axis of the conductor and providing said wiping surface. .Iaddend..Iadd. 39. The structure of claim 38 wherein said sheet metal has a thickness substantially thinner than the notch with respect to said longitudinal axis of said conductor. .Iaddend. .Iadd. 40. The structure of claim 38 wherein said curved surface comprise the side walls of the channel deformed inwardly. .Iaddend..Iadd. 41. In combination, an electrical contact terminal element formed of conductive sheet metal to provide a longitudinal channel with at least one pair of opposed transversely disposed pressure jaws integral therewith and having opposed conductor engaging wiping surfaces forming a notch; and an insulated metallic conductor with exposed metallic portions intermediate insulated portions thereof maintained in pressure engagement with said wiping surfaces in said notch, said pressure jaws each being deformed from said sheet metal to provide a smooth curved surface having an axis of curvature transverse to the longitudinal axis of the conductor for engaging said conductor and providing said wiping surface. .Iaddend.