The subject of the invention relates to an improved electrical contact, and more particularly to an electrical contact that may be received in existing contact cavities and, in some cases, may be adapted for use in high vibration atmospheres.

Many sensors are now used in applications where they are subject to high vibrations, such as in automotive sensing applications, the vibrations may lead to fretting corrosion, and, over the life time of the connector, cause a failure in the automotive sensing circuit. While it is always desirable to provide contacts for such use in high vibration atmospheres, it is also a requirement to maintain these contacts on a relatively close centreline. In fact it is desirable to keep these contacts on the same centreline and compatible with existing connector housings which are already available. This is advantageous to the end user, who has already established their packaging requirements within the automobile and, possibly, already established the size and layout of the sensor contacts. Some of these connector systems are somewhat standardized within the industry, with the housings varying only slightly and in the number of cavities in each housing. One such connector family is known as applicant's Junior Power Timer family, which is a highly recognized connector system presently used in automotive connection systems. The connector housing includes a front face adapted to receive a tab-type terminal, and a socket terminal that is situated within the housing to receive the tab. The socket terminal includes two contact arms in opposing relation and extending forwardly to a constricted portion for receiving the tab therebetween and exerting a normal force thereupon. For better alignment of the socket contact within the housing relative the front face, four

axially extending ribs are positioned in each corner of the housing on the inside of the contact passageway.

It is an object of this invention then to provide a new socket contact which can be used with existing connector housings.

It is a another object of this invention to provide an improved electrical socket contact which can be used in high vibration atmospheres.

It is yet another object of this invention to provide an improved electrical socket contact that has a short stiff locking lance.

At least one aspect of the invention is accomplished by providing an electrical contact having a central section, a front contact section and a wire section, where the front contact section includes a pair of opposed contact arms that extend from the central section for receiving a tab therebetween, a transversely disposed arm extends from the central section along at least one side of each of the opposed contact arms and is joined therewith at towards an extreme end of the contact arm, where the width of the contact along the contact section is less than the width of the central section.

At least one aspect of the invention is accomplished by providing an electrical contact having a central section, a front contact section and a wire section, where the front contact section includes a pair of opposed contact arms that extend from the central section for receiving a tab therebetween, wherein the central section includes a flexible portion enabling the front contact section to move relative the wire section.

At least one aspect of the invention is accomplished by providing an electrical contact having a central section, a front contact section and a wire section, the central section includes a wall from which a locking lance is cantilevered outward therefrom, the wall further

including a slit to define a band section from which the lance extends.

It is an advantage of one aspect of the invention that the contact will fit into a previously established connector contact cavity. It is an advantage of another aspect of the invention that the front contact portion may float relative the wire section so that fretting corrosion is prevented. It is another advantage that the slit provides a band section that provides additional resilience so that a stiff locking lance has the resiliency to be deflected for fitting into a contact cavity and have the resilience necessary to resiliently return to a position that would interfere with a shoulder along the cavity to prevent withdrawal therefrom. It is another advantage that the aforementioned features en mass or singularly may be incorporated into a single piece contact or a multi-piece contact, are easy and economical to manufacture, and may include other known advantageous features. A preferred embodiment of the invention will now be described by way of reference to the drawings where:

Figure 1 is a side view of the inner contact portion; Figure 2 a plan view of the opposite side; Figure 3 is a top view of the inner socket contact; Figure 4 is a front view of the socket contact of any of Figures 1-3;

Figure 5 is a view similar to that of Figure 1 together with an outer protective spring;

Figure 6 is a view similar to that of Figure 3 with the outer protective spring;

Figure 7 is a cross-sectional view through lines 7-7 of Figure 6;

Figure 8 is a front end view of the contact viewed in any of Figures 5-7; and Figures 9-11 are views of an alternate embodiment.

An anti-fretting version of the invention will now be described with reference first to Figures 1-4 where an inner contact is shown generally at 2. The inner contact includes a central section 6 with individual box shapes 8,10 and 12 that are interconnected by web members 14 and 16, thereby allowing longitudinal movement of the front contact section 20 relative to the wire crimp section 22. As shown best in Figures 3 and 4, two contact arms 24 extend forwardly from the box member 12 while two contact arms 26 extend forwardly from a lower portion of the box member 12 and are opposed to contact arms 24. Contact arms 24 and 26 are constricted at 28 and 30, thereby forming a receiving section for a tab of a mating contact (not shown) . Arms 34 and 36, as shown in Figure 1 and 2 respectively, also extend from the box member 12 and extend forwardly to L-shaped portions 40 and 42 where they are interconnected with the respective contact arms 24,26, as best shown in Figure 4.

To provide a compact contact section 20, the contact arms 24 and 26 have a width Wl, whereas the box member 12 has a width W2. The arms 34 and 36 are folded about the L- shaped sections 40 to lie adjacent to the side edges of the contact arms 26 in a transverse manner such that the contact arms are supported by a beam having a relevant dimension greater than the thickness of the material. The front contact section presents the narrowed width by necking the arms inward and being narrowed through transition zones 44, 46. This presents a nose that will fit into an existing cavity with a body substantial enough to incorporate the necessary features such as box closure, locking lances and secondary locking shoulders.

Finally, the side walls 50 which extend rearwardly from the section 8 have upper edges at 52 having locking barbs at 54 as will be described in greater detail herein. Furthermore, the base section 56 includes an opening at 58

thereby forming a rearwardly facing edge 60 from the section 8, also which will be described in greater detail herein.

With respect now to Figure 5, an outer assist spring is shown at 70 including side walls 72,73; a top wall 74; and a lower wall 75. In addition to the other functions described below, the outer assist spring 70 may carry a set of locking lances to retain the contact within a terminal cavity of a connector housing (not shown) . A rear portion of the assist spring 70 includes crimp sections 78 which are crimped around the upper edge 52 forward of the barb sections 54 to maintain the assist spring in secure position on the inner contact 2. It should be appreciated that the outer assist spring 70 is clinched to the rear portion of the inner contact 2 which is fixed, thereby allowing the forward contact section 20 to be longitudinally moveable within the assist spring 70 relative the wire section 22.

Forwardly extending arms 84 and 85 extend from walls 74 and 75 respectively. The arms 84 and 85 do not contact the contact arms 24 and 26, but rather are spaced apart to allow the longitudinal movement of the forward spring member 20. It should be appreciated from Figure 6 however, that the arms 84 and 85 are contoured to overly, at substantially the same width as, the contact arms 24 and 26. This is accomplished by the outer assist spring 70 including a transition section at 84,86, thereby forming a contoured spring arm 84. It should be appreciated that each outer edge of the spring arms 84 include folded-over tab sections 94 and 95 are spaced from respective edges 104 and 105 of the spring arms 34. As shown in Figure 7, the opposite side of the spring arms 84 and 85 also include tab members 94 and 95. The forward free ends of the arms 84 and 85 include inwardly directed sections at 88 and 89 spaced from the contact spring arms 24 and 26

respectively.

Advantageously then, the transition sections 44 and 46 of the inner contact 2 provide a compact inner front contact section at 20 having a substantially square cross section as shown in Figure 4. Even though the spring arms 24 and 26 are narrowed to a distance Wl, the contact arms are rigidified through the arms 34 and 36 which are integrally interconnected through the L-shaped free end portions at 40. Furthermore, the contact member 2 includes longitudinally moveable sections 8, 10 and 12 thereby allowing the section 8 to be maintained in a fixed position while the contact section 20 can move forwardly and rearwardly relative thereto. The front contact section 20 is moveable within the assist spring member 70, and the movement of the contact spring is guarded by the safety features provided by the outer assist spring. For example the tab members 94 and 95 prevent over-stressing of the contact arms 24 and 26, such that if the arms 24 and 26 expand too far outwardly, the edges 104 and 105 of the side arm springs 34 will contact the tab portions 94 and

95 preventing over-stressing thereof. Furthermore, the front end section 88 and 89 prevent over-stressing of the forward contact section 20 along the longitudinal axis by preventing displacement too far inwardly. With respect now to Figures 9-11, an alternate embodiment of a contact according to at least one aspect of the invention is shown at 202. The contact 202 has a central section 206 comprised of a lower wall 208 sidewalls 210 and 212 and top cover halves 214 and 216. The cover halves include complementary dovetail tab and slot 218, 220 features that join the contact together along the longitudinal axis. It is envisioned that other know techniques may be advantageous.

The front contact section 220 of this embodiment is virtually identical to the front contact section 20 of the

e bodiment of Figures 1-8, thereby enabling this contact to recognize the aforegoing advantages. However, the contact section 220 of this contact is not longitudinally moveable relative to the wire crimp section 222. As opposed to the afore-described contact section 2, which had the locking lances integral with the outer assist spring 70 (Figs. 5-7) , in the one-piece contact of 202, the locking lances 230 are integral with the side walls 210 and 212 of the central section 206. The locking lances 230 are formed such that they extend from a band section 232 in a cantilevered manner. The band section 232 is defined by a sheared line segment at 234 that is spaced from the location from which the locking lance 230 is cantilevered, as best seen in Figure 9. Note the sheared line segment may actually be a series of segments, interconnected if desired to form a path other than straight, such as a curve, a chevron, or a louver-like structure having multiple short slits to define the overall segment. The band section 232 enables a short stiff locking lance 230 to be incorporated into a contact where it would normally not be possible due to the required length of the lance.

Typically, a locking lance must be sufficiently long to assure that for the material chosen the lance will undergo resilient and not plastic deformation as the contact is inserted into the connector housing to assure the locking lance after being deflected will be able return to a position for engaging the backside of a shoulder after being passed thereby. By forming the band section 232, which has some flexibility, the locking lance 230 is torsionally moveable about the band portion 232. Furthermore, the additional flexibility of the band section 232 aids in the dampening of relative vibration between the mating contacts. Note, construction of this type may also be incorporated into contacts of any

configuration and may be incorporated into other parts of a contact which carry the locking lance, such as an outer back-up spring. Therefore, the term central section of the contact means that part of the contact which carries the locking lance and this invention should not be limited by the embodiment depicted.

Intermediate the base section 206 and the wire crimp section 222, the contact is constricted along arms 240 and includes a cutout section at 242, thereby allowing a stiff locking surface at 244. In this embodiment, the arms 240 extend approximately symmetrically from the central section forming an upper surface similar to locking surface 244.