[0001] Socket terminals which are adapted for quick make and break connections with a mating terminal are known. Terminals of this kind are used to make an electrical connection to a male or space terminal which is inserted and frictionally held in the socket terminal. A socket terminal of this type is shown in U.S. Patent Number 3,086,193.

[0002] It is often necessary to disconnect and reconnect such terminals a number of times, for example, for testing purposes prior to final inspection and shipment of the product on which such terminals are used. It is also required that the connection made with such terminals be maintained under conditions of vibration and possible strain in subsequent service. Traditionally, these terminals have a high insertion mating force which is not desirable, causing ergonomic problems with insertion when a mating connector is inserted into the socket terminal.

[0003] It would, therefore, be beneficial to provide a socket type terminal which has contact springs which have a reduced contact spring rate, thereby allowing the contact normal force to be more accurately controlled with the same manufacturing tolerances. More controlled normal force allows for a minimum contact normal force to be reliably maintained while reducing the insertion force required during mating.

[0004] The solution is provided by a receptacle terminal for receipt of a mating terminal therein. The receptacle terminal includes a contact portion which has a bottom wall and resilient contact arms. The resilient contact arms extend from opposed sides of the bottom wall. Each of the resilient contact arms has an opening extending therethrough with a first resilient contact section and a second resilient contact section extending on either side of the opening. The first resilient contact sections and the second resilient contact sections have arcuate portions which extend from the bottom wall to mating terminal engaging members. The first resilient contact sections and the second resilient contact sections generate a contact force when a mating terminal is inserted into the terminal. [0005] The invention will now be described by way of example with reference to the accompanying drawings in which:

[0006] FIG. 1 is perspective view of an illustrative embodiment of the terminal according to the present invention.

[0007] FIG. 2 is a top view of the terminal of FIG. 1.

[0008] FIG. 3 is a side view of the terminal of FIG. 1.

[0009] FIG. 4 is a bottom view of the terminal of FIG. 1.

[0010] FIG. 5 is a front view of the terminal of FIG. 1.

[0011] FIG. 6 is a cross-sectional view of the terminal of FIG. 2.

[0012] The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as "lower," "upper," "horizontal," "vertical," "above," "below," "up," "down," "top" and "bottom" as well as derivative thereof (e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as "attached," "affixed," "connected," "coupled," "interconnected," and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the invention expressly should not be limited to such preferred embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.

[0013] The present invention is directed to a terminal with reduced normal force. In particular, the invention is directed to a socket type terminal in which the curved cantilevered spring beams have a reduced contact spring rate.

[0014] As best shown in FIGS. 1 through 4, a receptacle, socket or female terminal 10 includes a contact portion 12, a wire barrel 14 behind the contact portion 12 and an insulation barrel 16 behind the wire barrel 14. The wire barrel 14 is configured for crimped connection with an end of a conductive core of an insulated wire. The insulation barrel 16 is configured for crimped connection with an end of the insulation coating or jacket of the wire. Although a wire barrel 14 and an insulation barrel 16 are shown, the contact portion 12 can be used with other types of termination members without departing from the scope of the invention. In the illustrative embodiment shown, the terminal 10 is stamped and formed from a metal plate having a good electrical conductivity.

[0015] Referring to FIGS. 1, 5 and 6, the contact portion 12 includes a bottom wall 20 and resilient contact arms 22 which extend from either side 24, 26 of the bottom wall 20. As best shown in FIG. 6, the bottom wall 20 has a spring arm 42 provided thereon. The spring arm 42 is stamped and formed form the bottom wall 20.

[0016] The spring arm 42 extends from the bottom wall 20 to create a raised portion or arm extending from the inner surface of the bottom wall 20 toward the resilient arms 22. The spring arm 42 includes a projection or embossment, such as, but not limited to, a detent, dimple or lance 41 (as best shown in FIG. 6) which is formed from the spring arm 42 to create a raised area on an inner surface of the spring arm 42. The lance 41 engages the mating terminal as the mating terminal is inserted into the terminal 10, as will be more fully described below.

[0017] In the illustrative embodiment shown, each resilient arm 22 has an opening or cutout 23 with a first resilient contact section 25 a and a second resilient contact section 25b extending on either side of the opening 23. The first resilient contact section 25a is positioned proximate a mating end 36 of the contact portion 12. The second resilient contact section 25b is removed from the mating end 36 toward the wire barrel 14. The openings extend between and separate the resilient contact sections 25a, 25b. In the embodiment shown, the openings 23 are formed by removing material from a blank prior to forming the terminal. The material removed can be reused in the manufacture of additional terminals. Other methods for forming the openings 23 may be used without departing from the scope of the invention.

[0018] As best shown in FIG. 5, the resilient contact sections 25a, 25b have arcuate or curled portions which extend from the bottom wall 20 to a mating terminal engaging member 50. In one illustrative embodiment, one or all of the resilient contact sections 25a, 25b may have a tapered or trapezoidal configuration, whereby the width of the respective arm at the root or base 60 (FIG. 3), which connects to bottom wall 20, is greater than the width of portion 62 (FIG. 3) of the respective arm proximate the mating terminal engaging member 50. However, other configurations can be used. The configuration of each respective contact section 25a, 25b of the resilient contact arms 22 allows the stiffness and spring rate of each respective resilient contact section 25a, 25b and the resilient contact arms 22 to be controlled. A wider root or base 60 allows for a higher spring rate and for a more even distribution of forces from the respective resilient contact sections 25a, 25b to the bottom wall 20. Conversely, the more narrow the respective resilient contact sections 25a, 25b, the lower the spring rate of the arm and the lower the effective spring rate of the resilient contact arms 22. Consequently, the respective resilient contact sections 25a, 25b may each be configured to generate a different contact force, resulting in different contact forces for the resilient contact arms 22.

[0019] In various illustrative embodiments, resilient contact sections 25b have a back surface or edge 66 which extends in a direction which is essentially perpendicular to the longitudinal axis of the terminal 10. This provides a reference surface which can be used when positioning the terminal 10 in a housing or when mating the mating terminal to the terminal 10. [0020] The mating terminal engagement members 50 of the resilient contact arms 22 extend from the resilient contact sections 25a, 25b and span opening 23. In the illustrative embodiment shown, the mating terminal engagement members 50 are asymmetrical, having lead-in surfaces 44 positioned proximate the mating end 36. The lead-in surfaces 44 are provided to prevent the stubbing of the mating contact on the edge of the resilient arms 22 and to help guide the mating terminal into a mating slot 46 of the contact portion 12 and to reduce the insertion force required to insert the mating terminal into the slot 46. A mating terminal engagement surface 52 is provided on each mating terminal engaging member 50. In the embodiment shown, the mating terminal engaging member 50 extends from the resilient contact arms 22, positioning the mating terminal engagement surface 52 at the top of the mating slot 46. The configuration of the resilient contact arms 22 provide the resiliency needed to allow the mating terminal engaging member 50 to move relative to the bottom wall 20 as the mating terminal is inserted into the slot 46. As best shown in FIG. 5, the mating terminal engagement surfaces 52 have an arcuate or rounded configuration. However, other configurations of the engagement surfaces 52 may be used.

[0021] In the illustrative embodiment shown, the spring arm 42 is stamped and formed from the bottom wall 20. The spring arm 42 is formed to allow a free end 43 thereof to move or be resiliently deformed relative to the bottom wall 20, allowing the spring arm 42 and the lance 41 to move toward and away from the mating terminal engaging member 50.

[0022] In the illustrative embodiment shown, the spring arm 42 has an end wall 40 provided thereon. The end wall 40 extends from the spring arm 42 to create a stop portion which extends from the inner surface of the spring arm 42 toward the mating terminal engaging member 50. The end wall 40 is provided to limit the distance the mating terminal can be inserted into the slot 46.

[0023] The configuration of the resilient contact arms 22 and the spring arm 42 allows the contact portion 12 to compensate for any slight misalignment of the mating terminal or any slight warpage or imperfections associated with the mating terminal. [0024] A terminal according to the teaching of the invention has a lower spring rate than known terminals. By controlling the space and size of the contact sections 25a, 25b and the openings 23, the normal forces and insertion forces of the resilient contact arms 22 can be controlled, while allowing for a proper electrical connection between the terminals 10 and the mating terminals. For example, the insertion force of a terminal made according to the present invention may be reduced in comparison to a terminal without individual contact sections 25a, 25b separated by openings 23.

[0025] In addition, as the spring rate is reduced, the resilient arms 22 allow for a greater spring deflection before taking a permanent set. This allows the terminal to be used with mating terminals which have some variance in manufacturing tolerances. In other words, because the resilient arms 22 have the ability to deflect a greater distance without taking a permanent set, the thickness of the mating terminal does not have be as precisely controlled.

[0026] In a fully inserted position, the lance 41 of the spring arm 42 and the mating terminal engagement surfaces 52 are all provided in electrical and mechanical contact with the mating terminal. The multiple areas of contact allow the receptacle contact 10 to be used in applications in which higher current levels, such as, but not limited to, 15 to 20 or more amps. The configuration of the spring arm 42 and mating terminal engagement surfaces 52 provides a stable and reliable electrical connection between the mating terminal and the terminal 10. The configuration of the lance 41 of the spring arm 42 and mating terminal engagement surfaces 52 provide for higher hertzian stresses, thereby eliminating or minimizing the fretting corrosion between the terminal 10 and the mating terminal, thereby providing a stable and reliable electrical connection between the mating terminal and the terminal 10.

[0027] The cooperation of the lance 41 and the mating terminal engagement surfaces 52 are spaced laterally relative to each other, allowing the connection between the mating terminal and the receptacle terminal 10 to be stable in all environments, thereby insuring that the mating terminal will remain properly positioned in the receptacle terminal 10 as vibration occurs. [0028] As the lance 41 of the spring arm 42 and the mating terminal engagement surfaces 52 are laterally offset from each other, the receptacle terminal 10 provides multiple contact areas even if the mating terminal is bent. In addition, the multiple contact areas resist twisting or misalignment of the mating terminal.

[0029] In one embodiment, the resilient arms 22 and are configured such that the contact areas of the mating terminal engagement surfaces 52 generate an equal and opposite force to resist the force generated by the lance 41 of the spring arm 42. In addition, the resilient arms 22 and are configured such that the contact areas of the lance 41 of the spring arm 42 generate an equal and opposite force to resist the force generated by the mating terminal engagement surfaces 52. However, the configuration of the resilient arms 22 may be varied to allow the contact areas to have varied forces associated therewith. In particular, the positioning of the lance 41 of the spring arm 42 can alter the force applied by each contact area.

[0030] The configuration of the resilient contact arms 22 and the spring arm 42 and the use of multiple contact areas allows for a lower normal force during mating and unmating of the mating terminal from the receptacle contact 10. This allows the mating terminal and receptacle contact 10 to be more durable over numerous cycles, as there is less plating wear due to the lower mating or normal forces. The number of contact areas also allows the receptacle contact 10 to be used at higher current levels, as the number of contact areas allows the extreme heat associated with the high current levels to be dispersed, thereby preventing welding of the contact asperities.

[0031] The terminal of the present invention has resilient contact arms which have a reduced contact spring rate, thereby allowing the contact normal force to be more accurately controlled with the same manufacturing tolerances. More controlled normal force allows for a minimum contact normal force to be reliably maintained while reducing the insertion force required during mating. The resilient contact arms provide a stable electrical connection while allowing for a lower insertion force of the mating terminal into the socket terminal.