RELATED APPLICATIONS

This application claims priority to United States Provisional Application No. 62/950,939, filed Dec. 20, 2019, which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention is directed to a busbar connection system and an electrical system comprising such a busbar connection system.

DESCRIPTION OF RELATED ART

Busbar connection systems are commonly used in particular in electrical power distribution systems in order to distribute electrical power from a power source to a number of electrical devices. Such an electrical power distribution system usually includes at least two electrical contacts which are spaced apart from each other at a predetermined distance for connection to a number of electrical devices. Each electrical device includes at least two pluggable connectors in order to respectively connect to one of the electrical contacts. The pluggable connectors of every electrical device are spaced apart from each other in the predetermined distance of the two electrical contacts of the electrical power system. In applications that require more power, several electrical contacts are ganged together allowing for more power transmission.

Due to manufacturing tolerances, the distance between the electrical contacts can have a variation that exceeds typical variations in known standard bus bar systems. The electrical connectors therefore have to be produced and installed with high accuracy, which results in high manufacturing costs. Certain individuals can appreciate an improved structure that allows for greater manufacturing tolerances and therefore reduced costs.

BRIEF SUMMARY

Accordingly, the present disclosure provides an improved busbar assembly which can be used with a less accurately manufactured pair of electrical contacts while providing reliable electrical connections.

An electrical connector includes an insulative housing, and a pair of contacts which are secured together by a clamp mounted within the housing. Each electrical contact includes a planar body, spring fingers extending from a first end of the body, and a coupling extending from the body to couple the electrical contacts to the housing. A first deflection zone between the clamp and first ends of the spring fingers allows the spring fingers to deflect in a lateral direction to receive the conductive component within the receiving space. A second deflection zone between the first ends of the spring fingers and the second ends of the bodies allow the bodies and spring fingers to deflect in the lateral direction when the conductive component is received within the receiving space, but the conductive component is not directly aligned with the receiving space.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is illustrated by way of example, and not limited, in the accompanying figures in which like reference numerals indicate similar elements and in which:

FIG. 1 depicts a perspective view of an electrical system which includes an embodiment of an electrical connector, an electrical element, and a conductive component;

FIG. 2 depicts a perspective view of the electrical connector shown in FIG. 1;

FIG. 3 depicts an exploded perspective view of the electrical connector shown in FIG. 2;

FIGS. 4 and 5 depict top plan views of electrical contacts of the electrical connector shown in FIG. 2;

FIGS. 6 and 7 depict enlarged, partial cross-sectional view of embodiments of a clamp and the electrical contacts;

FIG. 8 depicts an exploded top plan view of electrical contacts of an electrical connector that can be provided in the electrical connector shown in FIG. 1;

FIG. 9 depicts a cross-sectional view of the electrical contacts shown in FIG. 8, and in an assembled condition;

FIG. 10 depicts an exploded perspective view of electrical contacts of an electrical connector that can be provided in the electrical connector shown in FIG. 1;

FIGS. 11 and 12 depict side elevation views of the electrical contacts of FIG. 10;

FIG. 13 depicts an exploded perspective view of electrical contacts of an electrical connector that can be provided in the electrical connector shown in FIG. 1;

FIG. 14 depicts a cross-sectional view of the electrical contacts shown in FIG. 8, and in an assembled condition;

FIG. 15 depicts an exploded view of a clip shown in FIGS. 13 and 14;

FIG. 16 depicts a rear elevation view of the electrical connector shown in FIG. 2;

FIG. 17 depicts a cross-sectional view of the electrical connector shown in FIG. 2;

FIG. 18 depicts a schematic representation;

FIG. 19 depicts a perspective view of another embodiment of an electrical connector which can be used with the electrical element, and a conductive component shown in FIG. 1;

FIG. 20 depicts an exploded perspective view of the electrical connector shown in FIG. 19;

FIG. 21 depicts a side elevation view of clamped electrical contacts of the electrical connector shown in FIG. 19;

FIGS. 22 and 23 depict side elevation views of the electrical contacts of FIG. 21;

FIG. 24 depicts a cross-sectional view of the electrical connector shown in FIG. 19 and shown in perspective;

FIG. 25 depicts a bottom plan view of the electrical connector shown in FIG. 19;

FIG. 26 depicts a cross-sectional view of the electrical connector shown in FIG. 19;

FIG. 27 depicts a perspective view of another embodiment of an electrical connector which can be used with the electrical element, and a conductive component shown in FIG. 1;

FIGS. 28 and 29 depict side elevation views of electrical contacts of the electrical connector shown in FIG. 27;

FIG. 30 depicts a bottom plan view of the electrical connector shown in FIG. 27; and

FIGS. 31 and 32 depict cross-sectional views of the electrical connector shown in FIG. 27.

DETAILED DESCRIPTION

The appended drawings illustrate embodiments of the present disclosure and it is to be understood that the disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure.

An electrical system 20 includes an electrical connector 22, 222, 422, an electrical element 24, such as a circuit board, on which the electrical connector 22, 222, 422 is configured to be mounted, and a conductive component 26 configured to communicatively engage the electrical connector 22, 222, 422. In an embodiment, the conductive component 26 is a busbar and the electrical connector 22, 222, 422 is configured to transmit electrical power therethrough. In an embodiment, the conductive component 26 is another electrical connector, such as electrical connector 422. Other embodiments are contemplated in which the conductive component 26 is a circuit board or a cooperating connector of an electronic device. Instead of power that is transmitted through the electrical connector 22, 222, 422, signals can be transmitted.

In an embodiment, the conductive component 26 has an elongated and substantially rectangular-shaped body 28 that is configured to be gripped on both sides 30, 32 by the electrical connector 22 and which defines a mating edge 34. For example, the sides 30, 32 have surfaces that coincide with respective planes that extend along the longitudinal and elevation axes and are parallel to each other.

The electrical connector 22, 222, 422 includes first and second electrical contacts 36a, 36b, 236a, 236b, 436a, 436b, an insulative housing 38, 238, 438 in which the electrical contacts 36a, 36b, 236a, 236b, 436a, 436b are mounted, and a clamp 40 which connects the electrical contacts 36a, 36b, 236a, 236b, 436a, 436b together. In an embodiment, the electrical contacts 36a, 36b, 236a, 236b, 436a, 436b are configured to transmit electrical power therethrough. In another embodiment, the electrical contacts 36a, 36b, 236a, 236b, 436a, 436b are configured to transmit electrical signals therethrough. The embodiments shown in FIGS. 1-16 depict a right-angle connector, and the embodiments shown in FIGS. 19-32 depict a vertical connector.

Attention is invited to the embodiment of the electrical connector 22 shown in FIGS. 1-16. As shown in this embodiment, the electrical connector 22 and the electrical element 24 are oriented with respect to mutually perpendicular axes that include a longitudinal axis, an elevation (or vertical) axis, and a lateral (or horizontal) axis. This arrangement is typically called a “right-angle” system, but other embodiments may be arranged in another intermediate angle.

As shown in FIGS. 3-5, each electrical contact 36a, 36b has a connecting portion formed of a substantially rectangular-shaped planar body 42a, 42b and spring fingers 44a, 44b extending from the planar body 42a, 42b, and further has a mounting portion 46a, 46b extending from the planar body 42a, 42b, and a mounting flange 48a, 48b extending from the mounting portion 46a, 46b. The mounting portion 46a, 46b is fixed to the housing 38. The mounting flanges 48a, 48b are fixed to the electrical element 24. The planar bodies 42a, 42b and the spring fingers 44a, 44b, when clamped together by the clamp 40 as described herein, form a free standing beam within the housing 38. For purposes of clarity, the components of electrical contact 36a are described herein, and the like components of electrical contact 36b are denoted with the same reference numerals except with a “b” thereafter instead of an “a”.

The planar body 42a has a front end 50a, an opposite rear end 52a, and top and bottom edges 54a, 56a extending between the front and rear ends 50a, 52a which define a first side surface 58a and a second side surface 60a. A longitudinal axis 62a is defined by the planar body 42a from the front end 50a to the rear end 52a. The side surfaces 58a, 60a coincide with respective planes that extend along the longitudinal and elevation axes and are parallel to each other. An upper tab 64a extends upward from the top edge 54a, and a lower tab 66a extends downward from the bottom edge 56a. Each tab 64a, 66a is coplanar with the planar body 42a and is proximate to, but spaced from, the rear end 52a of the planar body 42a.

The spring fingers 44a extend from the front end 50a of the planar body 42a. As shown, the spring fingers 44a include a rear wall 68a extending from the front end 50a of the planar body 42a and at an angle relative to the longitudinal axis 62a, and a column of spaced apart contact beams 70a extending from a front end of the rear wall 68a. Each contact beam 70a generally forms a shallow U-shape having a curved or V-shape base 72a and angled portions 74a, 76a extending from the base 72a. Angled portion 74a extends between the base 72a and the rear wall 68a. Angled portion 76a forms a front end 75a of the electrical contact 36a.

The mounting portion 46a has a first section 78a which extends perpendicularly from the rear end 52a of the planar body 42a and a second section 80a which extends perpendicularly from the first section 78a and overlaps the side 60a of the planar body 42a. The second section 80a is planar and extends parallel to the longitudinal axis 62a and parallel to the planar body 42a. The first section 78a may be U-shaped. The second section 80a has a section 82a that extends downward from the first section 78a and extends parallel to the longitudinal axis 62a. The second section 80a has engagements which engage with the housing 38 to prevent the movement of the mounting portion 46a relative to the housing 38. A first engagement may be provided by a projection 84a that extends outward from an outer side surface of the second section 80a. The projection 84a may be formed as a barb, as shown, having an angled forward face which is angled relative to the plane defined by the second section 80a, and a rear face which is perpendicular to the second section 80a. A second engagement may be provided by a flange 86a that extends upward from a top end of the second section 80a. As shown, the flange 86a has a first flange section which extends upward from the second section 80a and a second flange section which extends outward from the first flange section and is perpendicular thereto.

The mounting flange 48a extends from the section 82a of the mounting portion 46a and is perpendicular to the second section 80a and to the planar body 42a. An opening 88a is provided through the mounting flange 48a.

The electrical contacts 36a, 36b are clamped together by the clamp 40 to form a clamped pair prior to insertion into the housing 38. In the clamped pair, the side surfaces 58a, 58b of the electrical contacts 36a, 36b face each other such that the planar bodies 42a, 42b are parallel to each other, the rear walls 68a, 68b of the spring fingers 44a, 44b angle outward from each other, the first sections 78a, 78b extend outward from each other, and the mounting flanges 48a, 48b extend outward from each other. The planar bodies 42a, 42b are coupled together by the clamp 40 to prevent relative movement between the planar bodies 42a, 42b. The planar bodies 42a, 42b are cantilevered from the first sections 78a, 78b, and the planar bodies 42a, 42b define a bending beam. As illustrated, the clamp 40 is located about midway along the length of the beam formed by the planar bodies 42a, 42b and the spring fingers 44a, 44b. The clamp 40 effectively alters the bending or flexing of the electrical contacts 36a, 36b when mated. The bending arm is essentially shortened, and the clamp 40 provides a fixed point of the bending beam. The clamp 40 is provided proximate to, but spaced from, the front ends 50a, 50b of the planar bodies 42a, 42b. In the clamped pair, the spring fingers 44a, 44b define a receiving space 90 for the conductive component 26 forward of the clamp 40, and the clamp 40 controls the size of the receiving space 90. The bases 72a, 72b of the contact beams 70a, 70b defines a width therebetween which is less than a width of the conductive component 26, such that when the conductive component 26 is inserted between the spring fingers 44a, 44b, the spring fingers 44a, 44b flex outward to allow entry of the conductive component 26 into the receiving space 90, but maintain electrical contact with the conductive component 26.

In an embodiment, as shown in FIGS. 6, the clamp 40 is provided by at least one rivet 92 having a body 94 which extends through apertures 96a, 96b in the planar bodies 42a, 42b. The rivet 92 has heads 98, 100 formed on each end of the body 94. One head 98 abuts against the side surface 60a of the planar body 42a, and the other head 100 abuts against the side surface 60b of the planar body 42b. In an embodiment, as shown in FIG. 7, the clamp 40 is provided by at least one screw 102 having a single head 104 and a body 106 depending therefrom which is threadedly connected to the apertures 96a, 96b in the planar bodies 42a, 42b. As shown, two rivets 92 or screws 102 are provided and are vertically aligned with each other, however, a single rivet 92 or screw 102 or more than two rivets 92 or screws 102 may be provided. Alternatively, the rivets 92 or screws 102 may be horizontally aligned. The side surfaces 58a, 58b of the planar bodies 42a, 42b abut against each in this embodiment, however, the planar bodies 42a, 42b may be separated from each other when the screw(s) 102 are used.

In an embodiment, as shown in FIGS. 8 and 9, the clamp 40 is provided by at least one projection 108 extending from the planar body 42a which seats within an opening 110 formed in the other planar body 42b. The projection 108 and the opening 110 may be press fit together to maintain the coupling of the planar bodies 42a, 42b. Alternatively, the projection 108 and the wall forming the opening 110 may be adhered or welded together. In an embodiment, the opening 110 is formed in a three-sided pocket 112. As shown, two projections 108/openings 110 are provided and are vertically aligned with each other, however, a projection 108/opening 110 or more than two projections 108/openings 110 may be provided. In an embodiment, the planar body 42a has one projection 108 and one opening 110, and the other body 42b has one corresponding opening 110 and one corresponding projection 108 for mating with the projection 108 and opening 110 of the planar body 42a. As shown, the side surfaces 58a, 58b of the planar bodies 42a, 42b abut against each in this embodiment; however, the side surfaces 58a, 58b of the planar bodies 42a, 42b may be spaced apart from each other.

In an embodiment, as shown in FIGS. 10-12, the clamp 40 is provided by a C-shaped clip 114 having a base 116 and a pair of legs 118, 120 extending from the base. The base 116 seats against the side surface 60a, the leg 118 extends through apertures 124a, 124b in the planar bodies 42a, 42b, the leg 120 extends through apertures 126a, 126b in the planar bodies 42a, 42b, and ends of the legs 118, 120 are bent to seat against the side surface 60b of the planar body 42b. As shown, a single clip 114 is provided, however, more than one clip 114 may be provided. The side surfaces 58a, 58b of the planar bodies 42a. 42b abut against each in this embodiment.

In an embodiment, as shown in FIG. 13-15, the clamp 40 is provided by at least one clip 128 having a body 130 which extends through apertures 132a, 132b, 134a, 134b in the planar bodies 42a, 42b, a head 136, 138 formed on each end of the body 130, and a collar portion 140 which extends from the body 130 between the head 136, 138 and is positioned between the planar bodies 42a, 42b. Head 136 abuts against the side surface 60a of the planar body 42a, and the head 138 abuts against the side surface 60b of the planar body 42b. The planar bodies 42a, 42b are held in a spaced apart relationship by the collar portion 140. If the clip 128 is formed of a conductive material, the electrical contacts 36a, 36b are electrically coupled together. If the clip 128 is formed of a nonconductive material, the electrical contacts 36a, 36b are electrically isolated from each other. As shown, two clips 128 are provided and are vertically aligned with each other, however, a single clip 128 or more than two clips 128 may be provided.

Any other suitable clamp may also be used. In some embodiments, an urging member (not shown) may be used in place of the clamp 40. The urging member allows for some relative movement between the electrical contacts 36a, 36b, while maintaining a clamping effect.

As shown in FIGS. 3, 16 and 17, the housing 38 has a top wall 142, a bottom wall 144, and side walls 146, 148 extending therebetween, which defines a cavity 150 that extends from a mating or front end 152 of the housing 38 to a mounting or rear end 154 of the housing 38. A longitudinal axis extends along the housing 38 from the mating end 152 to the mounting end 154. The front and rear ends of the cavity 150 are open to define a front opening 158 and a rear opening 160. Each top and bottom wall 142, 144 has an elongated slot 156 (only shown for top wall 142) which extends from the mating end 152 toward the mounting end 154 and which is in communication with the cavity 150 and the front opening 158. In the illustrated embodiment, the front opening 158 and the slots 156 have dimensions to accommodate receipt of the conductive component 26 therein when the mating edge 34 of the conductive component 26 is advanced into the front opening 158 and the slots 156 along a mating direction M1. The mating direction M1 extends substantially parallel to the longitudinal axis of the housing 38.

As shown in FIGS. 16 and 17, the housing 38 includes engagements which engage with the engagements of the clamped pair of electrical contacts 36a, 36b. This coupling of the engagements prevents the mounting portions 46a, 46b from moving relative to the housing 38, while the clamped planar bodies 42a, 42b can move in a generally lateral direction relative to the housing 38. The housing 38 has a first engagement in the form of a projection 162 extending inward from an inner side surface of the side wall 146 which engages with the projection 84a on the second section 80a of the electrical contact 36a, and a projection 164 extending inward from an inner side surface of the side wall 148 which engages with the projection 84b on the second section 80b of the electrical contact 36b. The projection 162, 164 on each side wall 146, 148 may be formed as a barb having which has an angled rear face which is angled relative to the plane defined by the respective side wall 146, 148, and a front face which is perpendicular to the respective side wall 146, 148. As shown, the rear and front surfaces are spaced from each other by a surface which is parallel to the respective side wall 146, 148. The housing 38 has a second engagement provided by a first wall 166 which extends inward from the side wall 146 and into the cavity 150, is proximate to, but spaced from the top wall 142, and extends longitudinally, and a first front wall 168 at a front end of the first wall 166, and provided by a second wall 170 which extends inward from the side wall 148 and into the cavity 150, is proximate to, but spaced from the top wall 142, and extends longitudinally, and a second front wall 172 at a front end of the second wall 170. The walls 166, 168 form a first channel 174 which receives the flange 86a of the electrical contact 36a, and the walls 170, 172 form a second channel 176 which receives the flange 86b of the electrical contact 36b.

The housing further includes spaced apart slots 178, 180 through the bottom wall 144 of the housing 38 which extend longitudinally from the mounting end 154 toward the mating end 152 and are in communication with the cavity 150. The slots 178, 180 receive the sections 82a, 82b of the mounting portions 46a, 46b therethrough. The slots 178, 180 have a lateral dimension which prevents lateral movement of the second leg portions 80a, 80b relative to the housing 38.

The housing 38 further includes a plurality of surfaces in the top wall 142 forming an elongated recess 182 extending longitudinally from the mounting end 154 toward the mating end 152, and a plurality of surfaces in the bottom wall 144 forming an elongated recess 184 extending longitudinally from the mounting end 154 toward the mating end 152. The upper tabs 64a, 64b are received in the recess 182, and the lower tabs 66a, 66b are received in the recess 184. The recess 182 has a width which is slightly wider than the combined widths of the tabs 64a, 64b, and the recess 184 has a width which is slightly wider than the combined widths of the tabs 66a, 66b.

The clamped electrical contacts 36a, 36b are inserted into the housing 38 by first inserting the spring fingers 44a, 44b through the mounting end 154 of the housing 38. The flanges 86a, 86b slide along the channels 174, 176, the tabs 64a, 64b slide along the recess 182, the tabs 66a, 66b slide along the recess 184, the section 82a of the mounting portion 46a slides along the slot 178 and extends downward from the bottom wall 144 of the housing 38, and the section 82b of the mounting portion 46b slides along the slot 180 and extends downward from the bottom wall 144 of the housing 38. The angled faces of the projections 84a, 84b on the electrical contacts 36a, 36b contact the angled faces on the projections 162, 164 on the housing 38, and upon continued insertion, the projections 84a, 84b move past the projections 162, 164. Once past, the flat faces of the projections 84a, 84b, 162, 164 abut against each other, and the front end of the flanges 86a, 86b abut against the front walls 168, 172. The clamped electrical contacts 36a, 36b are thus prevented from being easily removed from the housing 38. With the clamped electrical contacts 36a, 36b positioned within the housing 38, the mounting portions 46a, 46b are rigidly affixed to the housing 38, and the planar base planar bodies 42a, 42b are cantilevered from the first sections 78a, 78b. The clamped electrical contacts 36a, 36b inversely face each other.

To form the electrical system 20, the electrical connector 22 is electrically coupled to the electrical element 24 by securing the mounting flanges 48a, 48b to the electrical element 24, for example by screws 186 extending through the openings 88a, 88b of the mounting flanges 48a, 48b and into the electrical element 24. Thereafter, the conductive component 26 is inserted through the mating end 152 of the housing 38, and into the receiving space 90 to engage with the contact beams 70a, 70b on each side 30, 32 thereof to form an electrical connection therebetween.

The electrical system 20 defines first and second deflection zones Z1 and Z2, see FIG. 17. The first deflection zone Z1 extends between the clamp 40 and the front ends 75a, 75b of the spring fingers 44a, 44b. The second deflection zone Z2 extends between the front ends 75a, 75b of the spring fingers 44a, 44b and the rear ends 52a, 52b of the clamped planar bodies 42a, 42b. When the conductive component 26 is being engaged with the contact beams 70a, 70b, the contact beams 70a, 70b deflect in the first deflection zone Z1. The contact beams 70a, 70b provide for a stable normal force on the conductive component 26. When the conductive component 26 is received within the receiving space 90 but the conductive component 26 is not directly aligned with the receiving space 90, the second deflection zone Z2 allows for a degree of misalignment between the electrical connector 22 and the conductive component 26. If misaligned, the free standing beam formed by the clamped planar bodies 42a, 42b and the spring fingers 44a, 44b will deflect in a lateral direction around the longitudinal axes 62a, 62b within the housing 38 in the second deflection zone Z2 and relative to the mounting portions 46a, 46b and the electrical element 24. The widths of the recesses 182, 184 limit the amount of movement of the planar bodies 42a, 42b and the spring fingers 44a, 44b in the second deflection zone Z2 since the tabs 64a, 64b, 66a, 66b seat within the recesses 182, 184. This is representationally shown in FIG. 18. In this arrangement and as shown in the figures, the normal force exhibited on the conductive component 26 remains constant as the clamped electrical contacts 36a, 36b and the spring fingers 44a, 44b move in the lateral direction. As shown, the size of the receiving space 90 remains constant during the lateral deflection of the clamped electrical contacts 36a, 36b and the spring fingers 44a, 44b, and thus the force exhibited on the conductive component 26 will remain the same. If the electrical contacts were to float independently of each other, the electrical contacts will exhibit a higher spring force.

A pair of clamped electrical contacts 36a, 36b are shown, but multiple pairs of clamped electrical contacts 36a, 36b are contemplated.

Attention is invited to the embodiment of the electrical connector 222 shown in FIGS. 19-26. The electrical connector 222 and the electrical element 24 are oriented with respect to mutually aligned axes that include a longitudinal axis, an elevation (or vertical) axis, and a lateral (or horizontal) axis. This arrangement is typically called a “vertical” system.

Each electrical contact 236a, 236b has a connecting portion formed of a substantially rectangular-shaped planar body 242a, 242b and spring fingers 244a, 244b extending from the planar body 242a, 242b, and further has a mounting portion 246a, 246b extending from a top end of the planar body 242a, 242b, and a mounting flange 248a, 248b extending from the planar body 242a, 242b. The mounting portion 246a, 246b is fixed to the housing 238. The mounting flanges 248a, 248b are fixed to the electrical element 24. The planar bodies 242a, 242b and the spring fingers 244a, 244b, when clamped together by the clamp 40 as described herein, and the housing 238 form a free standing beam relative to the mounting flanges 248a, 248b. For purposes of clarity, the components of electrical contact 236a are described herein, and the like components of electrical contact 236b are denoted with the same reference numerals except with a “b” thereafter instead of an “a”.

As shown in FIGS. 21-23, the planar body 242a has a top end 250a, an opposite bottom end 252a, and side edges 254a, 256a extending between the top and bottom ends 250a, 252a which define a first side surface 258a and a second side surface 260a. A longitudinal axis 262a is defined by the planar body 242a from the top end 250a to the bottom end 252a. The side surfaces 258a, 260a coincide with respective planes that extend along the longitudinal and elevation axes and are parallel to each other. A first side tab 264a extends outward from the side edge 254a, and a second side tab 266a extends outward from the side edge 256a. Each tab 264a, 266a is coplanar with the planar body 242a section.

The spring fingers 244a extend from the top end 250a of the planar body 242a and are identically formed to spring fingers 44a, 44b. As such, the specifics are not repeated herein.

The mounting portion 246a has a first section 278a which extends perpendicularly from each side edge 254a, 256a of the planar body 242a and a second section 280a which is planar, extends perpendicularly from the first section 278a and overlaps the side 260a of the planar body 242a, and is parallel to the planar body 42a. The second section 280a extends parallel to the longitudinal axis 262a. The first section 278a may be U-shaped. The second section 280a has an engagement which engages with the housing 238 to prevent the movement of the mounting portion 246a relative to the housing 238. The engagement may be provided by a projection 284a that extends upwardly from each second section 280a and is coplanar with the second section 280a. The projection 284a may be formed as an elongated arm having a hook-shaped end. The tab 264a is proximate to, but spaced from, an upper end of the first section 278a.

The mounting flange 248a extends from the bottom end 252a of the planar body 242a and is perpendicular thereto. The mounting flange 248a is below a lower end of the second section 280a. An opening 288a is provided through the mounting flange 248a.

The electrical contacts 236a, 236b are clamped together by the clamp 40 (anyone of the clamps 40 shown in FIGS. 6-15, or any other suitable clamp, may be used) to form a clamped pair prior to insertion into the housing 238. In the clamped pair, the side surfaces 258a, 258b of the electrical contacts 236a, 236b face each other such that the planar bodies 242a, 242b are parallel to each other, the rear walls 268a, 268b of the spring fingers 244a, 244b angle outward from each other, the first sections 278a, 278b extend outward from each other, and the mounting flanges 248a, 248b extend outward from each other. The planar bodies 242a, 242b are coupled together by the clamp 40 to prevent relative movement between the planar bodies 242a, 242b. The planar bodies 242a, 242b and the mounting portions 246a, 246b are cantilevered from the mounting flanges 248a, 248b, and the planar bodies 242a, 242b define a bending beam. The clamp 40 effectively alters the bending or flexing of the electrical contacts 236a, 236b when mated. The bending arm is essentially shortened, and the clamp 40 provides a fixed point of the bending beam. The clamp 40 is provided proximate to, but spaced from, the top ends 250a, 250b of the planar bodies 242a, 242b.

As shown in FIGS. 20, 24 and 25, the housing 238 has a side wall 342, an opposite side wall 344, and side walls 346, 348 extending therebetween, which defines a cavity 350 that extends from a mating or top end 352 of the housing 238 to a mounting or bottom end 354 of the housing 238. A longitudinal axis extends along the housing 238 from the mating end 352 to the mounting end 354. The front and rear ends of the cavity 350 are open to define a top opening 358 and a bottom opening 360. Each side wall 342, 344 has an elongated slot 356 which extends from the mating end 352 toward the mounting end 354 and which is in communication with the cavity 350 and the top opening 358. In the illustrated embodiment, the top opening 358 and the slots 356 have dimensions to accommodate receipt of the conductive component 26 therein when the mating edge 34 of the conductive component 26 is advanced into the top opening 358 and the slots 356 along a mating direction. The mating direction extends substantially parallel to the longitudinal axis of the housing 238.

The housing 238 includes an engagement which engages with the engagement of the clamped pair of electrical contacts 236a, 236b. This coupling of the engagements prevents the planar bodies 242a, 242b and the mounting portions 246a, 246b from moving relative to the housing 238. The housing 238 has an engagement in the form of projections 362 extending inward from an inner side surface of the side wall 346 which engage with the respective projection 284 on the second section 280a of the electrical contact 236a, and projections (not shown) extending inward from an inner side surface of the side wall 348 which engage with the respective projection 284b on the second section 280b of the electrical contact 236b. The projection 362, 364 on each side wall 346, 348 may be formed as a barb having which has an angled face which is angled relative to the plane defined by the respective side wall 346, 348, and a planar face which is perpendicular to the respective side wall 346, 348.

The housing 238 further includes a plurality of surfaces in the side wall 342 forming an elongated recess 382 extending longitudinally from the mounting end 354 toward the mating end 352, and a plurality of surfaces in the side wall 344 forming an elongated recess 384 extending longitudinally from the mounting end 354 toward the mating end 352. The tabs 264a, 264b are received in the recess 382, and the tabs 266a, 266b are received in the recess 384. The recess 382 has a width which is slightly wider than the combined widths of the tabs 264a, 264b, and the recess 384 has a width which is slightly wider than the combined widths of the tabs 266a, 266b.

The clamped electrical contacts 236a, 236b are inserted into the housing 238 by first inserting the spring fingers 244a, 244b through the mounting end 354 of the housing 238. Outer surfaces of the projections 284a and the second sections 280a slide along an inner surface of the side wall 346, outer surfaces of the projections 284b and the second sections 280b slide along an inner surface of the side wall 348, the tabs 264a, 264b slide along the recess 382, and the tabs 266a, 266b slide along the recess 384. The hook-shaped ends of the projections 284a, 284b on the electrical contacts 236a, 236b engage with the projections 362 on the housing 238. The clamped electrical contacts 236a, 236b are thus prevented from being easily removed from the housing 238. With the clamped electrical contacts 236a, 236b positioned within the housing 238, the mounting portions 246a, 246b are rigidly affixed to the housing 238. The clamped electrical contacts 236a, 236b inversely face each other.

To form the electrical system, the electrical connector 222 is electrically coupled to the electrical element 24 by securing the mounting flanges 248a, 248b to the electrical element 24, for example by screws extending through the openings 288a, 288b of the mounting flanges 248a, 248b and into the electrical element 24. In this embodiment as shown in FIG. 26, the bottom end of the housing 238 is spaced from the mounting flange 248a, 248b to form a space 388. Thereafter, the conductive component 26 is inserted through the mating end 352 of the housing 238, and into the receiving space 290 to engage with the contact beams 270a, 270b on each side 30, 32 thereof to form an electrical connection therebetween.

The electrical system defines first and second deflection zones Z1 and Z2, see FIG. 26. The first deflection zone Z1 extends between the clamp 40 and the front ends 275a, 275b of the spring fingers 244a, 244b. The second deflection zone Z2 extends between the front ends 275a, 275b of the spring fingers 244a, 244b and the bottom ends 252a, 252b of the clamped planar bodies 242a, 242b. When the conductive component 26 is being engaged with the contact beams 270a, 270b, the contact beams 270a, 270b deflect in the first deflection zone Z1. The contact beams 270a, 270b provide for a stable normal force on the conductive component 26. When the conductive component 26 is received within the receiving space 290 but the conductive component 26 is not directly aligned with the receiving space 290, the second deflection zone Z2 allows for a degree of misalignment between the electrical connector 222 and the conductive component 26. If misaligned, the free standing beam formed by the clamped housing 238, the planar bodies 242a, 242b, and the spring fingers 244a, 244b will deflect in a lateral direction around the longitudinal axes 262a, 262b relative to the mounting flanges 248a, 248b in the second deflection zone Z2. In this arrangement, the normal force exhibited on the conductive component 26 remains constant as the housing 238, the clamped planar bodies 242a, 242b, and the spring fingers 244a, 244b move in the lateral direction. As shown, the size of the receiving space 290 remains constant during the lateral deflection of the housing 238, the clamped electrical contacts 236a, 236b and the spring fingers 244a, 244, and thus the force will remain the same.

A pair of clamped electrical contacts 236a, 236b are shown, but multiple pairs of clamped electrical contacts 236a, 236b are contemplated.

Attention is invited to the embodiment of the electrical connector 422 shown in FIGS. 27-32. The electrical connector 422 and the electrical element 24 are oriented with respect to mutually aligned axes that include a longitudinal axis, an elevation (or vertical) axis, and a lateral (or horizontal) axis. This arrangement is typically called a “vertical” system. mounting portion

Each electrical contact 436a, 436b has a connecting portion having a substantially rectangular-shaped planar body 442a, 442b and spring fingers 444a, 444b extending from the planar body 442a, 442b, and further has a mounting portion 446a, 446b extending from the planar body 442a, 442b, and a mounting flange 448a, 448b extending from the planar body 442a, 442b. The planar bodies 442a, 442b and the spring fingers 444a, 444b, when clamped together by the clamp 40 as described herein, form a free standing beam within the housing 438. The electrical contacts 436a, 436b are identically formed to the electrical contacts 236a, 236b with the exception of the following differences. The mounting portions 446a, 446b are coplanar with the respective planar bodies 442a, 442b, instead of being perpendicular thereto, and the mounting portions 446a, 446b do not include openings. In addition, a tab 521a, 521b extends outward from a side edge of each mounting flange 448a, 448b and is proximate to a lower end of the mounting portion 446a, 446b. Therefore, the specifics of the electrical contact 436a, 436b are not repeated herein and like components are denoted with like reference numerals, but with this embodiment being the in four hundreds.

The electrical contacts 436a, 436b are clamped together by the clamp 40 (anyone of the clamps 40 shown in FIGS. 6-15, or any other suitable clamp, may be used) to form a clamped pair prior to insertion into the housing 438 in the same manner as electrical contacts 236a, 236b, except that the mounting flanges 448a, 448b are parallel to each other. The planar bodies 442a, 442b are coupled together by the clamp 40 to prevent relative movement between the planar bodies 442a, 442b. As illustrated, the clamp 40 is located about midway along the length of a beam formed by the planar bodies 442a, 442b and the spring fingers 444a, 444b.

The housing 438 has a side wall 542, an opposite side wall 544, and side walls 546, 548 extending therebetween, which defines a cavity 550 that extends from a mating or top end 552 of the housing 438 to a mounting or bottom end 554 of the housing 438. A longitudinal axis extends along the housing 438 from the mating end 552 to the mounting end 554. The front and rear ends of the cavity 550 are open to define a top opening 558 and a bottom opening 560. Each side wall 542, 544 has an elongated slot 556 which extends from the mating end 552 toward the mounting end 554 and which is in communication with the cavity 550 and the top opening 558. In the illustrated embodiment, the top opening 558 and the slots 556 have dimensions which accommodate receipt of the conductive component 26 therein when the mating edge 54 of the conductive component 26 is advanced into the top opening 558 and the slots 556 along a mating direction. The mating direction extends substantially parallel to the longitudinal axis of the housing 438.

Like housing 238, the housing 438 includes an engagement (not shown), like projections 362, which engages with the projections 484a, 484b of the clamped pair of electrical contacts 436a, 436b. This coupling of the engagements prevents the mounting portions 446a, 446b from moving relative to the housing 438. Like housing 238, the housing 438 includes a plurality of surfaces in the side wall 542 forming an elongated recess 582 extending longitudinally from the mounting end 554 toward the mating end 552, and a plurality of surfaces in the side wall 544 forming an elongated recess 584 extending longitudinally from the mounting end 554 toward the mating end 552. The tabs 464a, 464b, 521a, 521b are received in the recess 582, and the tabs 466a, 466b, 523a, 523b are received in the recess 584. The recess 582 has a width which is slightly wider than the combined widths of the tabs 464a, 464b, and the recess 584 has a width which is slightly wider than the combined widths of the tabs 466a, 466b.

The housing 438 further includes a first mounting wing 525 extending outward from the side wall 546 and perpendicular to the longitudinal axis of the housing 438, and a second mounting wing 527 extending outward from the side wall 548 and perpendicular to the longitudinal axis of the housing 438. The mounting wings 525, 527 are horizontally aligned with each other.

The clamped electrical contacts 436a, 436b are inserted into the housing 438 by first inserting the spring fingers 444a, 444b through the mounting end 554 of the housing 438. Outer surfaces of the projections 484a and the second sections 480a slide along an inner surface of the side wall 546, outer surfaces of the projections 484b and the second sections 480b slide along an inner surface of the side wall 548, the tabs 464a, 464b, 521a, 521b slide along the recess 582, and the tabs 466a, 466b, 523a, 523b slide along the recess 584. The hook-shaped ends of the projections 484a, 484b on the electrical contacts 436a, 436b engage with the projections (not shown) on the housing 438 and the clamped electrical contacts 436a, 436b are thus prevented from being easily removed from the housing 438. With the clamped electrical contacts 436a, 436b positioned within the housing 438, the mounting portions 446a, 446b are rigidly affixed to the housing 438. The clamped electrical contacts 436a, 436b inversely face each other.

To form the electrical system 420, the electrical connector 422 is electrically coupled to the electrical element 24 by securing the mounting wings 525, 527 to the electrical element 24, for example by screws extending through openings of the mounting wings 525, 527 and into the electrical element 24. The housing 438 passes through an opening (not shown) in the electrical element 24. The electrical system 20 defines first and second deflection zones Z1 and Z2, see FIG. 32. The first deflection zone Z1 extends between the clamp 40 and the front ends 475a, 475b of the spring fingers 444a, 444b. The second deflection zone Z2 extends between the front ends 475a, 475b of the spring fingers 444a, 444b and the bottom ends 452a, 452b of the clamped planar bodies 442a, 442b. Thereafter, the conductive component 26 (or housing 438 and mounting flanges 448a, 448b of another electrical connector 422) is inserted through the mating end 552 of the housing 438, and into the receiving space 490 to engage with the contact beams 470a, 470b on each side 30, 32 thereof to form an electrical connection therebetween. When the conductive component 26 (or the mounting flanges 448a, 448b) is being engaged with the contact beams 470a, 470b, the contact beams 470a, 470b deflect in the first deflection zone Z1. The contact beams 470a, 470b provide for a stable normal force on the conductive component 26. When the conductive component 26 (or the mounting flanges 448a, 448b of another electrical connector 422) is received within the receiving space 490 but the conductive component 26 (or the mounting flanges 448a, 448b of another electrical connector 422) is not directly aligned with the receiving space 490, the second deflection zone Z2 allows for a degree of misalignment between the electrical connector 422 and the conductive component 26 (or the mounting flanges 448a, 448b of another electrical connector 422). If misaligned, the free standing beam formed by the planar bodies 442a, 442b and the spring fingers 444a, 444b will deflect in a lateral direction around the longitudinal axes 462a, 462b relative to the mounting flanges 448a, 448b and the housing 438 in the second deflection zone Z2. In this arrangement, the normal force exhibited on the conductive component 26 (or the mounting flanges 448a, 448b of another electrical connector 422) remains constant as the clamped planar bodies 442a, 442b and the spring fingers 444a, 444b move in the lateral direction relative to mounting flanges 448a, 448b and the housing 438. As shown, the size of the receiving space 490 remains constant during the lateral deflection of the clamped electrical contacts 436a, 436b and the spring fingers 444a, 444, and thus the force will remain the same.

The widths of the recesses 582, 584 limit the amount of movement of the planar bodies 442a, 442b and the spring fingers 444a, 444b in the second deflection zone Z2 since the tabs 464a, 464b, 466a, 466b seat within the recesses 582, 584.

A pair of clamped electrical contacts 436a, 436b are shown, but multiple pairs of clamped electrical contacts 436a, 436b are contemplated.

The disclosure provided herein describes features in terms of preferred and exemplary embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure.