Compression mating electrical connector

Electrical connector having substantially no sliding friction between electrical contact elements, said connector comprising:

• a plurality of substantially arcuate flexible ribbon contacts;
• a plug assembly for receiving therein a first plurality of wires, said plug assembly having mounted thereon a first set of said plurality of said ribbon contacts for terminating said first plurality of wires;
• a receptacle assembly for receiving therein a second plurality of wires and having a first recess for receiving therein said plug assembly, and having mounted thereon a second set of said plurality of said ribbon contacts for terminating said second plurality of wires;
• first and second contact support structures, each having a plurality of contact channels disposed thereon for receiving and aligning said first set and said second set respectively of flexible ribbon contacts, said first and second contact support structures disposed on said plug assembly and said receptacle assembly respectively, for superposing said first set of said flexible ribbon contacts over said second set of said flexible ribbon contacts while said plug assembly is inserted substantially into said receptacle assembly;
• and for precluding contact between said first set and said second set of said flexible ribbon contacts, until an articulation force flexes said first contact support structure substantially towards said second contact support structure, establishing contact between said first and said second set of said plurality of said ribbon contacts;
• and
• a shell for applying said articulating force to said first set of said plurality of said flexible ribbon contacts.

Electrical connector for establishing detachable electrical contact, said connector including a plug assembly for receiving therein a first insulated wire and a receptacle assembly for receiving therein a second insulated wire, said receptacle assembly having a first recess for receiving therein said plug assembly, said connector further comprising:

• a plurality of substantially arcuate flexible metallic ribbon contacts, each of said contacts having formed at one end at least one piercing blade for piercing insulation surrounding one of said first and second insulated wires and for making electrical contact with said wire;
• a plug body forming a substantial first half of said plug assembly, said plug body including a rigid contact blade having formed thereon at least one contact channel for receiving and aligning a first one of said plurality of ribbon contacts;
• a plug cap forming a substantial second half of said plug assembly, said plug cap having formed thereon at least one wire channel for receiving therein said first wire and at least one contact channel, said plug cap for retaining said first wire and said first one ribbon contact in mechanical alignment and electrical contact;
• at least one first interlocking detent for assembling said plug cap and said plug body as a substantially whole plug assembly after insertion of said first wire into said plug body;
• a receptacle body forming substantially a first half of said receptacle assembly, said receptacle body having formed thereon at least one wire channel for receiving said second wire and at least one contact channel, said receptacle body for retaining said second wire and said second one ribbon contact in mechanical alignment and electrical contact;
• a receptacle cap forming substantially a second half of said receptacle assembly, said receptacle cap including a flexible contact blade having at least one contact channel formed thereon for receiving one of said ribbon contacts, said receptacle cap for retaining said second wire and said ribbon contact in mechanical alignment and electrical contact;
• at least one second interlocking detent for assembling said receptacle cap and said receptacle body as a substantially whole receptacle assembly after insertion of said second wire into said receptacle body;
• a shell defining a second recess for receiving therein said plug assembly, said shell having formed, on an interior surface, a cam surface for engaging said flexible contact blade of said receptacle assembly as said plug assembly is inserted in said receptacle assembly thereby precluding electrical and mechanical contact between said ribbon contacts until said ribbon contacts are substantially superposed, thereafter flexing said flexible blade toward said rigid blade of said plug assembly, thereby making electrical contact without sliding and compression friction between said ribbon contacts;
• a stop disposed in said shell for limiting said slide travel of said plug assembly within said shell;
• and
• a bias spring, disposed in said shell for biasing said plug assembly towards on end of said shell
• at least one detent disposed respectively on said shell and said receptacle assembly for removably maintaining said shell and said receptacle in mechanical position.

The method of establishing detachable electrical contact substantially without sliding friction between electrical contact elements, said method comprising the steps of:

• terminating a first wire with a first flexible contact disposed on a flexible, cantilevered first carrier means further disposed on a plug means;
• terminating a second wire with a second contact disposed on a rigid, substantially immovable second carrier means further disposed on a receptacle means;
• inserting said plug means into said receptacle means;
• superposing said flexible contact over said second contact using a contact positioning means while said plug means is inserted into said receptacle means, said contact positioning means thereby precluding contact between said flexible contact and said second contact during substantially full insertion;
• articulating means for articulating said first carrier means once said plug means is substantially fully inserted in said receptacle, thereby establishing electrical contact between said first flexible contact and said second contact by reversibly deforming said first flexible contact onto said second contact;
• and
• reversibly maintaining said first flexible contact in compressive deformity with respect to said second contact.