Receptacle contact

1. A receptacle contact for receipt of a mating contact therein, the receptacle contact having a contact portion comprising:

side walls, each of the side walls having an opening provided therein;

a resilient contact arm extending between the side walls, the resilient contact arm having a fixed end and a distal end with at least one first contact area for contacting the mating contact positioned on the resilient contact arm proximate the distal end;

projections extending from the resilient contact arm, the projections extending through the openings of the side walls;

a weak area provided on the resilient contact arm, the weak area being positioned between the fixed end and the projections, the weak area having a second contact area for contacting the mating contact positioned proximate the projections;

whereby the projections engage a top wall of the openings of the side walls as the mating contact is inserted into the receptacle contact, causing the second contact area proximate the weak area to move into engagement with the mating contact, wherein the at least one first contact area and the second contact area engage the mating contact to provide a stable and reliable electrical connection therebetween.

2. The receptacle contact as recited in claim 1 , wherein the resilient contact arm has two bifurcated beams which extend from the weak area to the distal end of the resilient contact arm.

3. The receptacle contact as recited in claim 2 , wherein the at least one first contact area is provided on each of the bifurcated beams.

4. The receptacle contact as recited in claim 3 , wherein the receptacle contact has a second contact arm having a third contact area, the third contact area positioned laterally between the at least one first contact area of the resilient contact arm and the weak area of the resilient contact arm.

5. The receptacle contact as recited in claim 4 , wherein a support arm is provided to support the second contact arm proximate a distal end of the second contact arm.

6. The receptacle contact as recited in claim 4 , wherein the receptacle contact has a bottom wall which extends between the side walls, a support device is provide on the bottom wall proximate a front face of the receptacle contact, the support device cooperates with the second contact arm to allow forces applied to the second contact arm to be transferred through the support device to the bottom wall.

7. The receptacle contact as recited in claim 4 , wherein the receptacle contact has a bottom wall which extends between the side walls, an overstress projection is provided on the bottom wall proximate a distal end of the second contact arm, the overstress projection cooperates with the second contact arm to prevent the second contact arm from taking a permanent set.

8. The receptacle contact as recited in claim 1 , wherein the receptacle contact has a top wall which extends between the side walls, a support device is provide on the fourth wall proximate a front face of the receptacle contact, the support device cooperates with the resilient contact arm to allow forces applied to the resilient contact arm to be transferred through the support device to the top wall.

9. A receptacle contact for receipt of a mating contact therein, the receptacle contact comprising:

side walls, each of the side walls having an opening provide therein;

a first resilient contact arm extending between the side walls, the first resilient contact arm having a fixed end and a free end with at least one first contact area positioned proximate to the first free end, projections extending from the first resilient contact arm, the projections extending through the openings of the side walls, a weak area provided on the first resilient contact arm, the weak area being positioned between the fixed end of the first resilient contact arm and the projections of the first resilient contact arm, a second contact area is positioned proximate the weak area;

a second resilient contact arm extending between the side walls, the second resilient contact arm having a fixed end and a free end with a third contact area positioned proximate to the free end of the second resilient contact arm, the third contact area positioned laterally between the at least one first contact area of the first resilient contact arm and the weak area of the first resilient contact arm;

whereby the projections engage a wall of the opening as the mating contact is inserted into the receptacle contact, causing the second contact area proximate the weak area to move into engagement with the mating contact, thereby providing multiple areas of contact between the first and second resilient contact arms and the mating contact to provide a stable and reliable electrical connection therebetween.

10. The receptacle contact as recited in claim 9 , wherein a support arm is provided to support the second resilient contact arm proximate a free end of the second contact arm.

11. The receptacle contact as recited in claim 9 , wherein the receptacle contact has a bottom wall which extends between the side walls, a support device is provide on the bottom wall proximate a front face of the receptacle contact, the support device cooperates with the second resilient contact arm to allow forces applied to the second resilient contact arm to be transferred through the support device to the bottom wall.

12. The receptacle contact as recited in claim 9 , wherein the receptacle contact has a bottom wall which extends between the side walls, an overstress projection is provided on the bottom wall proximate a free end of the second resilient contact arm, the overstress projection cooperates with the second resilient contact arm to prevent the second resilient contact arm from taking a permanent set.

13. The receptacle contact as recited in claim 9 , wherein the first resilient contact arm has two bifurcated beams which extend from the weak area to the free end of the first resilient contact arm.

14. The receptacle contact as recited in claim 13 , wherein the at least one first contact area is provided on each of the bifurcated beams.

15. The receptacle contact as recited in claim 14 , wherein the receptacle contact has a top wall which extends between the side walls, a support device is provide on the top wall proximate a front face of the receptacle contact, the support device cooperates with the first resilient contact arm to allow forces applied to the first resilient contact arm to be transferred through the support device to the top wall.

16. A method of inserting a mating contact into a receptacle contact, the receptacle contact having side walls and a first resilient contact arm, the method comprising:

engaging the first resilient contact arm with the mating contact, forming a first contact area proximate a distal end of the first resilient contact arm between the first resilient contact arm and the mating contact;

moving the first resilient contact arm from an unstressed position;

engaging a wall of an opening with at least one projection of the first resilient contact arm to prevent further movement of a weak area of the first resilient contact arm;

moving a portion of the first resilient contact arm about the weak area of the first resilient contact arm after the at least one projection has engaged the wall of the opening, forming a second contact area proximate the weak area and the at least one projection between the first resilient contact arm and the mating contact.

17. The method of claim 16 , further comprising: wherein the first contact area is making an electrical connection between the mating contact and the at least one resilient contact arm at an area proximate the free end of the at least one first resilient contact arm and the second contact area is an area proximate the weak area of the first resilient contact arm.

18. The method of claim 16 , further comprising:

making multiple areas of electrical contact between the mating contact, the first resilient contact arm, and a second resilient contact arm.

19. The method of claim 18 , wherein the at least one resilient contact arm is a first resilient contact arm and a second resilient contact arm, the first resilient contact arm having the at least one projection positioned thereon, the second resilient contact arm having a support arm positioned proximate a distal end of the second resilient contact arm.

20. The method of claim 16 , wherein the first resilient contact arm having two bifurcated beams which extend from the weak area to a free end of the first resilient contact arm.