Electrical connector with coating piercing electrical contact
An electrical connector assembly includes a generally planar metallic substrate having a surface with an electrically nonconductive coating and an electrical connector having a contact tab extending therefrom that is in mechanical and electrical contact with the metallic substrate. The contact tab defines two sharp points that are formed by two triangular portions of the contact tab that pierce the electrically nonconductive coating. An electrical shield incorporating the contact tab and a method of forming the electrical shield are also provided herein.
1 . An electrical connector assembly, comprising:
a generally planar metallic substrate having a surface with an electrically nonconductive coating; and
an electrical connector having a contact tab extending from a connector body, the contact tab being in mechanical and electrical contact with the metallic substrate, the contact tab forms a V-shaped configuration defining an apex and two non-coplanar triangular portions, each triangular portion terminating at a respective outwardly facing sharp point, a clamping force applied at the apex causes the sharp points to move laterally away from one another to scrape through the electrically nonconductive coating, thereby establishing electrical contact between the electrical connector and the metallic substrate.
2 . The electrical connector assembly in accordance with claim 1 , wherein the two triangular portions are arranged at an oblique angle to each other.
3 . The electrical connector assembly in accordance with claim 2 , wherein the two triangular portions are arranged symmetrically about a centerline of the contact tab.
4 . The electrical connector assembly in accordance with claim 2 , wherein the two triangular portions are formed by a V-shaped fold in the contact tab.
5 . The electrical connector assembly in accordance with claim 4 , wherein the connector body is attached to the metallic substrate and in contact with the apex of the V-shaped fold in the contact tab.
6 . The electrical connector assembly in accordance with claim 5 , wherein the clamping force applied to the apex of the V-shaped fold in the contact tab causes the two sharp points formed by the two triangular portions of the contact tab to move away from one another.
7 . The electrical connector assembly in accordance with claim 5 , wherein a clamping force applied to the apex of the V-shaped fold in the contact tab causes the two sharp points formed by the two triangular portions of the contact tab to move an equal distance from a centerline of the contact tab.
8 . The electrical connector assembly in accordance with claim 1 , wherein a contact force applied to the contact tab is evenly distributed to each of the two sharp points.
9 . An electrical shield formed of sheet metal, comprising:
a contact tab extending from the electrical shield, the contact tab being in mechanical and configured to be in electrical contact with a metallic substrate, wherein the contact tab forms a V-shaped configuration defining an apex and two non-coplanar triangular portions, each triangular portion terminating at a respective outwardly facing sharp point, wherein a clamping force applied at the apex causes the sharp points to move laterally away from one another to scrape through an electrically nonconductive coating on a metallic substrate, thereby establishing electrical contact between the electrical shield and the metallic substrate.
10 . The electrical shield in accordance with claim 9 , wherein the two sharp points formed by the two triangular portions are arranged at an oblique angle to each other.
11 . The electrical shield in accordance with claim 10 , wherein the two triangular portions are arranged symmetrically about a centerline of the contact tab.
12 . The electrical shield in accordance with claim 10 , wherein the two triangular portions are formed by a V-shaped fold in the contact tab.
13 . The electrical shield in accordance with claim 9 , wherein a contact force applied to the contact tab is evenly distributed to each of the two sharp points.
14 . A method of forming an electrical shield from sheet metal, comprising:
forming a rectangular contact tab extending from the electrical shield and integral to the electrical shield; and
bending the contact tab at a centerline such that the contact tab defines a V-shaped configuration defining an apex and two non-coplanar triangular portions, each triangular portion terminating at a respective outwardly facing sharp point, the two sharp points are configured to pierce an electrically nonconductive coating on a metallic substrate
applying a clamping force at the apex which causes the sharp points to move laterally away from one another to scrape through the electrically nonconductive coating, thereby establishing electrical contact between the electrical connector and the metallic substrate.
15 . The method in accordance with claim 14 , wherein the two triangular portions are arranged at an oblique angle to each other.
16 . The method in accordance with claim 14 , wherein the two triangular portions are arranged symmetrically about a centerline of the contact tab.