WO2007031110A1

WO2007031110A1 - Electrical connector and process for assembling a contact terminal to an electrical connector

Info

Publication number: WO2007031110A1
Application number: PCT/EP2005/011129
Authority: WO
Inventors: Frédéric CHAZOTTES
Original assignee: Fci
Priority date: 2005-09-14
Filing date: 2005-09-14
Publication date: 2007-03-22
Also published as: WO2007031311A1

Abstract

The invention relates to an electrical connector comprising: - a housing (30) having at least a cavity designed to guide a contact terminal (66) and first locking means (82) designed to cooperate with the contact terminal (66) to prevent the extraction of the contact terminal (66); and - second locking means (64, 94, 98) adapted to be connected to the housing (30). The first locking means (82) are rigid and fixed with respect to the housing (30). The second locking means (64, 94, 98) are adapted to lay on the contact terminal (66) to retain the contact terminal (66) in abutment against the first locking means (82). The invention relates also to a process for assembling a contact terminal to an electrical connector.

Description

Electrical connector and process for assembling a contact terminal to an electrical connector.

FIELD OF THE INVENTION

The present invention relates to an electrical connector of the type comprising a housing having at least a cavity designed to guide a contact terminal and first locking means designed to cooperate with the contact terminal to prevent the extraction of the contact terminal and second locking means adapted to be connected to the housing.

BACKGROUND OF THE INVENTION Such a connector 1 , illustrated in figure 1 , includes a housing 2 having a row of cavities 4 extending from a rear face 6 to a front face 8. Each cavity 4 is designed to accommodate and retain a female contact terminal 10 comprising a metallic plugging cage 14 and a constricted portion 16 fixed to a wire 12, for example by crimping. To retain the female contact terminal 10 in the housing 2, a flexible catch 18 is molded in each cavity 4 of the housing. The resilience of this catch 18 tends to hold it in a position in which it projects into the cavity 4.

The female contact terminal 10 comes in abutment against a stop face 20 of the catch 18 to retain the female contact terminal 10 in the cavity in a position called a locking position.

The connector 1 further includes a cap 22, often referred as a secondary locking element, that is fitted over the front face 8 of the housing 2 and that prevents the catch 18 from flexing and releasing the female contact terminal 10 once the cap 22 is in place. The cap 22 is generally designed so that it cannot be inserted unless all female contact terminals 10 are fully engaged in all corresponding cavities 4 of the housing and locked in place. Otherwise, the cap 22 comes in abutment against the catch 18 of each cavity 4 that is flexed outwardly of the cavity 4.

However, the moulding of the housing 2 is problematic because each catch 18 is moulded in each cavity 4 in back draft and so required a complex moulding process.

Therefore, it is desirable to develop an electrical connector which is easier to mould and which performs the above mentioned functions. SUMMARY OF THE INVENTION

Accordingly, an object of the invention is to provide an electrical connector typed as recited in claim 1. Other features and advantages of the electrical connector are recited in the dependant claims.

An object of the invention is to provide a process for assembling a contact terminal to an electrical connector, as recited in claim 16.

Other aspects of the invention will be apparent from the following description, drawings and from the claims.

BRIEF DESCRIPTION OF THE FIGURES

- Figure 1 is a sectional view of an electrical connector of the state of the art; - figure 2 is a perspective view of parts of a first embodiment of the electrical connector according to the invention, in a not mounted state;

- figure 3 is a perspective view of the electrical connector illustrated in figure 2, in a fully mounted state;

- figure 4 is a view of the electrical connector illustrated in figure 2, in the fully mounted state, in cross section on plane marked IV-IV in figure 3 ;

- figure 5 is a view similar to the view in figure 4, in cross section on plane marked V-V in figure 3;

- figure 6 is a perspective front view of a cap designed to be engaged with the front face of a housing of the electrical connector illustrated in figure 2; - figure 7 is a perspective rear view of the cap of figure 4;

- figure 8 is a schematically view of the electrical connector illustrated in figure 2, in cross section on plane marked V-V in figure 3 where the cap and a female contact terminal are in a pre-locking position ;

- figure 9 is a schematically view similar to the view in figure 8 where the cap is in the pre-locking position and the female contact terminal in a locking position;

- figure 10 is a schematically view similar to the view in figure 8 where the cap and the female contact terminal are in the locking position;

- figure 11 is a schematically view similar to the view in figure 8 where the female contact terminal is incorrectly inserted; - figure 12 is a schematically view similar to the view in figure 8 where the female contact terminal is being extracted from the electrical connector; and

- figure 13 is a schematically view of a second embodiment of the electrical connector, similar to the view in figure 8, where the cap is not assembled to the housing;

- figure 14 is a schematically view of the electrical connector illustrated in figure 13, where the cap and the female contact terminal are in the locking position;

- figure 15 is a schematically view of a third embodiment of the electrical connector according to the invention, similar to the view in figure 8, where the cap and the female contact terminal are in the locking position;

- figure 16 is a schematically view of a fourth embodiment of the electrical connector according to the invention, similar to the view in figure 8, where the cap and the female contact terminal are in the locking position; - figure 17 is a schematically view of a fifth embodiment of the electrical connector according to the invention, similar to the view in figure 8, where the cap is in pre-locking position;

- figure 18 is a schematically view of a sixth embodiment of the electrical connector according to the invention, similar to the view in figure 8, where the cap and the female contact terminal are in a locking position;

- figure 19 is a sectional view of a connected female and a male electrical connector according to the first embodiment of the invention; and

- figure 20 is a schematically view according to a seventh embodiment of the electrical connector according to the invention, similar to the view figure 8, where the cap and the female contact terminal are in a locking position.

DETAILED DESCRIPTION OF A PREFERED EMBODIMENT

The electrical connector 28 according to the invention is illustrated in figures 2 and 3. It comprises a housing 30 and a cap 32 adapted to be coupled with the housing 30.

The terms "axial" and "radial" refer to an X- X direction drawn on figure 2, which corresponds to the direction of assembling of the cap 32 to the housing 30. The terms "inner" and "outer" refer to the interior and to the exterior of the electrical connector. The housing 30 is made from insulating material and has, in the example shown schematically, a parallelepiped general shape with a rectangular cross section. It may be regarded as having an upper wall 34, a lower wall 36 opposite the upper wall, a front face 38 and a rear face 40 opposite the front face. The external perimeter of the housing comprises a peripheral groove

46 adapted to receive the annular elastomer gasket 48 for providing sealing between the housing 30 and the cap 32.

The lower wall 36 of the housing is larger than the upper wall 34 and is in offset with respect to the upper wall 34 so as to project out of the front face 38 of the housing.

The outer face of the lower wall 36 is provided, from the groove 46 to the front face 38, with a primary 50 and a secondary 52 notches parallel to each other. These notches are intended to receive a hook 54 of the cap 32 to set the cap to the housing 30, respectively in a pre-locking position and in a locking position as shown in figure 4.

The housing 30 includes a chamber to hold and compress a grommet 44, as well known in the state of the art.

The housing 30 is formed with a row of cavities 56 extending from the front face 38 to the rear face 40, as shown in figures 2 and 5. The terms "rear" and "front" used in this description, correspond to the front face 38 and the rear face 40 of the housing.

Each cavity 56 may be regarded as comprising a support or a floor wall 58 and a ceiling wall 60 formed each on the inner upper wall 34 and respectively on the inner lower wall 36 of the housing. The ceiling wall 60 of each cavity is provided with a recess 62 which opens on the front face 38 of the housing and in the corresponding cavity 56 and which is dimensioned to accommodate the extremity of a resilient tongue 64 of the cap 32 as explained later on in the description. The upper corner of the recess 62 is chamfered to facilitate the insertion of the tongue 64. The cavities 56 are adapted to accommodate female contact terminals

66. The rear face 40 is conventionally the location for introducing the female contact terminals 66 into the cavities 56 along the direction X-X. The cavity has a section larger than the section of the contact terminal 72.

Each female contact terminal 66 has a general tubular shape provided with a constriction 68 corresponding to a crimping portion between an electrical wire 70 and a metallic plugging cage 72 adapted to receive a complementary male terminal, as shown in figures 2 and 5.

According to the case, the bottom surface of the plugging cage 72 can comprise a hole 71 only represented in figures 13 to 16 and 18. The plugging cage 72 is formed with a border or edge 74 extending along a transversal and radial plane and designed to abut against a retainer shoulder 76 formed in the cavity 56 to prevent the female contact terminal 66 to be extracted backward from it, when an operator has put the electrical connector in a locking position. The floor wall 58 of the cavity is provided with an embossment 78 having a slope 80 and an abrupt step 82. The step 82 provides a discontinuity in the alignment of an insertion region 86 of the floor wall 58, located anterior to the step 82, considering the insertion direction X-X, and a locking region 84 of the floor wall 58, located posterior to the step 82. The step 82 forms the retainer shoulder 76 intended to engage with the border 74 of the female contact terminal 66. Therefore, the high of the step 82 corresponds approximately to the high of the border 74.The step 82 is able to prevent the move of the female contact terminal 66 toward its insertion region 86 when a force is applied to the wire 70 in a direction reverse the insertion direction of the female contact terminal 66.

The slope 80 enables the female contact terminal 66 to raise in the cavity and being placed on the insertion region 86, in a position, called insertion position, which is at a defined radial distance from the locking region 84.

The locking region 84 is intended to receive and hold the female contact terminal 66 in a position, called locking position, where it cannot be moved in the reverse insertion direction and thus not be extracted from the cavity 56.

The insertion region 86 which is, in the direction perpendicular to direction XX, at a different level than the locking region 84, forms a passage for the conduct of the female contact terminal 66 toward the locking region 84.

The locking region 84, the step 82 and the insertion region 86 are fixed, immobile and rigid so that they are easy to mould.

The cap 32, shown on figures 6 and 7, is designed to be suitable for being manufactured in a single piece by moulding, generally of plastic material. The cap 32 may be regarded as having a front wall 87 extended by a perpendicular end skirt 88.

The front wall 87 is formed with plugging holes 90 of sufficient size to allow the complementary male terminal to pass through. The plugging holes 90 are positioned for being placed in front of the cavities 56 when the cap 32 is mounted on the housing 30.

The front wall 87 prevents the female contact terminal from going out of the cavity 66.

A chamfer 92 delimits the plugging holes 90 to make the access easier for the complementary male terminal to be plugged into the female contact terminal 66.

The front wall 87 is also provided with extracting holes 94 formed under each plugging holes 90 and being placed in front of the locking region 84 of the floor wall when the cap 32 is mounted on the housing 30. The extracting holes 94 are designed for inserting a tool 95 in order to extract the female contact terminal 66, as explained later on in the description.

The front wall 87 of the cap is also provided with resilient tongues 64 projecting out of it and extending through the rear of the cap 32 parallel to the skirt 88. When the cap 32 is in a pre-locking position, as shown in figure 8, each resilient tongue 64 is adapted to drive a female contact terminal 66 toward the locking region 84 in a locking position.

To this end, the end of each resilient tongue 64 comprises an inclination or a slope 98 directed for pushing the end of the female contact terminal 66 in a direction perpendicular to the insertion direction X-X.

Each resilient tongue 64 is adapted to engage in corresponding recess 62 of the cavity to hold the female contact terminal 66 located in this cavity 56, to lay on its locking region 84, in the locking position.

When the cap 32 is in the locking position, the end of the resilient tongue 64 is inserted in the recess 62. A longitudinal surface 99 of the resilient tongue is in contact with the top surface of the plugging cage 72 in order to lay the female contact terminal 66 on the locking region 84 and thus ensure the locking of the female contact terminal 66 into the cavity 56.

A flat portion of the skirt 88 includes a detent plate 100 designed to fix the cap 32 to the front face 38 of the housing. The extremity of the detent plate 100 which is assembled to the housing is provided with the hook 54. This hook 54 extends perpendicularly to the plate 100 to catch the primary 50 or the secondary notch 52 to assemble the cap 32 to the housing 30 in a pre-locking position or respectively in a locking position. The opposite extremity of the detent plate 100 is provided with a protuberance 102 for manipulating the detent plate 100 and controlling the position of the hook 54.

The way in which the connector is mounted stands directly from the foregoing. First of all, the cap 32 is mounted on the front face 38 of the housing in the pre-locking position, illustrated on figure 8. In this pre-locking position, the hook 54 is engaged in the primary notch 50.

The female contact terminal 66 is introduced into the cavity 56 from the rear face 40 of the housing. The female contact terminal 66 is driven in contact to the ceiling wall 60 of the cavity by the slope 80.

The end of the female contact terminal 66 comes in abutment against the slope 98 of the resilient tongue. Upon application of an axial insertion force on the wire 70, by an operant, the resilient tongue 64 is bent rearward and the resistance force resulting from this flexion pushes the extremity of the plugging cage 72 in a radial direction, namely in a direction perpendicular to the insertion direction X-X in order to place the female contact terminal 66 on the locking region 84, as shown on figure 9.

In this position, the border 74 of the female contact terminal 66 is in abutment against the retainer shoulder 86 of the cavity 56 to prevent the extraction of the female contact terminal 66 when a force is axially applied on the wire 70 in the reverse insertion direction.

When all female contact terminals 66 have been inserted in all cavities 56, the cap 32 is placed in the locking position, as shown on figure 10.

To this end, the hook 54 is engaged with the secondary notch 52. In the case of one or more of the female contact terminal is not disposed on the locking region 84, the end of the resilient tongues 64 located front on the cavities comprising this incorrectly inserted contact, comes in abutment against the surface of the front face 38 as shown in figure 11.

The cap 32 cannot be fixed to the front face of the housing. The cap 32 stays in the pre-locking position so that the complementary electrical connector cannot be plugged in the electrical connector 28, thus, the cap 32 ensures the TPA function (Terminal Position Assurance).

When one female contact terminal 66 has to be extracted from the cavity 56, the operant manipulates the protuberance 102 of the detent plate, and engages the hook 54 with the primary notch 50 to place the cap 32 in a pre- locking position. A stud of the specific tool 95 is inserted between the plugging cage 72 of the female contact terminal 66 and the locking region 84.

When the stud is introduced under the plugging cage 72, the resilient tongue 64 is pushed back rewards. The female contact terminal 66 is elevated and comes in contact with the ceiling wall 60 of the cavity, as shown in figure 12.

Since the stud has a thickness corresponding to the high of the retainer shoulder 76, the female contact terminal 66 is elevated at the same level than the inserting region 86. The female contact terminal 66 can then be taken out from the cavity 56 by pulling the wire 70 rearwards. Figure 19 illustrates a female 28 and a male 124 contact engaged together.

Due to the rigidity, the fixation and the immobility of the embossment 78, the electrical connector has a higher resistance to the traction force exerced on the wire. A second embodiment of the electrical connector is illustrated in figures 13 and 14.

In this embodiment, the support wall 58 is provided with a single protrusion 104 positioned on the locking region 84. The rear face of the protrusion 104 comprises a slope 106, and the front face of the protrusion 104 comprises an abrupt step 108.

The protrusion 104 is designed to be introduced into the hole 71 of the plugging cage 72. One edge 110 of the hole 71 is in abutment against the step 108 to prevent the female contact terminal 66 from being extracted backwards from it, when an operator has put the electrical connector in a locking position. The slope 106 enables the raising of the plugging cage 72 on the protrusion 104.

Since the cavity 56 has a section approximately of the same dimension as the section of the contact terminal 72, dimensions and position of the recess

62 relatively to the protrusion 104 are defined to allow the raising, in an inclined position relative to the direction XX, of the plugging cage when it is brought on the protrusion 104, a portion at least of the crimping portion of the terminal remaining on the level of floor wall 58. For this purpose a lower corner 112 of the recess 62 adjacent to the cavity 66 can be chamfered.

The cap 32 has the same shape, design and function as the cap 32 of the first embodiment of the electrical connector according to the invention.

A third embodiment of the electrical connector is illustrated in figure 15. In this embodiment, the support wall 58 comprises a protrusion 104 positioned on the locking region 84 and an embossment 78 positioned on the insertion region 86. The protrusion 104 forms a step and is adapted to be accommodate in the hole 71 of the plugging cage to prevent the extraction of the female contact terminal.

The slope 80 of the embossment is adapted to guide the female contact terminal 66 to raise in the cavity to bring the plugging cage 72 on the protrusion 104.

Like in the first embodiment, the cavity has a section larger than the section of the contact terminal 72.

According to a fourth embodiment of the electrical connector, illustrated in figure 16, the support wall 58 is flat and comprises a single protrusion 104 forming a step preventing the extraction of the contact terminal. The cavity 56 has a section larger than the dimension of the section of the contact terminal 72. The slope 106 of the protrusion enables the raising of the plugging cage 72 and the positioning of the female contact terminal 66 in the locking region. According to a fifth embodiment of the electrical connector illustrated in figure 17, the support wall 58 is provided with an embossment 78 having the same shape, design, position and function as the embossment 78 of the first embodiment of the invention.

The cavity 56 has a section larger than the dimension of the section of the contact terminal 72.

The upper wall 34 and the lower wall 36 of the housing have the same length such that the front face 38 is flat.

In this embodiment, the cap 32 is not assembled in contact to the front face 38 of the housing 30 but in a passage 114 extending from the upper wall 34 of the housing to the inner of the cavity 56. The end of a tab 116 of the cap 32 is adapted to come in abutment against the upper face of the plugging cage 72 to lay the plugging cage 72 on the locking region 84 and thus ensure the locking of the female contact terminal into the cavity 56. A front wall 118 extends in the continuation of the front face 38 of the housing. The front wall 118 closes partially the extremity of the cavity 56.

The front wall 118 is formed with a plugging hole 120 of sufficient size to allow the complementary male terminal to pass through.

An opening 122 is provided between the extremity of the front wall 118 and the support wall 58 of the cavity. The opening 122 is designed for inserting a stud in order to extract the female contact terminal 66 out of the housing. The opening 122 has the same function as the opening 94 described in relation to the first embodiment of the invention.

According to a sixth embodiment of the invention, illustrated in figure 18, the protrusion 104 is positioned at the end of the support wall 58 in the continuation of the front wall 38 of the housing 30. The front face of the protrusion 104 forms a step preventing the extraction of the contact terminal 66.

The cavity 56 has a section approximately of the same dimension as the section of the contact terminal 72 and a chamfer 112 is provided on the housing 30 between the recess 62 and the cavity 56 for enabling the raising of the plugging cage 72 and the positioning of the female contact terminal 66 in the locking region.

The electrical connector 228 according to a seventh embodiment of the invention is illustrated in figure 20. According to this embodiment, the upper wall 234 of the housing 230 is larger than the lower wall 236 and is in offset with respect to the lower wall 236 so as to project out of the front face 238 of the housing, as shown in figure 20.

Each cavity 256 extending from the front face 238 to the rear face 240, may be regarded as comprising a flat floor wall 258 formed on the inner lower wall 236 of the housing and a ceiling wall 260 formed on the inner upper wall 234.

The ceiling wall 260 of each cavity is provided with an embossment

261 having a rectangular section and projecting out of the ceiling wall 260 into the cavity 256. The front end 263 of the embossment 261 is located in front of the front end of the lower wall 236. A recess 262 is formed in the portion of the upper wall 234 extending beyond the front end 263 of the embossment 261.

This recess 262 opens on the front face 238 of the housing and in the corresponding cavity 256 and is dimensioned to accommodate the extremity of a resilient tongue 264 of the cap 232. The corner of the upper wall 234 behind the recess 262 is chamfered to facilitate the insertion of the tongue 264.

The cavities 256 are adapted to accommodate female contact terminals 266. The rear face 240 is conventionally the location for introducing the female contact terminals 266 into the cavities 256 along the direction X-X.

Each female contact terminal 266 has a general tubular shape provided with an electrical wire 270, a metallic plugging cage 272 and a crimping portion 268 located between the electrical wire 270 and the metallic plugging cage 272. The metallic plugging cage 272 is adapted to receive a complementary male terminal.

The bottom face of the crimping portion 268 is in the continuity of the bottom face of the wire 270.

The bottom face of the plugging cage 272 is offset with respect to the bottom face of the crimping portion 268 to form a shoulder 274. The shoulder 274 extends along a transversal and radial plane of the female contact terminal. This shoulder 274 is designed to abut against an abutment area 276 of the housing adjacent to the front corner 277 of the lower wall 286.

The cap 232 is adapted to be assembled to the housing 230 in a pre- locking position or in a locking position.

The cap 232 may be regarded as having a front wall 278 provided with resilient tongues 264 and support walls 282 both projecting out of the front wall 278 and extending through the rear of the cap 232 perpendicular to the front wall 278. When the cap 232 is assembled to the housing 230 in a locking position, each support wall 282 is located below each floor wall 258 of the corresponding cavity. Specifically, the upper face 284 of the support wall 282, in regard to the resilient tongue 264, is located at a lower level than the upper face 286 of the floor wall 258. The cap 232 is affixed to the housing 230 such that the difference of level between the upper face 286 of the floor wall of the housing and the upper face 284 of the support wall of the cap, corresponds approximately to the difference of level between the bottom face of the crimping portion 268 and the bottom face of the plugging cage 272.

The floor wall 258 which is at a higher level than the support wall 282, forms a passage for the conduct of the female contact terminal 266 toward the support wall.

The support wall 282 is intended to receive the plugging cage 272, so that the female contact terminal 266 is in a position where it cannot be moved in the reverse insertion direction and thus not be extracted from the cavity 256.

When the cap 232 is assembled to the housing 230 in a locking position, the corner 277 of the housing provides a step or a discontinuity in the alignment of the floor wall 258 of the housing, located anterior to the corner 277, considering the insertion direction X-X, and the floor wall 282 of the cap 232, located posterior to the corner 277.

The area 276 forms a retainer shoulder intended to engage with the shoulder 274 of the female contact terminal 266 to prevent the female contact terminal 266 to be extracted backward from the housing, when an operator has put the electrical connector in a locking position.

The support wall 282, the corner 277 and the floor wall 258 are fixed, immobile and rigid so that they are easy to mould.

The front wall 278 prevents the female contact terminal from going in the insertion direction and thus be extracted from the front end of the cavity 256. The front wall 278 of the cap is formed with plugging holes 290 of sufficient size to allow the complementary male terminal to pass through. The plugging holes 290 are positioned for being placed in front of the cavities 256 when the cap 232 is mounted on the housing 230.

A chamfer 292 delimits the plugging holes 290 to make the access easier for the complementary male terminal to be plugged into the female contact terminal 266.

The front wall 278 is also provided with extracting holes 294 formed under each plugging holes 290 and being placed adjacent to the support wall 282. The extracting holes 294 are designed for inserting a tool in order to extract the female contact terminal 266.

When the cap 232 is assembled to the housing 230 in a pre-locking position, each resilient tongue 264 is adapted to drive a female contact terminal 266 toward the support wall 282, in a locking position.

To this end, the end of each resilient tongue 264 comprises an inclination or a slope 298 directed for pushing the end of the female contact terminal 266 in a direction perpendicular to the insertion direction X-X.

Each resilient tongue 264 is adapted to engage in corresponding recess 262 of the cavity to hold the plugging cage 272 to lay on the support wall 282 of the cap 232 in the locking position.

When the cap 232 is in the locking position, the end of the resilient tongue 264 is inserted in the recess 262. A longitudinal surface 299 of the resilient tongue is in contact with the top surface of the plugging cage 272 in order to lay the plugging cage 272 on the support wall 282 and thus ensure the locking of the female contact terminal 266 into the cavity 256.

The terms "upper" and "lower" do not limit the scope of the invention to a way of fixing or positioning the connector.

The invention is described in connection to a female contact terminal but it can also be apply on a male contact terminal.

Claims

1. Electrical connector (28 ; 228) comprising:

- a housing (30 ; 230) having at least a cavity (56 ; 256) designed to guide a contact terminal (66 ; 266) and first locking means (76, 82 ; 104, 108 ; 276) designed to cooperate with the contact terminal (66 ; 266) to prevent the extraction of the contact terminal (66 ; 266); and

- second locking means (54, 64, 94, 98 ; 116 ; 232, 282) adapted to be connected to the housing (30 ; 230); characterized in that the first locking means (76, 82 ; 104, 108 ; 276) are rigid and fixed with respect to the housing (30 ; 230); and in that the second locking means (54, 64, 94, 98 ; 116 ; 232, 282) are adapted to lay on the contact terminal (66 ; 266) to retain the contact terminal (66 ; 266) in abutment against the first locking means (76, 82 ; 104, 108 ; 276).

2. Electrical connector (28 ; 228) according to claim 1 , wherein said second locking means (54, 64, 94, 98 ; 116 ; 232, 282) are adapted to drive the contact terminal (66 ; 266) along a direction perpendicular to the direction of introduction (X-X) of each contact terminal (66 ; 266) into each cavity (56 ; 256).

3. Electrical connector (28) according any of the claims 1 and 2, wherein the second locking means (54, 64, 94, 98 ; 116 ; 232, 282) are molded in a unitary construction independently from the housing (30).

4. Electrical connector (28) according to claim 1 , wherein one support wall (58) of each cavity (56) comprises an insertion region (86) for guiding the contact terminal (66) into the cavity, a locking region (84) for supporting the contact terminal (66), into the cavity, and the first locking means (76, 82 ; 104, 108) comprises a step preventing the extraction of the contact terminal (66), when the contact terminal (66) is positioned on the locking region (84), the step (76, 82 ; 108) being formed stationary, fixed and rigid with respect to the locking region (84).

5. Electrical connector (28) according to any of the claims 3 and 4, wherein the second locking means (54, 64, 94, 98) are intended to be set in a pre-locking or a locking position with respect to the housing (30) and wherein during the insertion of each contact terminal (66) into each cavity (56), said second locking means (54, 64, 94, 98) are adapted to guide each contact terminal (66) toward each locking region (84), when said second locking means (54, 64, 94, 98) are disposed in a pre-locking position.

6. Electrical connector (28) according to claim 5, wherein the second locking means (54, 64, 94, 98) comprise at least a resilient tongue (64) provided with a slope (98) directed to drive the contact terminal (66) trough the locking region (84), and wherein when said second locking means (54, 64, 94, 98) are disposed in a pre-locking position, the flexion resistance of the resilient tongue (64) is adapted to push the contact terminal (66) toward the locking region (84).

7. Electrical connector (28) according the claim 6, wherein the housing (30) comprises a recess (62) formed in a wall (60) opposite the support wall (58), the dimension of the recess (62) being adapted to accommodate the end of the resilient tongue (64) to lock the contact terminal (66) in the locking position, when said locking means (54, 64, 94, 98) are disposed in the locking position.

8. Electrical connector (28) according any of the claims 6 and 7, wherein the resilient tongue (64) comprises a face (99) adapted to lay on a face of the contact terminal (66) opposite the face in contact with the locking region (84), when said locking means are disposed in a locking position.

9. Electrical connector (28) according to any of the claims 6 to 8, wherein the resilient tongue (64) is adapted to come in abutment against a front face (38) of the housing (30) when the contact terminal (66) is incorrectly inserted in the cavity (56).

10. Electrical connector (28) according any of the claims 5 to 9, wherein the housing (30) is provided with snapping means (50, 52) and the second locking means (54, 64, 94, 98) are provided with corresponding snapping means (54) to place the second locking means (54, 64, 94, 98) in a pre-locking position or a locking position.

11. Electrical connector (28) according to any of the claims 3 to 10, wherein the second locking means (54, 64, 94, 98) comprises at least a hole (94) for introduction of a tool (95) positioned on a face of the locking means (54, 64, 94, 98) opposite the locking region (84) such that the tool (95) is adapted to be insert between the bottom face of the contact terminal (66) and the locking region (84) to drive the contact terminal (66) in alignment with the insertion region (86) for allowing its extraction.

12. Electrical connector (28) according to any of the claims 3 to 11 , wherein the first locking means (76, 82) comprises a single step positioned between the locking region (84) and the inserting region (86).

13. Electrical connector (28) according to any of the claims 3 to 11 , wherein the first locking means (104, 108) comprises a protrusion (104) positioned on the locking region (84), the protrusion (104) having a shape and a size adapted to be inserted in a hole (71) of the contact terminal (66), a portion of the protrusion (104) forming a step (108) preventing the extraction of the contact terminal out of the housing (30).

14. Electrical connector (28) according to claim 13, wherein the cavity (56) has a section approximately of the same dimension as the section of the contact terminal (72) and wherein the housing (30) comprises a recess (62, 112) formed in a wall (60) opposite the support wall (58), the dimension of the recess (62, 112) being adapted to allow the contact terminal (66) to be brought on the top of the protrusion (104) during its moving towards the locking region (84).

15. Electrical connector (28) according to claim 13, wherein the support wall (58) comprises an embossment (78) positioned on the insertion region (86) having a slope (80) directed towards a wall (60) opposite the support wall (58), the slope (80) being adapted to guide the contact terminal (66) on the top of the protrusion (104), during its moving towards the locking region (84).

16. Electrical connector (28) according to claim 3, wherein the housing (30) comprises a passage (114) extending from the cavity (56) to a wall (60) opposite the support wall (58), and adapted to accommodate the second locking means (116) to prevent the extraction of the contact terminal (66).

17. Electrical connector (228) according to claim 1 , wherein the first locking means (276) comprises an abutment area located on an end face (238) of the housing (230); and the second locking means (232) are intended to accommodate a first portion (272) of the contact terminal (266).

18. Electrical connector (228) according to claim 17, wherein the second locking means (232) comprises a support wall (282) adapted to support the first portion (272) of the contact terminal (266) , the cavity (256) comprising a floor wall (258) adapted to support a second portion (268, 270) of the contact terminal (266) and wherein the second locking means (232) are assembled to the housing (230) such that the support wall (282) is positioned at a different level than the floor wall (258) to define a step there between, the step being the abutment area (276).

19. Electrical connector (228) according to claim 17, wherein the first portion (272) of the contact terminal (266) comprises a plugging cage (272) defining a border (274) which is in abutment against the abutment area (276).

20. Process for assembling a contact terminal (66 ; 266) to an electrical connector (28 ; 228), wherein the process comprises the following steps:

- providing the electrical connector (28 ; 228) comprising a housing (30 ; 230) having at least a cavity (56 ; 256) and first locking means (76, 82 ; 108 ; 276) rigid and fixed with respect to the housing (30 ; 230); - providing at least a contact terminal (66 ; 266) having at least an edge (74,110);

- guiding the or each contact terminal (66 ; 266) into the or each cavity (56 ; 256) along a direction of introduction (X-X) until the edge (74,110) of the contact terminal (66) reaches the first locking means (76, 82, 108); - guiding the contact terminal (66) along a direction perpendicular to the direction of introduction (X-X) until the edge (74,110) of the contact terminal (66) comes in abutment against the first locking means (76, 82, 108) to prevent the extraction of the contact terminal (66).

- providing second locking means (54, 64, 94, 98 ; 116 ; 232, 282); - assembling the second locking means (54, 64, 94, 98 ; 116 ; 232,

282) to the housing (30 ; 230); and

- putting the second locking means (54, 64, 94, 98 ; 232, 282) against the contact terminal (66 ; 266) to retain the contact terminal (66 ; 266) in abutment against the first locking means (76, 82 ; 108 ; 276).