Patent Grant
10320099
The present invention relates generally to electrical connectors. More specifically, the present invention relates to a connector with an asymmetric base section.
Some electrical systems incorporate a number of electrical modules that are interconnected with one another via a backplane circuit board. Connectors on the modules facilitate insertion of the modules into complementary connectors on the backplane.
Each connector may be configured to couple one or more signals between the electrical module and the backplane. Signals transferred via the connector may be relatively high-frequency signals. Special care must be taken in the construction of the connector to minimize degradation of any signals communicated over the connector.
In one aspect, an electrical contact includes a base that includes first and second side edges, and a forward edge that extends between the first and second side edges. At least one contact arm extends from the forward edge of the base for making electrical contact with a contact pad. Each of the first and second side edges defines one or more protrusions configured to engage an interior portion of a connector housing for securing the electrical contact within the connector housing. The one or more protrusions on the first side edge are asymmetrically arranged with respect to the one or more protrusions on the second side edge, such that respective centers of each of the one or more protrusions on the first side edge are misaligned with respective centers of each of the one or more protrusions on the second side edge.
In a second aspect, an electrical connector assembly includes a first connector and a second connector configured to be mated to the first connector. The second connector includes a plurality of electrical contacts. At least some of the electrical contacts include first and second side edges, and a forward edge that extends between the first and second side edges. At least one contact arm extends from the forward edge of the base for making electrical contact with a contact pad. Each of the first and second side edges defines one or more protrusions configured to engage an interior portion of a connector housing for securing the electrical contact within the connector housing. The one or more protrusions on the first side edge are asymmetrically arranged with respect to the one or more protrusions on the second side edge, such that respective centers of each of the one or more protrusions on the first side edge are misaligned with respective centers of each of the one or more protrusions on the second side edge.
In a third aspect, an electrical product includes an electrical connector assembly. The electrical connector assembly includes a first connector and a second connector configured to be mated to the first connector. The second connector includes a plurality of electrical contacts. At least some of the electrical contacts include first and second side edges, and a forward edge that extends between the first and second side edges. At least one contact arm extends from the forward edge of the base for making electrical contact with a contact pad. Each of the first and second side edges defines one or more protrusions configured to engage an interior portion of a connector housing for securing the electrical contact within the connector housing. The one or more protrusions on the first side edge are asymmetrically arranged with respect to the one or more protrusions on the second side edge, such that respective centers of each of the one or more protrusions on the first side edge are misaligned with respective centers of each of the one or more protrusions on the second side edge.
The electrical contact 10 includes a base 12 and one or more arms 14 that extend from the base 12. The base 12 extends a length along a central longitudinal axis 16 of the base 12. In the exemplary embodiment, the base 12 extends the length from an arm end 18 of the base 12 to a mounting end 20 of the base 12. The arms 14 extend outwardly from the arm end 18 of the base 12. As will be described in more detail below, the arms 14 are configured to mate with a mating contact 22 (
The base 12 may include one or more mounting structures for mounting the base 12 within a housing (e.g., the housing 108 shown in
In the exemplary embodiment, the electrical contact 10 includes a mounting segment 26 that extends from the mounting end 20 of the base 12. The mounting segment 26 is configured to mount the electrical contact 10 to a circuit board (not shown). Alternatively, the electrical contact 10 is configured to terminate the end (not shown) of an electrical cable (not shown) at the mounting end 20 of the base 12 or is configured to mate with another mating contact (not shown) at the mounting end 20 of the base 12 (i.e., in addition to mating with the mating contact 22 at the arms 14). In the exemplary embodiment, the mounting segment 26 is an eye-of-the needle press-fit pin that is configured to be press fit into an electrical via (not shown) of the circuit board. But the mounting segment 26 may additionally or alternatively include any other structure for mounting the electrical contact 10 to the circuit board such as, but not limited to, solder tail, a surface mount pad (whether or not solder is used), another type of press-fit pin, and/or the like. Although the length of the base 12 is shown as being approximately straight, alternatively the length of the base 12 includes one or more bends such as, but not limited to, an approximately 90° bend and/or the like). For example, in some embodiments, the base 12 includes an approximately 90° bend such that the electrical contact 10 is a right-angle contact designed for use within an orthogonal electrical connector.
The electrical contact 10 may include any number of the arms 14. In the exemplary embodiment, the electrical contact 10 has a fork-like structure that includes two of the arms 14, namely the arms 14a and 14b. Each of the arms 14a and 14b extends a length outwardly from the base 12 along the central longitudinal axis 16 of the base 12. In the exemplary embodiment, the arms 14 extend the lengths outwardly from the arm end 18 of the base 12 to free ends 28 of the arms 14, as can be seen in
Each of the arms 14a and 14b includes one or more mating bumps 30 at which the arm 14 mates with the mating contact 22. In the exemplary embodiment, the arm 14a includes two mating bumps 30a and 30b, and the arm 14b includes two mating bumps 30e and 30d. But the arm 14a may include any number of the mating bumps 30, and the arm 14b may include any number of the mating bumps 30 (whether or not the number of mating bumps 30 of the arm 14b is the same as the number of mating bumps 30 of the arm 14a). Each of the mating bumps 30a, 30b, 30e, and 30d may be referred to herein as a “first” mating bump and/or a “second” mating bump.
Each mating bump 30 includes a mating surface 32. Specifically, the mating bumps 30a, 30b, 30e, and 30d include respective mating surfaces 32a, 32b, 32e, and 32d. Each mating bump 30 engages the mating contact 22 at the mating surface 32 thereof to establish an electrical connection with the mating contact 22. Each of the mating surfaces 32a, 32b, 32e, and 32d may be referred to herein as a “first” mating surface and/or a “second” mating surface. In the exemplary embodiment, the mating contact 22 is a contact pad of a circuit board 44 (
The electrical contact 10 may be fabricated from (i.e., include) any electrically conductive material such as, but not limited to, copper, nickel, gold, silver, aluminum, tin, and/or the like. In some embodiments, at least a portion of the electrical contact 10 (e.g., the arms 14a and/or 14b, the base 12, the mounting segment 26, the mating bumps 30a, 30b, 30e, and/or 30d, portions thereof, and/or the like) includes a base material that is coated with an electrically conductive surface coating (e.g., a plating and/or the like). The electrically conductive surface coating may be fabricated from any electrically conductive material such as, but not limited to, copper, nickel, gold, silver, aluminum, tin, and/or the like.
Optionally, one or more of the arms 14 is a spring that is configured to be resiliently deflected from a resting position when the arm 14 is mated with the mating contact 22. In the exemplary embodiment, each of the arms 14a and 14b is a resiliently deflectable spring. The arms 14a and 14b are shown in the resting positions in
Referring now solely to
As can be seen in
Referring now to
Referring now solely to
In the exemplary embodiment, each of the mating bumps 30e and 30d of the arm 14b is defined by a respective bend 36e and 36d in the arm 14b. But the mating bumps 30e and 30d are not limited to being defined by a bend of the arm 14b. Rather, in alternative to being defined by a bend, each of the mating bumps 30e and 30d may be defined by another structure such as, but not limited to, a segment of increased thickness and/or the like.
Referring now to
Referring now solely to
The different axial locations of the mating bumps 30 and the spacing between the mating bumps 30 is selected to provide the arms 14a and 14b with different predetermined geometries. In addition or alternatively to the different spacings and/or axial locations, the positions, orientations, dimensions (e.g., the lengths, widths, and/or the like), and/or the like of the arms 14a and/or 14b and/or other various components of the arms 14a and/or 14b (e.g., the base segment 34, any necked-down segments, and/or the like) may provide the arms 14a and 14b with the different predetermined geometries.
The different predetermined geometries of the arms 14a and 14b provide the arms 14a and 14b with different predetermined vibrational responses than each other. In other words, the arms 14a and 14b will vibrate differently (e.g., at different frequencies and/or the like) than each other in response to the same vibrational force exerted on the arms 14a and 14b. For example, the arms 14a and 14b may have different natural frequencies and/or the arms 14a and 14b may vibrate differently in response to the same forced vibration exerted on the arms 14a and 14b. It should be understood that in embodiments wherein the electrical contact 10 includes more than two of the arms 14, each arm 14 may be provided with a different vibrational response than each other or at least one of the arms 14 may have the same vibrational response as at least one other arm 14.
Each base 612a,b includes first and second side edges 620a,b and 625a,b. The forward edges 615a,b extend between respective first and second side edges 620a,b and 625a,b.
Each of the first and second side edges 620a,b and 625a,b defines one or more protrusions 630a,b and 635a,b (i.e., interference tabs 24) configured to engage an interior portion of a housing for securing the electrical contacts 610a,b within the housing.
In
In
As noted above, symmetrical arrangement of protrusions may be desired to avoid twisting of electrical contacts. However, in this case, applicants have determined that other features of the electrical contacts 610b help to prevent twisting, thus allowing for the asymmetrical arrangement of the protrusions 630b, 635b.
As more clearly shown in
In an exemplary implementation, where the ideal impedance is about 100 ohms, when a first electrical contact 610b is arranged adjacent to a second electrical contact 610b, such that a distance D1 between respective center axis of the respective bases sections is about 1.8 mm, an impedance between the base of the first electrical contact 610b and the base of the second electrical contact 610b may be greater than about 96Ω. In this implementation, the distance, D2, between the first edge of the base 612b of the first electrical contact 610b and the second edge of the base 612b of the second electrical contact 610b may vary by less than 28%.
The arms 14a and 14b are engaged with the mating contact 22. Specifically, the mating surfaces 32a, 32b, 32c, and 32d of the mating bumps 30a, 30b, 30c, and 30d, respectively, are each engaged with the mating contact 22. The engagement between the arms 14a and 14b and the mating contact 22 establishes an electrical connection between the electrical contact 10 and the mating contact 22. As can be seen in
The different axial locations of the mating bumps 30a and 30b of the arm 14a along the central longitudinal axis 16 may cause the mating bumps 30a and 30b to have different predetermined vibrational responses than each other. In other words, the mating bumps 30a and 30b may vibrate differently (e.g., at different frequencies and/or the like) than each other at the different corresponding points of engagement with the mating contact 22. For example, the mating bumps 30a and 30b may have different natural frequencies and/or may vibrate differently in response to a forced vibration exerted on the arm 14a. Similarly, the different axial locations of the mating bumps 30e and 30d of the arm 14b along the central longitudinal axis 16 may cause the mating bumps 30c and 30d to vibrate differently (e.g., at different frequencies and/or the like) than each other at the different corresponding points of engagement with the mating contact 22. For example, the mating bumps 30c and 30d may have different natural frequencies and/or may vibrate differently in response to a forced vibration exerted on the arm 14b. It should be understood that in embodiments wherein the arm 14a and/or the arm 14b includes more than two of the mating bumps 30, each mating bump 30 of each arm 14 may be provided with a different vibrational response than each other mating bump 30 of the same arm or at least one of the mating bumps 30 of an arm 14 may have the same vibrational response as at least one other mating bump 30 of the same arm 14.
Referring again to
The redundant electrical connection provided by the two mating surfaces of an arm 14 may facilitate preventing or reducing data loss caused by wear to the electrical contact 10 and/or the mating contact 22 such as, but not limited to, wear caused by contact fretting and/or the like. For example, the redundant electrical connection provided by the two arms 14 may facilitate preventing or reducing data transmission errors. The electrical contact 10 may thus be adapted for relatively high-speed data connections such as, but not limited to, data speeds of at least approximately 5 gigabaud (G-baud).
In addition or alternatively to providing two or more different wear rates, providing the at least two separate points of engagement with the mating contact 22 may reduce the force exerted on the mating contact 22 by the arm 14 at any single point of engagement with the mating contact 22. In other words, the force exerted on the mating contact 22 at each of the mating surfaces 32 of the same arm 14 may be less than if the arm 14 only engaged the mating contact 22 at a single point. Such a reduction in the force exerted on the mating contact 22 at any single point of engagement may reduce the amount of wear at such a single point of engagement, which may facilitate preventing the arm 14 from being electrically disconnected from the mating contact 22 because of wear to the mating contact 22. In addition or alternatively, such a reduction in the force exerted on the mating contact 22 at any single point of engagement (and/or the different axial locations of the mating bumps 30) may reduce the insertion and/or extraction force required to mate the electrical contact 10 with the mating contact 22, which may eliminate or reduce damage to the electrical contact 10 and/or the mating contact 22 as the contacts 10 and 22 are mated together.
Moreover, providing two or more different wear rates may facilitate preventing a higher resistance connection between the electrical contact 10 and the mating contact 22 that is caused by wear to the electrical contact 10 and/or the mating contact 22. For example, providing two or more different wear rates may reduce the amount of wear to an electrically conductive surface coating (e.g., a plating and/or the like) that extends on the mating contact 22 and/or the arm 14. Reducing the amount of wear to the coating(s) may prevent the coating(s) from being worn through. If the coating(s) is worn through, engagement with a base material of the mating contact 22 and/or the electrical contact 10 may increase the resistance of the electrical connection between the mating contact 22 and/or the electrical contact 10 above a desired level. Accordingly, by reducing the amount of wear to an electrically conductive coating that extends on the mating contact 22 and/or the arm 14, the at least two separate points of engagement between the arm 14 and the mating contact 22 may prevent the connection between the electrical contact 10 and the mating contact 22 from having a higher resistance than is desired.
The different predetermined vibrational responses of the arms 14a and 14b may facilitate preventing the electrical contact 10 from being electrically disconnected from the mating contact 22 because of wear to the mating contact 22. For example, the different predetermined vibrational responses of the arms 14a and 14b may cause wear to the mating contact 22 at the different rates. Accordingly, even if a first of the arms 14 of the electrical contact 10 has worn the mating contact 22 such that the first arm 14 no longer makes adequate or any electrically connected to the mating contact 22, the second arm 14 may have caused less or no wear to the mating contact 22 such that the second arm 14, and thus the electrical contact 10, remains adequately electrically connected to the mating contact 22. The different predetermined vibrational responses of the arms 14a and 14b may thus enable one of the arms 14 to provide a backup that maintains the electrical connection with the mating contact 22 upon electrical failure or a reduced quality of electrical connection of the other arm 14. The redundant electrical connection provided by the two arms 14 may facilitate preventing or reducing data loss caused by wear to the electrical contact 10 and/or the mating contact 22 such as, but not limited to, wear caused by contact fretting and/or the like. For example, the redundant electrical connection provided by the two arms 14 may facilitate preventing or reducing data transmission errors. The electrical contact 10 may thus be adapted for relatively high-speed data connections.
Although shown and described herein with respect to a contact pad of a circuit board, it should be understood that the electrical contact 10 may be used with mating contacts having other structures such as, but not limited to, a blade, a bar, an arm, a spring, and/or the like. The embodiments of the electrical contact 10 shown and/or described herein may be used to facilitate preventing the electrical contact 10 from being electrically disconnected from such other mating contact structures because of wear to the mating contact in a substantially similar manner to that described and/or illustrated herein with respect to the mating contact 22. Moreover, in a substantially similar manner to that described and/or illustrated herein with respect to the mating contact 22, the embodiments of the electrical contact 10 shown and/or described herein may be used to facilitate preventing a higher resistance connection between the electrical contact 10 and such other mating contact structures caused by wear to the electrical contact 10 and/or the mating contact.
The electrical connector assembly 100 includes an electrical connector 102 and a mating connector 104. The connectors 102 and 104 are complementary such that the connectors 102 and 104 are configured to mate together to establish an electrical connection therebetween. In the exemplary embodiment, the electrical connectors 102 and 104 are configured to be mounted on circuit boards (not shown).
The mating connector 104 includes a housing 106 and a plurality of the circuit boards 44 held by the housing 106. The circuit boards 44 include a plurality of the mating contacts 22 (
The embodiments described and/or illustrated herein may provide an electrical contact that is less likely to be electrically disconnected from a mating contact because of wear to the mating contact. The embodiments described and/or illustrated herein may provide an electrical contact that experiences less wear and/or causes less wear to a mating contact with which the electrical contact mates. For example, the embodiments described and/or illustrated herein may provide an electrical contact that reduces or eliminates wear caused by contact fretting. The embodiments described and/or illustrated herein may provide an electrical contact that prevents or reduces data loss caused by wear to the electrical contact and/or a mating contact with which the electrical contact mates. The embodiments described and/or illustrated herein may provide an electrical contact that provides a reliable and relatively high-speed data connection in relatively rugged environments. The embodiments described and/or illustrated herein may provide an electrical contact having a reduced insertion and/or extraction force. The embodiments described and/or illustrated herein may provide an electrical contact that causes less or no damage to a mating contact and/or the electrical contact as the mating contact and electrical contact are mated together.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the subject matter described and/or illustrated herein should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc., are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the subject matter described and/or illustrated herein should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc., are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
This application claims the benefit of priority to U.S. Provisional Application No. 62/348,651, filed Jun. 10, 2016, the content of which is hereby incorporated by reference in its entirety.
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