Information
-
Patent Grant
-
6547605
-
Patent Number
6,547,605
-
Date Filed
Friday, July 20, 200123 years ago
-
Date Issued
Tuesday, April 15, 200321 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Ta; Tho D.
- Tsukerman; Larisa
Agents
-
CPC
-
US Classifications
Field of Search
US
- 439 492
- 439 494
- 439 499
- 439 701
- 439 402
- 439 403
- 439 406
-
International Classifications
-
Abstract
An electrical connector uses a single flex circuit having two banks of electrical conductors each engaged to a series of terminals disposed or engaged in first and second carriers. The carriers are stacked upon one another and then inserted into a shroud of the electrical connector from a lateral direction. A clip retainer is then inserted from the rear into the shroud of the electrical connector between the first and second carriers to assure the position of the individual terminals within the respective carriers. The single flex circuit is replaced by a plurality of individual electrically insulated conductors in a second embodiment.
Description
TECHNICAL FIELD OF THE INVENTION
This invention relates to an electrical connector, and more specifically to a flex circuit electrical connector.
BACKGROUND OF THE INVENTION
Electrical connectors often have multiple terminals encased within an electrical connector housing or shroud. These terminals are individually crimped to multiple insulated conductors to complete the electrical circuit. Flex circuits or flat electrical conductors arranged along a single sheet of insulating substrate are also known within the art. Terminals are also known to be crimped at the end of the substrate individually engaging each individual conductor. After crimping, these terminals are then placed and locked within the core or housing of an electrical connector. The automation process of assembling an electrical connector which utilizes a flex circuit is limited. Furthermore, forming multiple rows of terminals from a single flex circuit within an electrical connector to establish a desired array or shape is also limited.
SUMMARY OF THE INVENTION
This invention provides a multi conductor electrical connector having two stacked carriers each having an inner face defining a series of grooves which individual house a plurality of terminals configured in rows. The conductor ends of a multi-conductor cable or flex circuit are preferably sonic welded to the rearward ends of the pre-mounted terminals within the carriers. The stacked carriers are inserted through a side clearance of a rearward clip portion of a shroud from a lateral direction and snap fitted therein. Once in the shroud, the opposite ends of the terminals are exposed through a forward opening defined by a forward annular portion of the shroud. Preferably, the electrical connector has a retaining clip which snap fits to, and between, the carriers and engages the terminals, preventing rearward movement of the terminals within the carriers when the terminals engage a mating connector. Longitudinally, extending within each groove is a flex arm which locks the terminals in place.
A feature of the present invention is the ability to engage or sonic weld the conductors of a flex circuit after the terminals are arranged within the carriers, thereby enhancing the manufacturing process. Another feature of the present invention is proving an electrical connector having two rows of terminals engaged to a single flex circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
The presently preferred embodiments of the invention are disclosed in the following description and accompanying drawings wherein:
FIG. 1
is a perspective view of an electrical connector of the present invention;
FIG. 2
is a perspective view of a first and second carrier engaged to a flex circuit;
FIG. 3
is a perspective view of the first and second carriers engaged to the flex circuit when folded over upon one another;
FIG. 4
is an exploded perspective view of the electrical connector;
FIG. 5
is a partial perspective cross sectional view of the electrical connector taken along line
5
—
5
of
FIG. 3
viewing in the direction of the arrows;
FIG. 6
a cross section view of the electrical connector taken along line
6
—
6
of
FIG. 3
viewing in the direction of the arrows;
FIG. 7
is a perspective view of a retaining clip of the electrical connector; and
FIG. 8
is a perspective view of a second embodiment of the electrical connector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to
FIGS. 1-3
, an electrical connector
20
is shown having a flat multi-conductor substrate or flex circuit
22
with two banks
23
of conductors
24
. A series of terminals
28
are positioned within a first insulating carrier
26
, then sonic welded to the ends of each respective individual conductor
24
of the first bank
23
of the flex circuit
22
. Likewise, a second carrier
30
houses a series of terminals
28
engaged to the ends of the conductors
24
of the second bank
23
of the same flex circuit
22
. The flex circuit
22
folds over forming a longitudinally extending return bend
25
stacking the first bank
23
with the second bank
23
. Consequently, the terminals
28
are configured in two stacked rows and, likewise, the first carrier
26
is stacked to the second carrier
30
. The flex circuit
22
is made substantially of an electrical insulating substrate material and the return bend
25
is generally free of metallic conductor strips.
With the first carrier
26
engaged to the second carrier
30
in a stacked formation, the carriers are simultaneously inserted laterally into a shroud
32
. The shroud
32
has a forward annular portion
34
defining a forward opening
48
through which the terminals
28
are exposed for the purpose of electrical engagement to a mating connector, not shown. Shroud
32
has a rearward clip portion
36
defining a side clearance
38
through which the stacked first and second carriers
26
,
30
pass laterally, during assembly as best shown in
FIGS. 4 and 5
. A retaining clip
40
inserts into the rearward clip portion
36
between the first and second carriers
26
,
30
from behind to assure the terminals
28
are properly positioned within the carriers
26
,
30
. The shroud and the carriers are made of an electrical insulating material such as, and preferably, plastic.
Referring to
FIGS. 2-4
, the first and second carriers
26
,
30
are identical to minimize manufacturing costs. Each carrier has an inner face
42
which defines a series of elongated grooves
44
wherein the terminals
28
reside. The grooves
44
extend through a forward face
46
. Face
46
is exposed through the forward opening
48
of the shroud
32
when the electrical connector
20
is assembled. Extending longitudinally forward within each groove
44
is a cantilevered locking arm
49
which flexes to accept the terminal
28
within the groove
44
, and returns to lock the terminal
28
in place. In assembly, the terminal
28
is engaged to an inner surface of the flex arm
49
. An opposite outer surface of the arms
49
are flush with the inner face
42
of each carrier
26
,
30
. The outer surface of the arms
49
of the first carrier
26
engages the outer surface of the arms
49
of the second carrier
30
when the carriers are stacked thereby preventing any further flexing of the arms and locking the terminals
28
in place. Projecting rigidly from the inner face
42
of each carrier
26
,
30
is a post
50
which is disposed substantially near a side edge of the carrier. A post hole
52
is located along the opposite edge of each carrier
26
,
30
. The posts
50
and the holes
52
are fully mated when the inner face
42
of the first carrier
26
is in contact with the inner face
42
of the second carrier
30
, thereby aligning and preventing the carriers from sliding in relation to one-another.
Both carriers
26
,
30
have an opposite or outer face
54
. A series of sonic welding access ports
55
extend through the outer face
54
of the carrier and communicate with each respective groove
44
defined by the inner face
42
. During assembly, the flex circuit
22
and the terminals
28
are orientated between a first and second member of a sonic welding assembly tool. The first member inserts through each port
55
, and the second member of the tool contacts the flex circuit
22
from the opposite side, enabling the tool to weld the conductors of the flex circuit
22
to the terminals
28
. After welding, the carrier
26
is stacked, or folded over, upon the carrier
30
. A variety of other means, such as laser welding or gluing, may also be used to engage the terminals
28
to the conductors of the circuit
22
After the sonic welding is complete, the stacked carriers
26
,
30
are inserted laterally and snap locked into the shroud
32
. To align and lock-fit the carriers
26
,
30
properly within the shroud
32
, the outer face
54
of each carrier defines a laterally extending slot
56
which receives a respective ledge
57
projecting radially inward from a back most perimeter of the rearward clip portion
36
of the shroud
32
. The two ledges
57
are parallel and project in opposition to one-another. Each ledge has a ramped prong
60
projecting radially inward from the respective ledge
57
, both disposed at the exposed end of each ledge
57
near the side clearance
38
. During assembly, as the stacked carriers
26
,
30
are laterally inserted through the side clearance
38
, the slots
56
receive the respective prongs
60
which are temporarily pried outward and away from each other achieved by the ramp feature on each prong as it makes contact with the respective carrier
26
,
30
. When the carriers
26
,
30
are fully inserted into the shroud
32
the prongs
60
snap fit past the trailing edges or sides of the respective carriers
26
,
30
locking the carriers within the shroud
32
.
Referring to
FIGS. 5 and 7
, the retaining clip
40
and snaps locks into the carriers
26
,
30
. Clip
40
has a leading upper return bend
62
and an opposite leading lower return bend
64
, each bend having a row of forward projecting tangs
66
which engage a rearward facing portion of the terminals
28
within each respective groove
44
of the carriers
26
,
30
. In the present embodiment, each carrier
26
,
30
is associated with five terminals
28
, therefore, the upper and lower return bends
62
,
64
each have five tangs
66
. The upper return bend
62
has a rearward extending wing
67
which is planar and parallel to an identical rearward extending wing
67
of the lower return bend
64
.
Referring to
FIGS. 6 and 7
, each carrier
26
,
30
has at least one ramped projection
68
extending radially inward from the inner face
22
just forward of and between the ports
55
. When the retaining clip
40
inserts into the assembled connector
20
from the rear, the projections
68
cause the wings
67
to flex inward until the projections snap into respective apertures
70
which extend through each wing. To assist this snap fit, each wing
67
has a ramped surface
72
associated with each aperture
70
and which slopes radially outward in the rearward direction and up to the respective aperture
70
. When assembled, the wings
67
are engaged between the carriers
26
,
30
and a planar tab portion
74
of the clip
40
projects outward therefrom, between the wings
67
acting as a strain relief and routing feature for the flex circuit
22
. Furthermore, the tab portion
74
provides a means to grip the retaining clip
40
during insertion into or disassembly of the electrical connector
20
.
Referring to
FIG. 8
, a second embodiment of the electrical connector
20
′ is shown wherein the flex circuit
22
of the first embodiment is replaced with a plurality of individually electrically insulated conductors
22
′. Electrical connector
20
′ is otherwise identical to connector
20
.
Although the preferred embodiments of the present invention are disclosed various changes and modifications may be made thereto by one skilled in the art without departing from the scope and spirit of the invention as set forth in the appended claims. Furthermore it is understood that the terms used herein are merely descriptive rather than limiting and various changes may be made without departing from the scope and spirit of the invention.
Claims
- 1. An electrical connector comprising:an elongated first carrier having an inner face; an elongated second carrier having an inner face which faces and contacts the inner face of the first carrier; a first terminal engaged to the inner face of the first carrier; a second terminal accessible from the inner face of the second carrier; and a shroud having a forward annular portion engaged unitarily to a rearward clip portion, the clip portion having a side clearance, wherein the first and second carriers are snap fitted into the clip portion through the side clearance from a lateral direction.
- 2. The electrical connector as set forth in claim 1 further comprising:an elongated ledge extended laterally within the shroud and projecting radially inwardly from the shroud; and the first carrier having an outer face disposed opposite the inner face, the outer face defining a laterally extending slot which receives the respective ledge as the first and second carriers are side mounted into the clip portion of the shroud.
- 3. The electrical connector as set forth in claim 2 wherein the first carrier has a first weld access port extending laterally through the first carrier exposing the first terminal, and wherein the second carrier has a second weld access port extending laterally through the second carrier exposing the second terminal.
- 4. An electrical connector comprising:an elongated first carrier having an inner face; an elongated second carrier having an inner face which faces the inner face of the first carrier; a first terminal engaged to the inner face of the first carrier; a second terminal engaged to the inner face of the second carrier; a shroud having a forward annular portion engaged unitarily to a rearward clip portion, the clip portion having a side clearance, wherein the first and second carriers are snap fitted into the clip portion through the side clearance from a lateral direction; an elongated ledge extended laterally within the shroud and projecting radially inwardly from the shroud; the first carrier having an outer face disposed opposite the inner face, the outer face defining a laterally extending slot which receives the respective ledge as the first and second carriers are side mounted into the clip portion of the shroud; wherein the first carrier has a first weld access port extending laterally through the first carrier exposing the first terminal, and wherein the second carrier has a second weld access port extending laterally through the second carrier exposing the second terminal; a retaining clip engaged to the first carrier, disposed between the first and second carriers and projecting rearward from the shroud, wherein the clip is constructed and arranged to assure the position of the first and second terminals within the first and second carriers, the clip having an aperture; and the first carrier having a projection snap fitted into the aperture.
- 5. The electrical connector as set forth in claim 4 wherein the elongated ledge has an end prong disposed near the side clearance and extended rigidly inwardly from the ledge and wherein the first carrier snap fits past the end prong as the first and second carriers are side mounted into the clip portion of the shroud.
- 6. The electrical connector as set forth in claim 5 further comprising a flex circuit having a first bank having a first conductor engaged electrically to the first terminal and a second bank having a second conductor engaged electrically to the second terminal.
- 7. The electrical connector as set forth in claim 6 wherein the clip has a leading upper return bend and a leading lower return bend each having a wing extending rearward, the wing of the upper return bend having the aperture, the wing of the lower return bend having another aperture which engages another projection of the second carrier.
- 8. The electrical connector as set forth in claim 7 wherein the clip has a tab extending rearward from and between the upper and lower return bend portions and between the first and second banks of the flex circuit.
- 9. The electrical connector as set forth in claim 8 further comprising:the first and second carriers being identical; the shroud having a second elongated ledge in opposition to the first elongated ledge, the second elongated ledge residing within a laterally extending slot defined by an outer face of the second carrier; the retaining clip engaged to the second carrier, the retaining clip having a second aperture; and the second carrier having a projection snap fitted into the second aperture.
- 10. The electrical connector as set forth in claim 9 wherein the first and second carriers each have a groove defined by the respective inner faces, each groove extending longitudinally through a forward face of each first and second carrier, the first and second terminals engaged within the respective groove, and the forward faces exposed through a forward opening defined by the annular portion of the shroud.
- 11. The electrical connector as set forth in claim 10 wherein the upper and lower return bends of the clip each have a tang extended forward within the respective groove of the first and second carriers, the tangs being engaged to the respective first and second terminals.
- 12. The electrical connector as set forth in claim 11 wherein the first and second carriers each have a post projecting outward from the inner face and a hole defined by the inner face, the post of the first carrier being disposed in the hole of the second carrier and the post of the second carrier being disposed in the hole of the first carrier.
- 13. An electrical connector comprising:a plurality of conductors; a plurality of terminals, each one of the plurality of terminals engaged to a respective one of the plurality of conductors; a first carrier having an inner face, a groove, and a forward face, the inner face defining the groove which extends forward through the forward face; a second carrier having an inner face, a groove, and a forward face, the inner face defining the groove which extends forward through the forward face, the inner face of the first carrier engaged to the inner face of the second carrier, wherein each one of the plurality of terminals are disposed within a respective one of the grooves of the first and second carriers, the plurality of terminals being exposed through the forward faces of the respective first and second carriers; the first and second carriers each having a cantilevered flex arm disposed within the respective grooves and engaged to the respective terminals of the first and second carriers, the flex arm of the first carrier engaged to the flex arm of the second carrier along an imaginary plane of the inner faces; and a shroud having a rearward clip portion and a forward annular portion defining a forward opening, the forward faces of the first and second carriers exposed through the forward opening, the clip portion having a side clearance, wherein the first and second carriers are snap fitted into the clip portion through the side clearance from a lateral direction.
- 14. The electrical connector as set forth in claim 13 further comprising:the clip portion of the shroud having an elongated ledge extended laterally from the gap and projecting inwardly from the shroud; and the first and second terminal carriers each having an outer face disposed opposite the inner faces, each outer face defining a laterally extending slot which receives the respective ledge as the first and second terminal carriers are side mounted into the clip portion.
- 15. An electrical connector comprising:an elongated first carrier having an inner face; an elongated second carrier having an inner face which faces the inner face of the first carrier; a first terminal engaged to the inner face of the first carrier; a second terminal engaged to the inner face of the second carrier; a shroud having a forward annular portion engaged unitarily to a rearward clip portion, the clip portion having a side clearance, wherein the first and second carriers are snap fitted into the clip portion through the side clearance from a lateral direction; and a flex circuit having a first bank having a first conductor engaged electrically to the first terminal and a second bank having a second conductor engaged electrically to the second terminal.
US Referenced Citations (26)