Patent Application
20190280404
The present application relates generally to the field of electrical connectors, and more particularly to a type of connector used to connect an electrical wire to an electrical component.
The following description is provided to assist the understanding of the reader. None of the information provided or references cited is admitted to be prior art.
Various types of connectors are used for forming connections between an insulated wire and any manner of electronic or electrical component. These connectors are typically available as sockets, plugs, and shrouded headers in a vast range of sizes, pitches, and plating options. Typically, a connector is electrically coupled to an electrical component that is designed to receive the connector. For example, an electrical component typically must be designed to have a female socket in order to receive a male contact tine. However when it is desirable to make an electrical connection between a flat conductive pad of an electrical component (e.g., a printed circuit board) and an electrical connector, the lack of mechanisms for mechanically securing the components presents new challenges. In other words, traditional connections in which a flat conductive pad and electrical connector are merely touching lack a sufficiently secure mechanical connection that is resilient to vibration, shock, and other forces that may cause the connection to fall apart. Furthermore, when a flat conductive pad is in a limited space, it is difficult to mechanically secure a wire to the flat conductive pad.
The systems, methods and devices of this disclosure each have several innovative aspects, no single one of which is solely responsible for the desirable attributes disclosed herein.
An electrical contact includes a cage-like structure, a wire connecting portion, and a flexing contact portion. The cage-like structure includes a plurality of sidewalls that define a wire inlet at a proximal end of the electrical contact. The wire connecting portion includes a first contact tine that extends from a first sidewall of the cage-like structure and a second contact tine that extends from a second sidewall of the cage-like structure. The first and second contact tines create a pinch-point that can compress a conductive core of a corresponding wire.
The flexing contact portion includes an end wall, an elastic portion that extends from the end wall toward the proximal end, and an extension portion that extends from the elastic portion. The end wall is located as a distal end of the electrical contact. That is, the wall is connected to a base at an opposite end from the wire inlet. The flexing contact portion may also include a nose portion that extends from the distal end of the extension portion. In an embodiment, the nose portion is gold plated to increases its conductivity. The nose portion extends from the extension portion in a different direction than the extension portion extends from the elastic portion. In other words, the nose portion is rounded (e.g., bent downward toward the cage-like structure. In one embodiment, the extension portion includes a straight segment that extends between the elastic portion and the nose portion. In other words, the extension portion is not bent or curved as it extends from the elastic portion to the nose portion.
The elastic portion includes a curved portion between the end wall and the extension portion. Additionally, the elastic portion and the extension portion are cantilevered from the end wall (e.g., they are connected to the end wall at one side). Further, at least a portion of the extension portion is cantilevered over the wire connection portion. In an embodiment, the width of the end wall is greater than the width of the elastic and extension portion. This helps minimize interference from other objects when the electrical contact is being used. The cage-like structure, the wire connecting portion, and the contact portion may all be of a single conductive element. Alternatively, the cage-like structure, the wire connecting portion, and the contact portion may be separate elements that are mechanically and electrically coupled together. One of the pluralities of sidewalls includes a base that extends along the wire connecting portion and connects to the end wall. In other words, the base extends from the wire inlet at the proximal end to the flexing contact portion at the distal end. The end wall extends perpendicularly to the base at the distal end.
The electrical contact may be used in a system that includes a printed circuit board, an electrical component having a contact pad, and a wire. For example, a portion of the base of the electrical contact may be mounted to the printed circuit board or other rigid structure. In this system, the contact pad can be conductively coupled to the flexing contact portion, and the wire can be conductively coupled to the wire connection portion, thereby forming an electrically-conductive connection between the wire and the electrical component.
In an embodiment, to form such a connection, the wire is inserted into a wire inlet opening at the proximal end of the electrical contact. A conductive core of the wire is extended into the wire connecting portion of the electrical contact such that the conductive core of the wire is compressed between a first contact tine and a second contact tine of the electrical contact. The electrical contact is also positioned adjacent to the contact pad of the electrical component such that the flexing contact portion makes contact with the contact pad. As a result, the contact pad is conductively coupled the electrical contact and the wire. The flexing contact portion stores elastic energy due to distortion of the flexing contact portion while it is being positioned. The stored elastic energy supplies a force back on the contact pad. This configuration is beneficial at least in part because it helps ensure that the electrical contact and the electrical component stay conductively coupled during movement or shifting of either component. In one embodiment, the contact between the electrical contact and the electrical component is between the nose portion of the electrical contact and the contact pad of the electrical component.
Reference will now be made to various embodiments, one or more examples of which are illustrated in the figures. The embodiments are provided by way of explanation of the invention, and are not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to yield still a further embodiment. It is intended that the present application encompass these and other modifications and variations as come within the scope and spirit of the invention.
Disclosed herein is an electrical contact with a flexing contact portion. Such electrical contacts are used to efficiently and reliably mechanically and electrically couple one or more wires to an electrical component (e.g., a printed circuit board). Specifically, the electrical contact allows for a quickly assembled connection between the conductive element of an electrical wire, the electrical contact, and the electrical component. Further, the flexing contact portion ensures that the electrical connection between the electrical contact and electrical component is secure and reliable. Specifically, the flexing contact portion is designed to allow the electrical contact to shift or move slightly relative to the electrical component without disrupting the electrical connection. More specifically, the flexing contact can be moved (e.g., bent downward) during connection of the electrical contact with the electrical component, which allows for greater design and spacing tolerances when manufacturing and assembling the electrical contact and electrical component. Moreover, the flexing contact creates a more reliable electrical connection to an electrical component because, when the electrical contact is properly connected to the electrical component, the flexing contact portion will exert a force onto the electrical component due to compression of the flexing contact portion. Additionally, the unique design of a nose portion on the flexing contact portion ensures that the electrical contact will not damage an electrical component even when forcibly removed from its connected position. Lastly, an electrical contact with a flexing contact portion allows a user to conductively couple a wire to a flat conductive pad that is located in a limited space. That is, a user can simply attach a wire to the electrical contact (outside of the limited space) and insert the electrical contact into the limited space such that the flexing contact portion conductively couples with the flat conductive pad.
Various embodiments of an electrical contact are illustrated throughout
For ease of explanation, the plurality of sidewalls of the cage-like structure 130 are depicted to include a base 131, a first sidewall 120, a second sidewall 122, and an upper surface 121. The base 131 extends from the cage-like structure 130 and connects the cage-like structure 130, the wire connecting portion 140, and the flexing contact portion 150.
The wire connecting portion 140 includes the base 131, a first contact tine 101, a second contact tine 102, an upper wire guide 135, and a lower wire guide (not shown in
The upper wire guide 135 extends from the upper surface 121 of the cage-like structure 130 in the same direction that the base 131 and contact tines 101 and 102 extend (i.e., from a sidewall of the cage-like structure 130 toward the distal end of the electrical contact 100). Additionally, as the upper wire guide 135 extends from the upper surface 121 it also extends towards the centerline axis 190. The upper wire guide 135 ensures that the conductive core of a corresponding wire is guided towards the pinch-point 107 of the first and second contact tines 101 and 102. Further, the upper wire guide 135 may also be another mechanical and electrical contact point between the electrical contact 100 and the corresponding wire. A lower wire guide (not depicted) may also extend from a lower portion (i.e., the base 131) of the cage-like structure, as shown in
The flexing contact portion 150 is connected to the base 131 and includes an end wall 113, an elastic portion 114, an extension portion 115, and a nose portion 116. The end wall 113 is connected to the base 131 at a distal end 199 of the electrical contact 100. The end wall 113 is depicted as a bent-up portion of the base 131. In alternative embodiments, the end wall 113 may be a different element than the base 131. In
The elastic portion 114 extends from the end wall 113 and is connected to the extension portion 115. In an embodiment, the elastic portion 114 has a width that is less than the width of the base 131 and the end wall 113 to permit greater relative flexibility of the elastic portion 114 relative to the base 131 and end wall 113. The elastic portion 114 allows for the extension portion 115 and nose portion 116 to be flexible in terms of the angle that they extend relative to the end wall 113 and the base 131. That is, the elastic portion 114 allows for the extension portion 115 to extend along a plane parallel to the base 131 (i.e., ninety degrees relative to the end wall 113) when a force is applied to the extension portion 115 or nose portion 116. Alternatively, the elastic portion 114 relaxes when the force is not applied to the extension portion 115 or nose portion 116 and causes the extension portion 115 to extend in a non-parallel direction to the base (i.e., a neutral position that has less than a ninety degree bend relative to the end wall 131).
The elastic portion 114 stores elastic energy that allows for the extension portion 115 and nose portion 116 to forcibly make contact with a corresponding device when the elastic portion 114 is distorted from its neutral position. For example, when the electrical contact 100 is inserted into a corresponding receptacle, the elastic portion 114 ensures that the extension portion 115 and nose portion 116 form a mechanical and electrical connection to a corresponding conductive pad or other conductive area of an electrical component. When an adjacent component forces the flexing contact portion 150 from its neutral position, the elastic portion 114 stores elastic energy and exerts a force back toward the adjacent component (and toward its neutral position). The force applied by the elastic portion 114 ensures that the electrical contact 100 is actively creating a frictional force to mechanically secure the electrical contact 100 in its desired positioning. Without the flexing contact portion 114, the electrical contact 100 would need to have much smaller tolerances so as to form a much closer fit and connection to a corresponding device than that required with electrical contact 100. Thus, the flexing contact portion 114 increases the versatility and reliability of the electrical contact 100 when compared to traditional contacts.
As stated above, the extension portion 115 extends from its proximal end at the elastic portion 114 to its distal end furthest away from the elastic portion. The distal end of the extension portion 115 is further connected to the nose portion 116. The nose portion 116 may be gold plated on one or more sides. The gold plating helps ensure that an electrical connection is created between the nose portion 116 and a conductive element of a corresponding electrical device. The length that the extension portion 115 extends from the elastic portion 114 will depend on the application and design of electrical contact 100 and/or the corresponding electrical device to which the electrical contact 100 is to be connected.
Additionally, the nose portion 116 extends from the extension portion 115 at a non-parallel angle (e.g., downward) to ensure that the electrical contact 100 does not damage corresponding devices when it is removed from that corresponding device. That is, bending the nose portion 116 downward (i.e., toward the base 131 ensures that an edge of the nose portion 116 or extension portion 115 cannot accidentally grab a corresponding device (e.g., a portion of a PCB board) and damage the corresponding device.
As depicted in
The electrical contact 350 includes an end wall 313, an elastic portion 314, an extension portion 315, a nose portion 316, a first contact tine 301, a second contact tine (not depicted), and a cage-like structure 330. The electrical component 390 includes a contact pad 391 that may be connected to additional electronic circuitry.
In an operation 502, a conductive core of the electrical wire is extended into a connection portion of the electrical contact such that the conductive core is compressed between two contact tines of the electrical contact and an electrical and mechanical connection is created there between. The electrical contact may include an upper wire guide and a lower wire guide that assist in positioning the conductive core of the electrical wire between the two contact tines during insertion of the electrical wire into the electrical contact. For example, the upper wire guide may help ensure that the conductive core of the wire does not travel above the pinch-point, and the lower wire guide may help ensure that the conductive core of the wire does not travel below the pinch-point.
In an operation 503, the electrical contact is positioned adjacent to a contact pad of an electrical component such that a force is applied between the contact pad and a flexing contact portion of the electrical contact. As a result, the flexing contact portion of the electrical contact stores elastic energy and applies a counteractive force toward the contact pad via a point of contact between the flexing contact portion of the electrical contact and the contact pad of the electrical component. The point of contact between the contact pad and electrical contact may be made via an extension portion and/or a nose portion of the flexing contact portion of the electrical contact. The electrical contact may be further mounted on a printed circuit board, wiring board, electrical device, or other structure before or after being positioned adjacent to the contact pad. In one embodiment, the electrical contact may be soldered, welded or otherwise conductively coupled to a contact pad of the device of which it is mounted. In alternative embodiments, the electrical contact may simply be affixed to an insulated portion of a device (e.g., a board or housing). The positioning of the electrical contact and corresponding electrical component may be done by compressing the electrical contact into a receptacle, where the contact pad of the electrical component is located within the receptacle.
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
The foregoing description of illustrative embodiments has been presented for purposes of illustration and of description. It is not intended to be exhaustive or limiting with respect to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the disclosed embodiments. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.
This application claims the benefit of and priority to U.S. patent application Ser. No. 15/967,654, filed May 1, 2018, which claims priority to U.S. Provisional Application No. 62/513,655, filed Jun. 1, 2017, each of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62513655 | Jun 2017 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15967654 | May 2018 | US |
| Child | 16425143 | US |
