Information
-
Patent Grant
-
6468106
-
Patent Number
6,468,106
-
Date Filed
Monday, January 29, 200123 years ago
-
Date Issued
Tuesday, October 22, 200222 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Paumen; Gary F.
- McCamey; Ann
Agents
- Tarolli, Sundheim, Covell, Tummino & Szabo L.L.P.
-
CPC
-
US Classifications
Field of Search
US
- 439 67
- 439 493
- 439 77
- 439 876
- 439 499
-
International Classifications
-
Abstract
An apparatus (10) includes a base (20) and a plurality of electrically conductive frets (14) connected to the base. The frets (14) have exposed portions (82) on a first surface (40) of the base (20). The apparatus (10) further includes a cover (22) and a pad (80) that is connected with a second surface (62) of the cover (22). The cover (22) is connected with the base (20) such that the second surface (62) of the cover overlies the first surface (40) of the base and the pad (80) overlies the exposed portions (82) of the frets (14). The pad (80) is compressed between the frets (14) and the cover (22).
Description
FIELD OF THE INVENTION
The present invention relates to electrical connectors. In particular, the present invention relates to a fret assembly for a flat cable.
BACKGROUND OF THE INVENTION
It is known to use an electrical connector to terminate cables in order to help provide a means by which to connect and disconnect the cable. One such type of electrical connector is a fret assembly for a flat cable. A known fret assembly includes conductive frets disposed in a housing. The housing is connected to the cable such that the frets are placed in electrical contact with the conductors in the cable.
SUMMARY OF THE INVENTION
An apparatus comprises a base and a plurality of electrically conductive frets connected to the base. The frets have exposed portions on a first surface of the base. The apparatus further comprises a cover and a pad that is connected with a second surface of the cover. The cover is connected with the base such that the second surface of the cover overlies the first surface of the base and the pad overlies the exposed portions of the frets. The pad is compressed between the frets and the cover.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the present invention will become apparent to one skilled in the art to which the present invention relates upon consideration of the following description of the invention with reference to the accompanying drawings, in which:
FIG. 1
is a perspective view of a fret assembly in accordance with the present invention;
FIG. 2
is an exploded perspective view of the fret assembly of
FIG. 1
;
FIG. 3
is a sectional view, taken generally along line
3
—
3
of
FIG. 1
;
FIG. 3
a
is a magnified view of,a portion of the fret assembly of
FIG. 3
;
FIG. 4
is a top view of a portion of the fret assembly of
FIG. 1
;
FIG. 5
is a bottom view of the portion of the fret assembly of
FIG. 4
;
FIG. 6
is a bottom view of another portion of the fret assembly of
FIG. 1
; and
FIGS. 7
a
and
7
b
are enlarged sectional views, taken generally along line
7
—
7
in
FIG. 1
, showing parts of the fret assembly in different conditions.
DESCRIPTION OF AN EMBODIMENT OF THE INVENTION
As representative of an embodiment of the present invention,
FIG. 1
illustrates a fret assembly
10
. The fret assembly
10
comprises a housing
12
and a plurality of frets
14
connected to the housing. The housing
12
comprises a base
20
and a cover
22
. The housing
12
is adapted to receive and attach to a cable
24
.
Referring to
FIGS. 2
,
4
and
5
, the base
20
has a generally rectangular shape defined by a front edge
30
, an opposite rear edge
32
and first and second side edges
34
and
36
, respectively, that extend between the front and rear edges. The base
20
also includes an upper surface
40
and an opposite lower surface
42
. The base
20
may also include resiliently deflectable locking tabs
44
. In the illustrated embodiment, one locking tab
44
is positioned adjacent the intersection of the front edge
30
and the first side edge
34
and another locking tab is positioned adjacent the front edge
30
and the second side edge
36
. The locking tabs
44
are resiliently deflectable inward towards the first and second side edges
34
and
36
, respectively.
Referring to
FIGS. 2 and 6
, the cover
22
has a generally rectangular shape defined by a front edge
50
, an opposite rear edge
52
and first and second side edges
54
and
56
, respectively, that extend between the front and rear edges. The cover
22
also includes an upper surface
60
and an opposite lower surface
62
. In the illustrated embodiment, the front and rear edges
50
and
52
of the cover
22
are generally the same length as the front and rear edges
30
and
32
(
FIG. 2
) of the base
20
, whereas the first and second side edges
54
and
56
of the cover
22
are shorter than the first and second side edges
34
and
36
of the base
20
.
The base
20
(
FIGS. 2
,
4
and
5
) includes a plurality of cylindrical sockets
70
spaced in a predetermined pattern about the upper surface
40
of the base. The sockets
70
extend through the base from the upper surface
40
to the lower surface
42
. The sockets
70
have a first portion
72
of a first diameter that extends from the upper surface
40
into the base
20
. As illustrated in
FIG. 5
, the sockets
70
have a second portion
74
of a second diameter, larger than the first diameter, that extends from the lower surface
42
into the base
20
.
The base
20
(
FIGS. 2 and 4
) also includes a plurality of locator pins
90
that protrude from the upper surface
40
of the base in a predetermined pattern. First locator pins
92
have a generally circular cross-section and second locator pins
94
have an elongated or oval-shaped cross-section.
The cover
22
(
FIGS. 2 and 6
) includes a plurality of pins
76
spaced in a predetermined pattern about the lower surface
62
of the cover. The predetermined pattern of the pins
76
corresponds to the predetermined pattern of the sockets
70
. The diameter of the pins
76
is about equal to the first diameter of the first portion
72
of the sockets
70
. The cover
22
also includes a pair of sockets
78
that extend into the lower surface
62
of the cover. The sockets
78
are generally cylindrical and are spaced along the second side edge
56
of the cover
22
in a pattern that corresponds to the first locator pins
92
.
The cover
22
further includes a rectangular pad
80
connected with the lower surface
62
of the cover. Preferably, the pad
80
is constructed of a silicone material. Such a material is preferable because it is deflectable, resilient, and able to withstand heat. Those skilled in the art, however, will recognize that the pad
80
may be constructed of alternative materials, such as plastics, that are capable of withstanding heat, but may or may not be readily deflectable and/or resilient.
Preferably, the housing
12
(
FIG. 1
) is constructed of a plastic material and the frets
14
are constructed of a metal, such as copper. The frets
14
may be connected to the base
20
by known means, such as by insert molding the frets in the housing, heat staking the frets to the housing, or bonding the frets to the housing with an adhesive. Those skilled in the art will recognize that other suitable materials may be used to construct the fret assembly
10
. Those skilled in the art will also recognize that other suitable materials and methods may be used to connect the frets
14
to the base
20
.
In the illustrated embodiment, the frets
14
are connected to the base
20
by insert molding the frets in the base
20
. The frets
14
are positioned such that enclosed portions
100
(
FIG. 4
) of the frets are surrounded by the base
20
and exposed portions
82
of the frets
14
are exposed on the upper surface
40
of the base. The exposed portions
82
lie generally flush with the upper surface
40
(see
FIG. 3
a
).
As shown in
FIG. 4
, the fret assembly
10
includes eight frets
14
, each having a generally L-shaped configuration. The frets
14
each have a first leg
110
that extends from the front edge
30
towards the rear edge
32
of the base
20
in a direction generally parallel to the first an second side edges
34
and
36
. Each of the frets
14
also has a second leg
112
that extends perpendicularly from an end of the first leg
110
opposite the front edge
30
of the base
20
. A portion of each of the first legs
110
of the frets
14
forms a pin
116
that protrudes from the front edge
30
of the base
20
in a direction perpendicular to the front edge.
The second legs
112
comprise portions of the exposed portions
82
of the frets
14
and thus are exposed on the upper surface
40
of the base. In the illustrated embodiment, six of the frets
14
include second legs
112
that extend toward the second side edge
36
and two of the frets have second legs that extend towards the first side edge
34
. The second legs
112
are thus spaced apart and extend parallel to each other.
The number of frets
14
included in the fret assembly
10
, the pattern along which each of the frets is formed, and the arrangement and spacing of the frets on the base
20
is illustrative of only one particular embodiment of the present invention. Those skilled in the art will appreciate that the number, pattern, arrangement and spacing of the frets
14
may vary widely depending on the particular application for which the present invention is applied. Also, those skilled in the art will recognize that the housing
12
may be formed in a desired shape in order to accommodate use of the fret assembly
10
within the confines of a particular location in which use of the fret assembly is desired.
Referring to
FIG. 2
, the cable
24
comprises a plurality of conductors
120
surrounded by an insulating material
122
. The conductors
120
are spaced from each other and extend generally parallel to each other, thus giving the cable
24
a generally flat configuration. Portions of the insulating material
122
are removed from the cable
24
to provide exposed portions
124
of the conductors
120
. The exposed portions
124
of the cable
24
are arranged in a generally rectangular area
126
. As illustrated in
FIG. 2
, solder
128
is applied to each of the exposed portions
124
. The solder
128
may be in the form of a solder paste that sticks to the exposed portions
124
or may be in the form of solder that has been melted and cooled to adhere to the exposed portions
124
.
The cable
24
includes a plurality of locator holes
130
that extend through the cable. First locator holes
132
have a generally circular shape that corresponds with the cross-section of the first locator pins
92
. Second locator holes
134
have an elongated or oval shape that corresponds with the cross-section of the second locator pins
94
. A third locator hole
136
has a circular shape that corresponds with the cross-section of the pins
76
. The first and second locator holes
132
and
134
are arranged in a predetermined pattern that corresponds to the predetermined pattern of the first and second locator pins
92
and
94
on the base
20
. The third locator hole
136
is located in a position that corresponds to the position of the pin
76
adjacent the second side edge
56
of the cover
22
.
Assembly of the fret assembly
10
is indicated generally by the dashed lines in FIG.
2
. To attach the cable
24
to the fret assembly
10
, the cable is placed on the base
20
such that the first and second locator pins
92
and
94
extend through the first and second locator holes
132
and
134
, respectively, which helps to position the cable
24
relative to the base
20
. As a result, the exposed portions
124
of the conductors
120
are positioned adjacent the exposed portions
82
of the second legs
112
of the frets
14
. This is shown in
FIGS. 3 and 3
a.
When the exposed portions
124
of the conductors
120
are positioned adjacent the exposed portions
82
of the frets
14
, the solder
128
is disposed between the adjacent exposed portions. The width and spacing of the exposed portions
124
of the conductors
120
is equal to or about equal to the width and spacing of the exposed portions
82
of the second legs
112
of the frets
14
. Thus, when the cable
24
is placed on the base
20
, each of the exposed portions
124
of the conductors
120
overlies an exposed portion
114
of a single fret
14
.
Those skilled in the art will recognize that it may be desirable for an exposed portion
124
of a single conductor
120
to overlie the exposed portions
114
of a plurality of frets
14
. In such an instance, the exposed portion
124
of the conductor
120
may have a width large enough to overlie exposed portions
114
of a plurality of frets
14
. Alternatively, a conductor
120
may extend transverse to the frets
14
so as to have exposed portions
124
that overlie exposed portions
114
of a plurality of frets
14
.
It may also be desirable for exposed portions
114
of a plurality of conductors
120
to overlie the exposed portion
114
of a single fret
14
. In such an instance, the exposed portion
114
of the single fret
14
may have a width large enough to overlie the exposed portions
114
of a plurality of conductors
120
. Alternatively, a fret
14
may extend transverse to the conductors
120
such that exposed portions
124
of a plurality of conductors overlie the exposed portion
114
of a single fret
14
.
When the cable
24
is positioned on the base
20
, the housing
12
is placed in a closed condition wherein the cover
22
overlies the base
20
. The closed condition is illustrated in FIG.
1
. When the housing
12
is in the closed condition, the lower surface
62
(
FIG. 3
) of the cover is positioned facing the upper surface
40
of the base
20
. The pins
76
are aligned with and extend into the sockets
70
(see FIG.
2
). The first locator pins
92
extend through the cable
24
and into the sockets
78
in the cover
22
(see FIG.
2
). The pins
76
and the first locator pins
92
thus help position the cover
22
relative to the base
20
. Also, when the housing
12
(
FIGS. 3 and 3
a
) is in the closed condition, the pad
80
is positioned adjacent the cable
24
on the side of the cable opposite the exposed portions
124
of the conductors
120
. When the housing
12
is in the closed condition, the cable
24
and the pad
80
are compressed between the base
20
and the cover
22
.
Referring to
FIGS. 7
a
and
7
b
, when the housing
12
is in the closed condition, the pins
76
on the cover
22
extend through the sockets
70
in the base
20
such that a portion
130
of each pin extends into the second portion
74
of a respective socket. The portion
130
can then be melted to connect or “heat stake” the cover
22
to the base
20
. In doing so, the melted portion
130
of the pin
76
decreases in length and increases in diameter to fill the larger diameter of the second portion
74
of the socket
70
(see
FIG. 7
b
). This creates an interference between the melted portion
130
of the pin
76
and the first portion
72
of the socket
70
, which secures the cover
22
to the base
20
.
Referring to
FIGS. 3 and 3
a
, when the cover
22
is connected to the base
20
, the cable
24
and the pad
80
are compressed between the base and the cover. The pad
80
deflects under the compressive force applied by the base
20
and the cover
22
. The pad
80
thus transmits the compressive force to the overlying exposed portions
124
of the conductors
120
and the exposed portions
82
of the second legs
112
of the frets
14
. The resiliency of the material used to construct the pad
80
urges the pad to return to its original, uncompressed shape. This helps maintain the compressive force on the overlying exposed portions
124
of the conductors
120
and the exposed portions
82
of the frets
14
when the cover
22
is connected to the base
20
. As a result, the base
20
, cover
22
and cable
24
are held and maintained in an assembled position when the cover
22
is connected to the base
20
.
While the base
20
, cover
22
and cable
24
are held together in the assembled position, the solder
128
may be melted or “flowed” and then cooled in order to connect the exposed portions
124
of the conductors
120
to the exposed portions
82
of the frets
14
. As illustrated in
FIGS. 3
,
3
a
and
5
, the base
20
may include a passage
150
for providing access to surfaces
152
of the second legs
112
of the frets
14
opposite the exposed portions
82
. The passage
150
allows a heat source (not shown), such as a heater bar or an induction heater, to heat the frets
14
, which conduct heat to the solder
128
. The solder
128
is thus melted to connect the conductors
120
to the frets
14
.
Those skilled in the art will recognize that, when the solder
128
is being flowed, handling of the fret assembly
10
may tend to disturb the alignment of the base
20
, cover
22
, and the cable
24
. Advantageously, the compressive force applied by the pad
80
helps to maintain the relative positioning of the base
20
, cover
22
and cable
24
. This helps to eliminate stress on the fret assembly
10
which may disrupt the relative positioning of the base
20
, cover
22
and/or cable
24
.
When the fret assembly
10
is in the assembled condition, the deflection of the pad
80
helps to distribute the compressive force applied to the cable
24
by the base
20
and the cover
22
generally evenly across the cable. This helps to ensure that the solder
128
, when melted, is spread evenly and uniformly between the conductors
120
and the frets
14
. In the case where the solder
128
comprises a solder paste, the pad
80
helps distribute the paste evenly between the conductors
120
and the frets
14
before the solder is flowed.
Once assembled, the fret assembly
10
(
FIG. 1
) may be plugged into a suitable receptacle (not shown), which receives the pins
16
to electrically connect conductors of the receptacle to the cable
24
via the frets
14
. The locking tabs
44
cooperate with the receptacle in a known manner to maintain the fret assembly
10
connected to the receptacle. The fret assembly
10
thus supports the cable
24
for connection to the receptacle.
From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications in the invention. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.
Claims
- 1. A fret assembly connectable to a flat cable that includes a plurality of spaced apart conductors surrounded by an insulating material, the conductors including exposed portions wherein the conductors are exposed through the insulating material, said fret assembly comprising:a base having an upper surface; a plurality of electrically conductive frets connected to said base, said frets having exposed portions on said upper surface of said base; a cover connectable to said base such that a lower surface of said cover overlies said upper surface of said base; and a pad connected with said lower surface of said cover; the flat cable being receivable between said base and said cover such that the exposed portions of the conductors overlie said exposed portions of said frets and said pad overlies a surface of the flat cable opposite the exposed portions of the conductors, said fret assembly further comprising a layer of solder disposed between the exposed portions of the conductors and said exposed portions of said frets, said pad being compressed between said cover and said base when said cover is connected to said base, said pad when compressed compressing said layer of solder between the exposed portions of the conductors and said exposed portions of said frets.
- 2. The fret assembly recited in claim 1, wherein said pad when compressing said layer of solder between the exposed portions of the conductors and said exposed portions of said frets helping to flow said solder evenly over the exposed portions of the conductors and said exposed portions of said frets when said solder is melted.
- 3. The fret assembly recited in claim 1, wherein said solder comprises a solder paste, said pad when compressed between said cover and said base helping to distribute said solder paste evenly between the exposed portions of the conductors and said exposed portions of said frets.
- 4. The fret assembly recited in claim 1, wherein said pad is deflectable when compressing said layer of solder between the exposed portions of the conductors and said exposed portions of said frets, said pad helping to distribute said compressive force in equal amounts between the exposed portions of the conductors and said exposed portions of said frets.
- 5. The fret assembly recited in claim 1, wherein the conductors of the flat cable are spaced side by side in a generally flat configuration and extend parallel to each other.
- 6. The fret assembly recited in claim 1, wherein said exposed portions of said frets are spaced side by side in a generally flat configuration and extend parallel to each other.
- 7. The fret assembly recited in claim 1, wherein said layer of solder connects the conductors to said frets after said layer of solder is melted and flowed.
- 8. The fret assembly recited in claim 1, wherein the exposed portions of each of the conductors are compressed against a respective one of said exposed portions of said frets.
- 9. The fret assembly recited in claim 1, wherein each of the exposed portions of the conductors are compressed against only one of said exposed portions of said frets.
- 10. The fret assembly recited in claim 1, wherein said base surrounds portions of said frets.
- 11. The fret assembly recited in claim 1, wherein said pad is constructed of a deflectable material.
- 12. The fret assembly recited in claim 11, wherein said deflectable material consists essentially of a silicone material.
- 13. A fret assembly connectable to a flat cable that includes a plurality of spaced apart conductors surrounded by an insulating material, the conductors including exposed portions wherein the conductors are exposed through the insulating material, said fret assembly comprising:a base having an upper surface; a plurality of electrically conductive frets connected to said base, said frets having exposed portions on said upper surface of said base; a cover connectable to said base such that a lower surface of said cover overlies said upper surface of said base; and a pad connected with said lower surface of said cover; the flat cable being receivable between said base and said cover such that the exposed portions of the conductors overlie said exposed portions of said frets and said pad overlies a surface of the flat cable opposite the exposed portions of the conductors, said fret assembly further comprising a layer of solder disposed between the exposed portions of the conductors and said exposed portions of said frets, said pad being compressed between said cover and said base when said cover is connected to said base, said pad when compressed compressing said layer of solder between the exposed portions of the conductors and said exposed portions of said frets, said base including a passage on a lower surface of said base opposite said upper surface of said base, said passage exposing a surface of said frets opposite said exposed portions of said frets, said passage being adapted to receive means for applying heat to said exposed surfaces of said frets in order to melt and flow said layer of solder.
- 14. Apparatus comprising:a base having an upper surface, said base including a plurality of electrically conductive frets having exposed portions on said upper surface of said base; a cable that includes a plurality of spaced apart conductors surrounded by an insulating material, said conductors including exposed portions wherein said conductors are exposed through said insulating material, said cable being positioned on said base such that said exposed portions of said conductors overlie said exposed portions of said frets; a layer of solder disposed between said exposed portions of said conductors and said exposed portions of said frets; a cover connected to said base such that a lower surface of said cover overlies said upper surface of said base; and a pad connected with said lower surface of said cover, said pad overlying a surface of said cable opposite the exposed portions of said conductors, said pad being compressed between said cover and said base, said pad urging said exposed portions of said conductors and said exposed portions of said frets into abutting engagement with said layer of solder.
- 15. Apparatus comprising:a base having an upper surface, said base including a plurality of electrically conductive frets having exposed portions on said upper surface of said base, said base including a passage on a lower surface of said base opposite said upper surface of said base, said passage exposing a surface of said frets opposite said exposed portions of said frets; a cable that includes a plurality of spaced apart conductors surrounded by an insulating material, said conductors including exposed portions wherein said conductors are exposed through said insulating material, said cable being positioned on said base such that said exposed portions of said conductors overlie said exposed portions of said frets; a layer of solder disposed between said exposed portions of said conductors and said exposed portions of said frets; a cover connected to said base such that a lower surface of said cover overlies said upper surface of said base; and a pad connected with said lower surface of said cover, said pad overlying a surface of said cable opposite the exposed portions of said conductors, said pad being compressed between said cover and said base, said pad urging said exposed portions of said conductors and said exposed portions of said frets into abutting engagement with said layer of solder, said passage being adapted to receive means for applying heat to said exposed surfaces of said frets in order to melt and flow said layer of solder.
US Referenced Citations (6)
