Patent Application
20150118921
The subject matter herein relates generally to a leadframe for a contact module and a method of manufacturing the same.
Some electrical connectors include individual contact modules or chicklets that are loaded into a connector housing. The contact modules typically have signal contacts arranged in pairs that carry differential signals. Some conventional contact modules are formed from an overmolded leadframe(s). For an improved electrical connection, the signal contacts of at least some known contact modules have mating ends with opposed beams or paddles that mate to both sides of a corresponding header signal contact for redundant or multiple points of contact. However, due to the excessive amount of material needed to form the double beam at the mating end, the signal contacts require a large pitch or spacing distance therebetween, which leads to a large overall profile or a reduction in the density of signal contacts within the electrical connector. To overcome such problems, at least some known contact modules include two overmolded leadframes that overlay or internest with each other to form the contact module. Such design is costly and difficult to manufacture. Additionally, because such design includes two overmolded leadframes, the time to manufacture such contact modules is doubled as compared to designs that use a single overmolded leadframe.
A need remains for an improved contact module and electrical connector design that has high density and low manufacturing costs.
In one embodiment, a leadframe for a contact module is provided that includes signal contacts arranged in pairs carrying differential signals. Each pair of signal contacts includes a first signal contact and a second signal contact. Each signal contact has a mating beam at an end thereof configured to be electrically connected to a corresponding header contact of a header assembly. Each mating beam includes a stem and a branch extending from the stem. A first paddle extends from the stem and a second paddle extends from the branch. In an initial, stamped orientation, the mating beams are stamped such that the mating beams of the first and second signal contacts within the same pair of signal contacts are angled non-parallel to one another.
Optionally, a centerline may be defined between the mating beams of the first and second signal contacts within the same pair. The first paddle of the mating beam associated with the first signal contact may extend along a first paddle axis angled oblique with respect to the centerline. The first paddle of the mating beam associated with the second signal contact may extend along a second paddle axis angled oblique with respect to the centerline. The first and second paddle axes may be angled inward at approximately equal angles relative to the centerline.
Optionally, a centerline may be defined between the mating beams of the first and second signal contacts within the same pair. The first paddle of the mating beam associated with the first signal contact may extend along a first paddle axis angled oblique with respect to the centerline. The second paddle of the mating beam associated with the first signal contact may extend along a second paddle axis generally parallel to the first paddle axis.
Optionally, the mating beams may be arranged on a tight pitch. Optionally, if the mating beams were not angled inward, the mating beams of adjacent pairs of signal contacts may overlap.
Optionally, a centerline may be defined between the mating beams of the first and second signal contacts within the same pair. The first paddles may be arranged interior of the second paddles closer to the centerline. The second paddles may have exterior edges facing outward away from the centerline. The exterior edges of the second paddles may be angled oblique with respect to the centerline. The second paddles may be outside of the first paddles. Adjacent second paddles of mating beams of signal contacts of different pairs may be angled away from each other.
Optionally, the branch and second paddle of each mating beam may be folded over the stem and first paddle of the corresponding mating beam such that the first and second paddles are parallel to one another and define a socket configured to receive the corresponding header contact. The mating beams may be moved outward to a final, formed orientation wherein each of the first and second paddles are parallel to one another.
In a further embodiment, a method of manufacturing a leadframe is provided that includes providing a leadframe by stamping a metal blank to include pairs of signal contacts having mating beams that are non-parallel to each other and forming the mating beams into a final form, the mating beams having a parallel alignment in the final form.
In another embodiment, a receptacle assembly is provided having a receptacle housing configured to be mated with a header assembly and contact modules received in the receptacle housing. Each contact module includes a dielectric frame having a front and opposite first and second sides and a leadframe held by the dielectric frame. The leadframe has signal contacts arranged in pairs carrying differential signals. The signal contacts are generally arranged along a leadframe plane parallel to and between the first and second sides. The signal contacts have mating beams at ends thereof each extending forward of the dielectric frame to be electrically connected to a corresponding header contact of the header assembly in a mating direction. Each mating beam includes a stem, a branch, a first paddle extending from the stem and a second paddle extending from the branch. The mating beams are stamped in an initial, stamped orientation such that the mating beams within the same pair of signal contacts are angled toward one another and such that the mating beams are angled away from the mating beams of any immediately adjacent pair of signal contacts. The branch and second paddle of each mating beam are folded over the stem and first paddle such that the first and second paddles are parallel to one another and define a socket for the corresponding header contact of the header assembly. The mating beams are pressed to a final, formed orientation such that each of the first and second paddles are parallel to the mating direction.
The midplane assembly 102 includes a midplane circuit board 110 having a first side 112 and second side 114. The midplane assembly 102 includes a first header assembly 116 mounted to and extending from the first side 112 of the midplane circuit board 110. The midplane assembly 102 includes a second header assembly 118 mounted to and extending from the second side 114 of the midplane circuit board 110. The first and second header assemblies 116, 118 each include header contacts 120 electrically connected to one another through the midplane circuit board 110. In an exemplary embodiment, the header contacts 120 are arranged in pairs configured to convey differential signals. The first and second header assemblies 116, 118 include header ground shields 122 that provide electrical shielding around corresponding header contacts 120. The first and second header assemblies 116, 118 each include a header housing 124 used to hold the header contacts 120 and the header ground shields 122.
The first connector assembly 104 includes a first circuit board 130 and a first receptacle assembly 132 coupled to the first circuit board 130. The first receptacle assembly 132 is configured to be coupled to the first header assembly 116. When the first receptacle assembly 132 is coupled to the first header assembly 116, the first circuit board 130 is orientated perpendicular with respect to the midplane circuit board 110.
The first receptacle assembly 132 includes a front housing 138 used to hold a plurality of contact modules 140. The contact modules 140 are held in a stacked configuration generally parallel to one another. The contact modules 140 hold a plurality of signal contacts (not shown) that are electrically connected to the first circuit board 130 and define signal paths through the first receptacle assembly 132. The signal contacts are configured to be electrically connected to the header contacts 120 of the first header assembly 116. In an exemplary embodiment, the contact modules 140 provide electrical shielding for the signal contacts. Optionally, the signal contacts may be arranged in pairs carrying differential signals.
The second connector assembly 106 includes a second circuit board 150 and a second receptacle assembly 152 coupled to the second circuit board 150. The second receptacle assembly 152 is configured to be coupled to the second header assembly 118. The second receptacle assembly 152 has a header interface 154 configured to be mated with the second header assembly 118. The second receptacle assembly 152 has a board interface 156 configured to be mated with the second circuit board 150. In an exemplary embodiment, the board interface 156 is orientated perpendicular to the header interface 154. When the second receptacle assembly 152 is coupled to the second header assembly 118, the second circuit board 150 is orientated perpendicular to the midplane circuit board 110. The second circuit board 150 is oriented perpendicular to the first circuit board 130.
The second receptacle assembly 152 includes a front housing 158 used to hold a plurality of contact modules 160. The contact modules 160 are held in a stacked configuration generally parallel to one another. The contact modules 160 hold a plurality of signal contacts 162 (shown in
In the illustrated embodiment, the first circuit board 130 is oriented generally horizontally. The contact modules 140 of the first receptacle assembly 132 are orientated generally vertically. The second circuit board 150 is oriented generally vertically. The contact modules 160 of the second receptacle assembly 152 are oriented generally horizontally. The first connector assembly 104 and the second connector assembly 106 have an orthogonal orientation with respect to one another.
The contact module 160 is coupled to the front housing 158 such that the signal contacts 162 are received in corresponding signal contact openings 200. Optionally, a single signal contact 162 is received in each signal contact opening 200. The signal contact openings 200 may also receive corresponding header contacts 120 (shown in
The front housing 158 is manufactured from a dielectric material, such as a plastic material, and provides isolation between the signal contact openings 200 and the ground contact openings 202. The front housing 158 isolates the signal contacts 162 and the header contacts 120 from the header ground shields 122. The front housing 158 isolates each set of receptacle and header contacts 162, 120 from other sets of receptacle and header contacts 162, 120.
The ground contact openings 202 are C-shaped in the illustrated embodiment to receive the C-shaped header ground shields 122. Other shapes are possible in alternative embodiments, such as when other shaped header ground shields 122 are used. The ground contact openings 202 are chamfered at the mating end 204 to guide the header ground shields 122 into the ground contact openings 202 during mating. The signal contact openings 200 are chamfered at the mating end 204 to guide the header contacts 120 into the signal contact openings 200 during mating.
The signal contacts 162 may form part of a leadframe 230 (shown in
The contact module 160 may include a ground shield 228 (shown in
With additional reference to
The signal contacts 162 have mating beams 232 at a front of the leadframe 230 and mounting portions 234 at another end of the leadframe 230, such as a bottom of the leadframe 230. The front and bottom are generally perpendicular to one another. The mating beams 232 and mounting portions 234 may be provided at other portions of the leadframe 230 in alternative embodiments.
The leadframe 230 is generally planar and defines a leadframe plane. The mating beams 232 and mounting portions 234 are integrally formed with the conductors of the leadframe 230. The conductors extend along predetermined paths between each mating beam 232 and corresponding mounting portion 234. The mating beams 232 are configured to be mated with and electrically connected to corresponding header contacts 120 (shown in
The mating beams 232 include a plurality of mating interfaces 250 to define multiple points of contact with the header contacts 120 (shown in
Gaps 240 are defined between the signal contacts 162. The gaps 240 between signal contacts 162 of different pairs may be relatively larger than the gaps 240 between the signal contacts 162 within a pair. The size or length of the gaps 240 may define the pitch(s) of the signal contacts 162. The pitch between the signal contacts 162 within the pair may be smaller than the pitch between adjacent signal contacts 162 of different pairs.
Each of the conductors defining signal contacts 162 has a predetermined length defined between the mating beams 232 and mounting portions 234. The lengths of the conductors may be different, due at least in part to the right angle nature of the contact module 160. For example, the radially inner conductors are generally shorter than the radially outer conductors. While the signal conductors within a differential pair have approximately equal lengths, because of factors such as the size constraint of the contact module 160 and the cost or complexity of manufacture, the radially inner signal contact 162 within each differential pair is generally slightly shorter than the radially outer signal contact 162 of the same differential pair. Any difference in length may lead to skew problems, as the signals within the differential pair travel along different path lengths. Skew compensation may be provided, such as by changing a width or thickness of the signal contacts 162 along predetermined lengths thereof and/or surrounding the signal contacts 162 with different dielectrics (such as plastic versus air) along predetermined lengths thereof.
Each mating beam 232 includes a stem 262 at the base of the mating beam 232. The first paddle 252 extends from the stem 262. Each mating beam 232 includes a branch 264 extending from the stem 262. The second paddle 254 extends from the branch 264. The first and second paddles 252, 254 extend generally forward from the stem 262 and branch 264, respectively. The branch 264 and second paddle 254 form part of the folded over portion 256 (shown in
Returning to
In an exemplary embodiment, in the initial stamped orientation, the leadframe 230 is stamped such that the first and second mating beams 232a, 232b of the first and second signal contacts 162 within the same pair 260 of signal contacts 162 are angled toward one another. Such mating beams 232a, 232b are angled toward the centerline 266. Such mating beams 232a, 232b are angled away from the adjacent mating beams 232 of adjacent pairs 260 of signal contacts 162.
In the initial, stamped orientation, the leadframe 230 is stamped such that the first paddle 252 of the first mating beam 232a extends along a first paddle axis 270 angled oblique to the centerline 266. The second paddle 254 of the first mating beam 232a extends along a second paddle axis 272 that is generally parallel to the first paddle axis 270. Alternatively, the second paddle axis 272 may be angled at a different angle than the first paddle axis 270. The first paddle 252 of the second mating beam 232b extends along a third paddle axis 274 angled oblique with respect to the centerline 266. The second paddle 254 of the second mating beam 232b extends along a fourth paddle axis 276 that is generally parallel to the third paddle axis 274. Alternatively, the fourth paddle axis 276 may be angled at a different angle than the third paddle axis 272. Each of the paddle axes 270, 272, 274, 276 is angled oblique to the centerline 266. The first and second paddle axes 270, 272 may be angled inward at first and second angles 280, 281, respectively, to the centerline 266. The third and fourth paddle axes 274, 276 may be angled inward at third and fourth angles 282, 283, respectively, to the centerline 266. The angles 280, 281 may be approximately equal angles to the centerline 266. For example, the first angle 280 may be approximately +3°, while the second angle 281 may be approximately −3°. The angles 282, 283 may be approximately equal angles to the centerline 266. For example, the third angle 282 may be approximately +3°, while the fourth angle 283 may be approximately −3°. The angles 280, 281, 282, 283 may be other angles in alternative embodiments, such as approximately +/−5°, +/−10°, and the like. Alternatively, the first and third paddle axes 270, 274 may be angled less or not angled at all relative to the centerline 266, while the second and fourth paddle axes 272, 276 are angled at greater angles than the angles of the first and third paddle axes 270, 274.
The first paddles 252 are arranged interior of the second paddles 254 closer to the centerline 266. The second paddles have exterior edges 284 facing outward away from the centerline 266. Optionally, the exterior edges 284 of the second paddles 254 are angled oblique to the centerline 266. Optionally, the exterior edges 284 may be oriented parallel to the corresponding paddle axes 272, 276. The second paddles 254 are arranged outside of the first paddles 252. Adjacent second paddles 254 of mating beams 232 of different pairs 260 are angled away from one another. For example, the second paddle 254 of the first mating beam 232a of one pair 260 is positioned adjacent to the second paddle 254 of the second mating beam 232b of an adjacent pair 260. Both such paddles 254 are angled in opposite directions toward their corresponding centerlines 266.
After the leadframe 230 is stamped, the leadframe 230 is processed by bending, drawing, forming or other metalworking processes to shape the leadframe 230, such as the mating beams 232. The branch 264 and second paddle 254 of each mating beam 232 are folded over the stem 262 and first paddle 252 of the corresponding mating beam 232. The first and second paddles 252, 254 are arranged parallel to one another and define a socket 290 (shown in
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 invention 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.
