Connectors used to transmit electrical power, such as alternating current (AC) power and/or direct current (DC) power, may include a power contact mounted within an electrically-insulative housing. In a typical application, the connector may be mounted to a substrate, such as a circuit board, and the connector may be may be configured to mate with a corresponding power cable assembly. Specifically, each power contact within the housing may include one or more male contact beams and/or female receptacles that mate with that of the opposite gender within the power cable assembly.
When mating and un-mating the cable assembly with the mounted connector, substantial forces may be exerted on the individual power contacts within the cable assembly and within the mounted connector. These forces may dislodge the power contacts from their position in the housing and/or power cable if they are not sufficiently retained.
The capacity and efficiency of power transmission through power contacts may be affected by the contact's shape, size, material, internal resistance, extent of physical contact with the mating contact, etc. A contact's power transmission performance may relate to the quality and extent of physical contact between complementary contacts. Deformation of power contacts (e.g., by the forces of mating and unmating the connector) that affect the quality and extent of physical contact may affect the contact's power transmission performance. Traditionally, improving a contact's power transmission capacity and physical contact stability has been met with increasingly larger, heavier connectors. Increases in size and conductive materials often drive increases in manufacturing costs.
The disclosed electrical connectors and contacts employ a novel structure for improved performance in power capacity and physical contact stability and still allowing for lower manufacturing costs. For example, the electrical contacts may be stamped-metal contacts that include first and second contact beams that deflect independently of one another during mating of the power receptacle contact with a complementary blade contact. Each beam may extend from abutting respective body portions. The power receptacle contact may include a first clip that extends from the first contact beam. The first clip may define a blade receiving area between the first and second contact beams. An edge of the first clip may abut the second contact beam. The edge of the first clip may overlap the second contact beam. The power receptacle contact may include a second clip that extends from the second contact beam. The second clip may define a blade receiving area between the first and second contact beams. The contact beams may each be part of respective contact halves that are substantially identical.
The contacts may include various retention features to provide stability when mating and un-mating. For example, a power connector may include a housing and a contact received in the housing. The contact may include a body portion and a contact beam that extends from the body portion. The body portion may be a planar body portion. The contact beam may extend from the body portion in a first direction.
The contact may include first and second protrusions. The first protrusion may prevent the contact from moving in the first direction relative to the housing. For example, the first protrusion may include a latch that extends from the contact body and engages the housing.
The second protrusion may prevent the contact from moving in a second direction relative to the housing. The second direction may be opposite the first direction. The second protrusion may include a tab that extends from the planar body portion and engages the housing.
The contact may include a plurality of fingers that extend from the body portion in the second direction. The tab may prevent the fingers from spreading when a force in the second direction is applied to the contact portion.
Certain terminology may be used in the following description for convenience only and should not be considered as limiting in any way. For example, the terms “top,” “bottom,” “left,” “right,” “upper,” and “lower” designate directions in the figures to which reference is made. Likewise, the terms “inwardly,” “outwardly,” “upwardly,” and “downwardly” may designate directions toward and away from, respectively, the geometric center of the referenced object. The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.
The electrical connector 10 may include a housing 12, a power contact 14 for AC power, a power contact 15 for DC power, a signal contact 16 (shown in
The power contacts 14, 15 and signal contacts 16 may be mounted within the housing 12. As shown, connector 10 is depicted with five of the power contacts 14. The electrical connector 10 may include more or less than five of the power contacts 14 shown. Similarly, alternative embodiments can be configured with more or less than the number of power contacts 15 and signal contacts 16 than what is depicted.
The electrical connector 10 may be used in any application for which electrical conductivity between components is desired. For example, the electrical connector 10 may enable electrical conductivity between the power contacts 14 and a power cable assembly (not shown). The electrical connector 10 may enable electrical conductivity between the power contacts 14 and a complementary electrical connector (not shown). The electrical connector 10 may enable electrical conductivity between the power contacts 14 and a conductive trace on a substrate (not shown) to which the electrical connector 10 is mounted.
The housing 12 may include one or more passages 56. The power contacts 14 may be retained within the passages. The passages 56 may extend through the housing 12 to enable connector mating on both sides of the housing 12.
The housing 12 may include a retention feature to secure one or more power contacts 14. The projections 58 may help retain the power contacts 14 in the housing 12. In particular, the projections 58 each include a vertically-oriented lip 60 and a stop 80. Adjacent projections 58 may define a passage 56. The connector 10 may include one or more passages 56.
The power contact 14 may be received by the passage 56 as depicted in
As depicted in
The first and second halves 22a, 22b may each be configured with an alignment feature such as a projection 27. The projection 27 of each of the first and second halves 22a, 22b may be received in a corresponding through-hole formed in the other of the first or second halves 22a, 22b. Interference between the projection 27 and the peripheral surfaces of the corresponding through holes may maintain the first and second halves 22a, 22b in a state of alignment when, for example, the power contact 14 is inserted into the housing 12.
Contact beams 34a, 34b may each extend from respective first and second body portions 24a, 24b. A first contact beam 34a may extend from the first body portion 24a in a first direction 31. A second contact beam 34b may extend from the second body portion 24b in the first direction 31. Thus, each of the first and second halves 22a, 22b may each include a respective contact beam 34a, 34b that extends from the respective body portion 24a, 24b.
The contact beams 34a, 34b may be substantially flat. The contact beams 34a, 34b of each corresponding first half and second half 22a, 22b may face and abut each other. As shown in
Each of the contact beams 34a, 34b may define an area 35 of reduced thickness (as shown in
The reduced-thickness areas 35 on each beam 34a, 34b may correspond to the portion of the beam 34a, 34b that contacts the faston receptacle. The outwardly-facing surfaces of the reduced thickness areas 35 may be substantially planar and may be substantially parallel to each other. Being substantially planar and substantially parallel may reduce the potential for an unbalanced or otherwise inadequate connection between the power contact 14 and the mating connector.
Each of the first and second halves 22a, 22b may include one or more protrusions to help secure the contact 14 within the housing 12. For example, the contact 14 may have a first protrusion that prevents the contact 14 from moving in a first direction 31 relative to the housing 12. The contact 14 may have a second protrusion that prevents the contact from moving relative to the housing 12 in a second direction that is opposite the first direction 31. The second direction may correspond to the direction in which the contact 14 is inserted into the housing 12.
The first protrusion may include a latch 32. The latch 32 may adjoin a respective body portion 24a, 24b of the corresponding first or second half 22a, 22b. The latch 32 may be angled in relation to the corresponding body portion 24a, 24b, as shown in
The second protrusion may be a tab 40. Each of the first and second halves 22a, 22b may include the tab 40. The tab 40 may be formed in the corresponding body portion 24a, 24b of the first or second half 22a, 22b. The tabs 40 may each extend in a direction substantially perpendicular to the major surface of the respective body portion 24a, 24b.
To illustrate, when the contact 14 is inserted into the housing 12, the tab 40 may prevent the contact 14 from moving further into the housing 12 and the latches 32 may engage the housing 12, preventing the contact 14 from moving back out of the housing 12. A third protrusion may be another latch 32, such that there are latches 32 at both sides of the body portion 24a, 24b with the tab 40 in between, relative to a direction perpendicular to the first direction 31.
The power contact 14 may be configured to receive corresponding contacts at each end. As shown, the power contact 14 may receive a first corresponding contact (not shown) at the contact beam 34a, 34b. Power contact 14 may received a second corresponding contact (not shown) at the fingers (e.g., angled contact beams 26 and substantially straight contact beams 28). For example, each pair of straight contact beams 28 may be received between a pair of angled contact beams of the second corresponding connector (not shown). Each pair of angled contact beams 26 of the connector 10 may receive a pair of straight contact beams of the second corresponding connector (not shown).
When the power contact is received in the housing 12, the tab 40 may prevent the insertion force of mating the first corresponding contact to deform the arrangement of the fingers. The insertion force of mating the first corresponding contact may tend to cause the fingers to spread apart and for the contact to bow. This deformation may cause less aligned mating between the fingers and the second corresponding contact, which may affect the contact's power transmission performance. The tab 40 may be disposed in-line with the direction of the insertion force. The tab 40 may be disposed substantially centered with respect to the fingers. The tab 40 may be disposed between the fingers and the contact beam 34a, 34b. The tab 40 may abut the housing and may tend to protect the alignment of the fingers for mating with the second corresponding contact in the presence of insertion force at the first corresponding contact. For example, the fingers may be substantially parallel to one another. The tab 40 may abut the housing under insertion force at the contact beam 34a, 34b such that the fingers remain substantially parallel to one another.
Power contacts 140, 141 may have a first half 142a and a substantially identical second half 142b. The first and second halves 142a, 142b each include a respective body portion 143a, 143b that abut one another. A respective contact beam 144a, 144b may extend from each body portion 143a, 143b in a first direction 31. Each respective contact beam 144a, 144b may be offset from a centerline of the body portion 143a, 143b from which it extends. The contact beams 144a, 144b may face each other when the respective body portions 143a, 143b abut one another. The contact beams 144a, 144b may be substantially flat.
The power contact 140, 141 may include latches 32. Although not depicted in
The receptacle contact beams 144a, 144b may be configured to receive a male contact blade of a corresponding power contact. The contact surface of the contact beams 144a, 144b (e.g., the surface of the contact beams 144a, 144b that contacts the male contact blade of a corresponding electrical contact), may be offset from a vertical plane defined by a surface of the body portion 143a, 143b from which it extends. For example, the vertical plane may be defined as passing through the center of the power contact 140, 141. The offset may be approximately one-half of the thickness of a corresponding male contact blade. For example, the offset may be approximately 0.016 inch.
With regard to the first half 142a, a first clip 148a may extend from the first contact beam 144a. The clip 148a may define a blade receiving area between the first contact beam 144a and the second contact beam 144b. With regard to the second half 142b, a second clip 148b may extend from the contact beam 144b. The second clip 148b may define a blade receiving area between the first contact beam 144a and the second contact beam 144b. The clips 148a, 148b may be C-shaped, for example. As shown in
The arrangement of contact beam 144a, 144b and clip 148a, 148b may enable the contact beams 144a, 144b to deflect independently of each other, when mating (i.e., receiving a corresponding male contact beam in the defined blade receiving area). The receptacle contact beams 144a, 144b may deflect when mated with the corresponding male contact beams. The blade receiving area between each clip 148a, 148b and the corresponding contacting surface of the male contact blade may act as the initial point of deflection.
Independent deflection may result in independent loading of the receptacle contact beams 144a, 144b, which may help to ensure that the contact surfaces of the contact beams 144a, 144b remain substantially parallel to the contact surfaces of the corresponding male contact blade. The independent loading of the receptacle contact beams 144a, 144b also may help to ensure that the receptacle contact beams 144a, 144b and the male contact blade remain in a state of equilibrium once mated.
As shown in
As the contact 14 is being inserted into the housing, the angled orientation of the latches 32 may cause the latches 32 to deflect inwardly as they contact the projections 58. The resilience of the latches 32 may cause each latch 32 to spring outwardly, toward its un-deflected position, as it clears the corresponding lip 60. In their un-deflected positions, the latches 32 may abut the corresponding lip 60, preventing the contact 14 from moving in the first direction 31. For example, the latches 32 in cooperation with the projections 58 may prevent the contact 14 from backing out of its corresponding passage 56 when, for example, a corresponding AC power cable assembly is demated from the electrical connector 10 (i.e., pulled away from the connector 10 in the first direction 31).
As shown in
The contact 14 may be inserted into the housing 12. A stop 80 may correspond with a tab 40 on the power contact 14. The stop 80 may, in cooperation with the tab 40 of the contact 14, prevent the contact from moving in a second direction that is opposite the first direction 31.
As the contact 14 is inserted into the housing, interference between the tab 40 and the associated stop 80 may prevent movement of the power contact 14 further into the housing. The stops 80 and the projections 58, by providing retention for the contacts 14, may obviate the need for structure in addition the housing to retain the contacts 14.
The tab 40 may prevent the fingers (e.g., angled contact beams 26 and substantially straight contact beams 28) from spreading apart when a force in the second direction is applied to the contact 14, such as when a corresponding AC power cable assembly is pushed onto and mated to the electrical connector 10, for example.
The shroud 18 may include a body 64 and two latch bars 66 that each may be connected to the body 64 by way of a plurality corresponding of latch arms 68. The body 64, latch bars 66, and latch arms 68 may define one or more openings 70.
The location of the opening 70 may correspond to the location of the projections 58 on the housing 12. As shown in
The shroud 18 may be retained to the housing 12 when an opening 70 receives a corresponding projection 58. When the shroud 18 is received by the housing 12 a ramp 74 of each latch bar 66 may engage the angled surfaces 72 of the corresponding projections 58. Contact between the angled surfaces 72 of the projections 58 and the ramps 74 may cause the latch bars 66 and the latch arms 68 to deflect, until the horizontally-oriented lips 62 at the edge if the angled surfaces 72 clear the latch bars 66. The resilience of the latch arms 68 may cause the latch bars 66 to move toward their un-deflected positions as the horizontally-oriented lips 62 become disposed within the corresponding openings 70. Once retained, the shroud 18 may be covered by a surfaces of a substrate when the connector 10 mounted to further helps to prevent the horizontally-oriented lips 62 from becoming disengaged from the latch bars 66.
While the shroud 18 is being mated to the housing 12, two partitions 97, defined within the body 64 of the shroud 18, may provide alignment. Each partition 97 may be received in a corresponding pocket 96 (i.e., the space defined between adjacent columns of projections 58 on the housing 12 as shown in
The shroud 18 and the housing 12 may include a polarization feature that helps prevent the shroud 18 from being installed incorrectly on the housing 12. In particular, the shroud 18 may include two projections 82. The projections 82 may be formed on opposite sides of the body 64 of the shroud 18. The projections 82 may be located below the center of the shroud 18 (i.e. the projections 82 may be located closer to the bottom of the shroud 18 than the top, as shown in
The middle portion 50 of the housing 12 may define two pockets 84 formed in the rearward-facing side thereof. Each pocket 84 may receive a corresponding projection 82 when the shroud 18 is installed correctly on the housing 12. The off-center location of the projections 82 may provide interference between the projections 82 and the middle portion 50 of the housing 12, when an attempt is made to install the shroud 18 incorrectly, e.g., upside down as shown in
The outermost projection 82, e.g., the projection 82 located on the right side of the housing 12, from the perspective of
The shroud 18 may include a polarization feature that helps prevent the power contacts 14 and a corresponding AC power cable from being mated incorrectly. In particular, the body 64 of the shroud 18 may define two slots 90 formed in a top portion thereof and may define two slots 92 formed in a bottom portion thereof.
The top slots 90 and the bottom slots 92 may be configured to receive relatively small diameter ribs and relatively large diameter ribs, respectively, on the connector of the AC power cable that mates with the connector 10. Accordingly, the top slots 90 may have a relatively small width, and the bottom slots 92 may have a relatively large width. The spacing between the top slots 90 may be different than that of the bottom slots 92. The noted differences in the spacing and widths of the slots 90, 92 may prevent the connector of the corresponding AC power cable from being installed incorrectly, i.e., upside down. Once the AC power cable is correctly oriented, latches on the connector of the AC power cable may be received in through-holes 94 defined by the body 64 of the shroud 18 to help retain the AC power cable to the shroud 18, and thus, the connector 10.
This application claims the benefit of U.S. Provisional Application No. 60/976,620 filed Oct. 1, 2007.
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