Abstract:
A miniature electrical connector device includes an insulating body member having electrically conductive feet extending from the body. The device may be configured for interconnecting subassemblies of electronic products such as cellular telephones and the like. The connectors may be used to engage a loudspeaker, microphone, or other unit to another conductive member, including for example a circuit board. A pair of connector elements extend beyond an insulating body for electrical contact with a conductive member. Further, a metallic or conductive can having an outer engaging surface operatively connected to a loudspeaker coil may be provided. Channels or divisions in the metallic can may be configured to receive the foot of a connector element within the channel. Connector elements include a closed end or an open end defined by extending arms. The connector may provide outwardly facing contact surfaces defined on extending arms for mating contact with respective pads of circuit board assemblies.

Description:
FIELD OF THE INVENTION 
     This invention pertains to electrical connectors, and in particular, miniature connectors that enable secure and efficient electrical interconnections between electronic subassemblies such as printed circuit boards (PCB&#39;s) and electronic devices. 
     BACKGROUND OF THE INVENTION 
     Prior art methods have been employed for some time to interconnect electronic subassemblies, such as printed circuit boards. For example, in connecting electronic components such as loudspeakers and the like to circuit boards within cellular phones, connectors have been used to mate such electronic components to the circuit board. 
     A primary concern for cellular phones and other relatively small electronic devices is the limited space available to connect boards or subassemblies within the electronic device. Using conventional connectors, conductive electrical metallic alloy contacts are used to flex in a pressing action against other electrical devices, such as a contact pad on a circuit board. This pressing action forms a secure electrical pathway. As the need for smaller connectors has increased, it has become more difficult to provide for a secure electronic connection in a limited amount of space. 
     Electrical connectors using metallic electrical contacts must provide for a certain minimum beam length in order to facilitate enough flexibility to engage an electrical surface securely. Without a certain minimum or threshold length, the metal used to construct the elongated contacts cannot withstand the stress and pressure of flexibly engaging an electrical contact surface. The miniaturization of connectors, therefore, has made it more difficult to provide for a metallic contact beam of sufficient length and strength to provide a secure connection. In modern connectors, the beam length of the metallic contacts has been minimized such that the total length of the beam approaches the size (or diameter) of the insulative body which itself holds these metallic contacts in place. Thus, it is highly desirable to provide for a minimum beam length for electrical contacts using a smaller total connector body diameter. 
     SUMMARY OF THE INVENTION 
     It is a principal object of the present invention to provide an improved electrical connector particularly suited for interconnecting loudspeakers, microphones, and other electronic subcomponents. 
     Still another object of the invention is to provide a connector that exhibits, in a small overall size or package, a maximized beam length for electrical contacts to facilitate greater miniaturization of the overall connector. 
     Additional objects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention. 
     An electrical connector device for engaging a loudspeaker to another conductive member is provided in one embodiment of the invention. The device includes a circuit board. Further, the connector comprises an insulating body having an inner surface and an outer surface. In general, the connector is integrated into the electronic device, or loudspeaker, and is not a separate entity. At least one pair of connector elements are configured within said body, each said connector element comprising contact feet having a proximal end and a distal end. The distal end of the contact feet extend generally beyond the outer surface of the insulating body for electrical contact with a conductive member. Further, the proximal end of the contact feet extend into the receptacle for electrical contact with the loudspeaker. The contact feet are configured to flex along their length to provide for pressing contact against the conductive member. 
     Additionally, a conductive can having an outer engaging surface operatively connected to the loudspeaker is provided. The can also includes an interior, and contains at least one channel on its interior. 
     The channel of the can is configured to receive the foot of a connector element, thereby facilitating a path for the connector element within the channel that provides for pressing contact of the connector element against the conductive member. This pressing contact enables the overall length of the connector element to be maximized relative to the diameter of the electrical connector device. 
     The electrical connector device further comprises, as one option, an orientation slot to facilitate placement of the connector during manufacture. The electrical connector device is provided, in another embodiment, such that the proximal end of the contact feet comprise electrical contact pads. 
     In one aspect of the invention, the electrical connector device is provided wherein the contact feet are S-shaped. The electrical connector device is also provided in which the length of the contact feet is greater than the diameter of the insulative body. 
     In one embodiment of the invention, an electrical connector device is provided in which the can comprises an upper flat surface, wherein the can electrically engages a loudspeaker upon its upper surface. 
     In another embodiment of the invention, the electrical connector contact feet extend across the width of at least a portion of the can and at least a portion of the body. In other aspects of the invention, the can comprises a portion of a carrier strip for a plurality of electrical connector devices. 
     In one aspect of the invention, an electrical connector device is provided in which the contact feet flex along their length to provide for pressing contact against a printed circuit board (PCB). In one optional embodiment, the electrical connector device includes a carrier strip that comprises iron. 
     In one embodiment, an electrical connector device is provided for engaging a loudspeaker to another conductive member, including a circuit board, in a stacked configuration. In this alternative embodiment, the connector comprises an insulating body having an inner surface and an outer surface. Further, at least one connector element is configured within the body. The connector element comprises contact feet, a proximal end and a distal end. The distal end of the connector element extends beyond the outer surface of the insulating body for electrical contact with a conductive member, and the proximal end of the connector element extends into the receptacle for electrical contact with the loudspeaker. In addition, a pad projection is located along the length of the connector element. A can having an outer engaging surface operatively connected to the loudspeaker is also provided, the can further comprising at least one channel. The channel of the can is configured to receive the connector element. 
     In one aspect of the invention, the electrical connector also comprises a top ridge which facilitates “pick and place” automated manufacturing. In one embodiment, the electrical connector is provided with at least one connector element that is L-shaped. The electrical connector device also is provided in which the connector element has no more than one stress point along its length while flexed. In other embodiments, more than one stress point is provided in the connector element. 
     An electrical connector device is also provided in which the body comprises at least one keyway aperture. In one embodiment, the electrical connector device provides at least two connector elements generally parallel to each other within the body, the elements forming a top space between each other. In one aspect of the invention, the electrical connector device is provided in which the pad projections to interact with speaker connection wires. 
     One embodiment of the invention further includes a top space that occupied by an air flow reduction means. In loudspeaker applications, the air flow between and around the electrical contacts (i.e. through the device) is very important to maintain the acoustical quality of the loudspeaker that is associated with the connector. An air flow reduction means may increase the sound quality of the loudspeaker to which the connector is attached. 
     The electrical connector device also is provided in which the pads of the device comprise an upper surface and a lower surface, in which the air flow reduction means (or upper cap) extends over the upper surface of the contact elements. In one aspect of the invention, the electrical connector device may include an air flow reduction means which extends below the lower surface of the pads (i.e., sometimes referred to as a “lower cap”). In some applications, an air flow reduction means, or cap, below the pads facilitates a more efficient overall design. 
     The electrical connector device of the invention may be manufactured in a carrier strip in an assembly line procedure. The techniques for this type of manufacture are known to persons of skill in the art, and provide a convenient means for keeping and storing the devices until they are placed into a cellular phone or other suitable electronic end product. 
     To aid in precise positioning of the connector element on circuit boards, engaging structures, such as male or female members, may be defined on the body member so that a positioning cap or ridge or similar device may be used to grasp and precisely locate the connector on the circuit board. This structure may also serve as positioning or alignment structure matable with complimenting structure on the circuit boards. 
     The contacts of the connector comprise, in one embodiment, leaf springs that bend under a load and provide a tensioning force sufficient to keep them in constant physical contact with an electrical contact or pad to develop an electrical circuit. 
     It should be recognized that a plurality of connector subassemblies according to the invention can be utilized in any number of different configurations. For example, a plurality of connector assemblies could be placed on a single loudspeaker, microphone, or other device in any desired pattern upon a circuit board. 
     The present connector assembly is not limited by any particular material of construction and, in this regard, any conventional suitable materials may be utilized in the manufacture of the electrical connector device components. 
     Applicants have found that the particular configurations shown in the inventions of this application are very efficient at retaining the connector elements within the insulating body in contact with their respective conductors without any additional mechanical structures, such as adhesives, solder, and the like. It is a relatively inexpensive procedure to simply mold the connector assembly directly into the body member, with a metallic conductive can being incorporated into the insulative body. 
     The present invention will be described in greater detail below through preferred embodiments as illustrated in the attached Figures. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A full and enabling disclosure of this invention, including the best mode shown to one of ordinary skill in the art, is set forth in this specification. The following Figures illustrate the invention: 
     FIG. 1 is a perspective view of one embodiment of the electrical connector of the invention; 
     FIG. 2 shows the underside of the connector shown in FIG. 1; 
     FIG. 3 shows a side view of the connector shown in FIG. 1; 
     FIG. 4 shows a cross-sectional view of the connector shown in FIG. 1, the cross-section taken along lines  4 — 4  of FIG. 1; 
     FIG. 5 is a cross-section of the connector shown in FIG. 1 in which the connector has been engaged on its top surface by an electronic component, and on its bottom surface is engaged by a printed circuit board; 
     FIG. 6 depicts an alternative configuration of the invention; 
     FIG. 7 shows the underside of the connector shown in FIG. 6; 
     FIG. 8 shows a side view of the connector shown in FIG. 6; 
     FIG. 9 depicts a cross-sectional view of the connector shown in FIGS.  6 — 7 , the cross-section taken along lines  9 — 9  of FIG. 7; 
     FIG. 10 shows the cross-section of FIG. 9 wherein the connector has been mated on its top surface to an electronic component and on its bottom surface to a printed circuit board; 
     FIG. 11 depicts still another alternative configuration of the invention which utilizes an upper cap to restrict air flow; 
     FIG. 12 shows the configuration of FIG. 11 with the upper cap installed; and 
     FIG. 13 shows a view of the underside of the connector shown in FIGS.  11 — 12 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference now will be made to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not as a limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in this invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features and aspects of the present invention are disclosed in or are obvious from the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions. 
     In electrical connectors for microphones, loudspeakers, and other electronic devices, efforts have been made to enable short pieces of metal to act as flexible electrical contacts in a small scale environment. For example, connectors used in cellular telephones and other such devices which are designed to connect electronic subcomponents such as microphones and loudspeakers to the internal telephone assembly usually rely upon flexible metallic electrodes or contacts to provide for electrical connectivity. As such devices become smaller and smaller with technological progress, it becomes more difficult to provide a sufficient contact element length to enable spring-action or flexibility in such devices. Therefore, the geometry that is adopted by contacts within such connectors is very important to ensure a reliable connection, while still achieving miniaturization. 
     In many connectors, it is desirable to orient the contacts within the connector so that the beam length of the contacts (i.e., the length of the electrical contacts) is maximized as compared to the diameter of the electronic connector device. One method of achieving such a result is to integrate the insulative body with a metallic can as provided in this invention. 
     Turning now to FIG. 1, a connector  20  is shown in perspective view with an insulative body  21  near the center of the connector. Connector elements  22   a  and  22   b  are shown near the center of the insulative body, where they form electrical contact pads on the upper surface of the insulative body. Connector elements  22   a  and  22   b  typically are welded, in the process of manufacture, to the electronic component onto the conductive members  23   a  and  23   b . The connector engages conductive member  23   a  and  23   b  on its lower margin, and the foot of connector element  22   b  is shown near the lower portion of FIG. 1 where it engages conductive member  23   a  of a printed circuit board (the printed circuit board is shown in FIG.  4 ). A circular can  24  surrounds the insulative member. 
     If comprised of metal, the can may serve as a magnetic electrical conductor. Metal is preferred as a material for the can. In some cases, the can receives the magnetic core of a loudspeaker or a voice coil on its upper surface for electrical communication with an electronic device such as a loudspeaker, microphone or the like. The can includes recesses  25   a-c  into which portions of the insulative body protrude. An electronic device such as a loudspeaker  26  may engage the connector  20  on its upper surface as shown in FIG.  1 . Usually, the connector is integrated into the electronic device by soldering or welding techniques known in the art, and is not usually a stand-alone unit. The rim of the can may include a slot  27  that may be used as an orientation marker when the connector  20  is provided for installation in an electronic handset or a cellular telephone. 
     The underside of the connector  20  shown in FIG. 1 is provided in FIG.  2 . The distal end  28  of the contact foot  22   b  and the distal end  29  of the contact foot  22   a  is shown in FIG.  2 . The connector elements  22   a  and  22   b  are capable of folding into channel  30   a  and channel  30   b , respectively, when the connector is mated to a printed circuit board. The distal end  28  contacts conductive member  23   a  of the printed circuit board and the distal end  29  of connector  22   a  contacts the conductive member  23   b  of the printed circuit board  31  (printed circuit board is shown in FIG.  4 ). FIG. 3 shows a side view of the connector shown in FIGS.  1 — 2 . In FIG. 3, voice coil  36   a  and  36   b  is shown on either side, connected by the diaphragm  35  that extends over the top of the can  24 , as seen in the Figure. 
     In FIG. 4, a cross-sectional view of the connector  20  is shown, including also the electronic device  26  shown in the upper portion of FIG. 4. A contact pad  32  of connector element  22   a  is shown at the upper portion of the connector. A lower surface  33  of the insulative body  21  is seen at the lower margin of the connector. The distal ends  28  and  29  of the connector elements  22   a  and  22   b , respectively, are placed in contact with the conductive members  23   a  and  23   b  of the printed circuit board  31  when the connector is installed for use. The electronic device  26  may comprise a loudspeaker, microphone, or other subassembly. 
     FIG. 5 shows the connector of FIG. 4 wherein the connector element  22   a  is pressed against conductive member  23   b  to provide electrical communication to the printed circuit board  31 . Thus, the connector element  22   a  is held by spring tension force against the printed circuit board conductive member  23   b . In designing the connector elements, it if preferable to have a reduced number of bends, or stress points, along the length of the connector element. In FIG. 5, connector element  22   a  contains two bends, or stress points, one near the contact pad  32 , and one about mid-way along its length. Further, the tip of the connector element is bent at the distal end  29  of the contact foot. The other connector element  22   b  is also flexibly engaged to conductive member  23   a.    
     In another alternative embodiment of the invention, a connector  100  is provided in which the contact elements form a multi-lobed structure. As shown in FIG. 6, cropped contact tails  103   a  and  103   b  emerge out of and above airflow reduction insulator  101 . The insulator in this embodiment is designed to reduce the amount of air or space that surrounds the electrical contact elements, which proves useful in connectors that are used for loudspeakers. In a loudspeaker connector, the movement of air through the center of the connector can have a pronounced affect upon the performance of the loudspeaker to which it is connected, and it has been found that in some configurations reducing the airflow along the center of the connector is desirable. In FIG. 6, metal support can  102  is shown as a circular disk of material. In some cases, the can is comprised of metal. It is usually necessary to use a soft magnetic iron for the can in order to adequately provide for a magnetic loudspeaker circuit, for example. Ridges  104   a ,  104   b , and  104   c  emerge above the airflow reduction insulator  101 . Ridges supply a gripping location for pick-and-place manufacturing techniques that use automated gripping devices in the manufacture of cellular telephones and the like which involves the installation of the connectors. Top space  105  is located between the contact elements  107   a  and  107   b.    
     FIG. 7 shows the underside of the connector  100  shown in FIG.  6 . Plastic keyway  106  shows the integration of the insulative body  108  with the metal support can  102 . Furthermore, keyway or aperture  109  and aperture  110  are shown in FIG.  7 . Contact elements  107   a  and  107   b  are shown emerging from the bottom of the connector  100 , and such connectors are configured to springingly engage contact pads of a printed circuit board. FIG. 8 shows a side view of the connector shown in FIGS. 6-7, and FIG. 9 shows a side cross-sectional view of the connector shown in FIGS. 6-8. FIG. 10 shows the cross section of FIG. 9 except that the connector in FIG. 10 includes deflected contact elements. Deflected contact element  107   a  is shown under tension where it electrically engages contact  34   a  of the electronic device  26  via the cropped contact tail  103   a . Contact tails  103   a  and  103   b  are typically welded or soldered to the electronic device during manufacture of the unit. Furthermore, at the distal end of the contact element  107   a  electrical communication is established with conductive member  23   b  of the printed circuit board (PCB)  31 . 
     An additional alternative embodiment of the invention is shown in FIG.  11 . FIG. 11 shows connector  200  which comprises an insulative body  201  held within a metallic can  223  having ridges  202   a ,  202   b , and  202   c  on its upper surface. Keyways  203   a ,  203   b , and  203   c  provide passage from the upper portion of the connector to the lower portion of the connector. Contact element foot  205   a  is shown in FIGS.  11  and FIG.  12 . Both contact feet  205 A and  205   b  are shown in FIG.  13 . Contacts  206   a  and  206   b  are shown near the upper portion of the connector in FIG.  11 . 
     An upper cap  207  is shown detached form the connector in FIG.  11 . The upper cap  207  provides protection for the electrical contacts, and further restricts airflow in those applications for which airflow restriction is advantageous. FIG. 11 shows the upper cap  207  detached from the connector. However, in FIG. 12 the upper cap  207  is installed in a location generally between the ridges  202   a ,  202   b  and  202   c , generally above the contact elements. Contact tails  208   a  and  208   b  are shown emerging from the underside of the upper cap  207  in FIG. 12, and they usually are welded to the electronic component in a unified structure. 
     FIG. 13 shows the underside of the connector shown in FIGS. 11 and 12. In FIG. 13, the lower cap  209  is shown installed as a portion of the insulation body  201  shown near the center of FIG.  13 . In some applications, the lower cap  209  may be integrated with the insulative body  201 . In the assembly and manufacture of the connectors of the invention, contacts may be held together side-by-side on a contact carrier strip. A carrier strip provides in a continuous row a series of electrical connectors, and is used to manufacture numerous connectors from one strip of metallic material in a high speed stamping process. 
     It is understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions. The invention is shown by example in the appended claims.