Abstract:
A connector housing having a contact secured therein is provided. The connector housing includes inner walls that define a contact-receiving chamber. The contact-receiving chamber includes a channel along at least a portion of one of the inner walls for receiving a contact retention member. The contact-receiving chamber may include multiple channels for receiving multiple contact retention members. The contact includes a body section having the contact retention member thereon. The contact may include multiple body sections. The contact retention member includes a bulge portion flared outward in a direction transverse to the body section. The contact retention member may include multiple bulge portions and the multiple bulge portions may flare outward and inward in opposite directions from one another. When the contact is loaded into the housing and the contact retention member is received by the channel, the bulge portion frictionally engages at least one of the inner walls of the contact-receiving chamber. The frictional engagement of the bulge portion to at least one of the inner walls secures the contact within the connector housing.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    Certain embodiments of the present invention generally relate to electrical contacts and to connector housings for electrical contacts, and more particularly, to apparatus for securing power contacts in connector housings.  
           [0002]    Connector housings are designed to hold various types of contacts, including power and signal contacts. Power contacts are used for mid- to high-range servers (e.g., for power applications). Individual power contacts can accommodate up to 48 amps and 600 volts. When eight power contacts are aligned adjacent to one another in a connector housing, each power contact can accommodate 30 amps. Installed power contacts, as well as signal contacts, have solder tails that protrude downward from and out of the connector housing in a predefined pattern. Typically the connector housing and contacts are loaded or dropped onto printed circuit boards such that the solder tails fit through a corresponding pattern of holes in the printed circuit board and may protrude from the opposite side of the printed circuit board. The solder tails are then wave soldered to the printed circuit board.  
           [0003]    Power contacts are presently manufactured with a latch that loosely secures the power contacts into a connector housing. The power contact is designed to only be loosely secured in the connector housing due to the combination of expected tolerances in the power contact and in the connector housing. When a power contact is installed, the latch moves into a window on the connector housing, thereby loosely securing the power contact in the connector housing. The tolerances allow for the power contact to travel into the connector housing beyond the final resting position of the power contact so that the latch can pop up into the window. Once the latch enters the window, the power contact can only slightly move rearward until the latch engages the window. The latch, upon engaging the window, restricts any further rearward movement of the power contact.  
           [0004]    However, several disadvantages exist with the above noted power contact design, primarily stemming from the fact that the power contact, being loosely secured in the connector housing, remains free to move about within the connector housing after installation. First, the power contact moves within the connector housing when the connector housing is loaded onto the printed circuit board. Because of this movement, the solder tails of the power contacts may not properly align with and fall into the corresponding pattern of receiving holes on the printed circuit board. If loading the connector housing onto the printed circuit board is an automated process, then failure of the solder tails to properly align and fall into the corresponding pattern of receiving holes can result in defective products. If loading the connector housing onto the printed circuit board is a manual process, then failure of the solder tails to properly align and fall into the corresponding pattern of receiving holes, results in delays until the solder tails can be properly placed into the corresponding pattern of receiving holes.  
           [0005]    Secondly, movement of the power contact interferes with wave soldering of the solder tails to the printed circuit board. During wave soldering, a wave of solder engages the ends of the solder tails that protrude through the underside of the printed circuit board. As the solder wave engages the solder tails, the solder tails are free to move up and down relative to the printed circuit board. Consequently, solder tails can be displaced upward and then be soldered to the printed circuit board without the ends of the solder tails fully protruding through the underside of the printed circuit board. If the ends of the solder tails do not fully protrude through the underside of the printed circuit board, it is harder to determine by visual inspection whether or not solder connections between the solder tails and the printed circuit board are defective.  
           [0006]    The third problem is movement of the power contacts during mating and unmating of connector housings. Movement of the power contacts relative to the connector housing during mating or unmating can result in increased normal forces on the power contacts that can reduce the lifespan of the power contacts.  
           [0007]    A need remains for an improved power contact and connection between the power contact and connector housing.  
         BRIEF SUMMARY OF THE INVENTION  
         [0008]    An embodiment of the present invention provides a connector housing and a contact secured therein. The connector housing includes inner walls that define a contact-receiving chamber. The contact-receiving chamber includes a channel along at least a portion of one of the inner walls. The channel is tapered wider at its receiving end, allowing the channel to easily receive a contact retention member portion of the contact. The contact is configured to connect to a mating contact of a mating connector housing. The contact includes a body section having a contact retention member thereon. The contact retention member includes a bulge portion flared outward in a direction transverse to the body section. When the contact is loaded into the housing and the contact retention member is received by the channel, the bulge portion frictionally engages at least one of the inner walls of the contact-receiving chamber. The frictional engagement of the bulge portion to at least one of the inner walls secures the contact within the connector housing. The bulge portion may define an outer envelope of the contact retention member that is both greater than a predetermined thickness of the body section and wider than the channel in the contact-receiving chamber.  
           [0009]    Optionally, the contact retention member can have multiple bulge portions flared in opposite directions form one another, or, alternatively, the contact retention member can have a series of rectangular boxes punched in opposite sides of the body section.  
           [0010]    The connector housing may have multiple contact-receiving chambers with multiple contacts secured therein. Also, any of the contacts may have a pair of body sections aligned parallel to one another. Correspondingly, the contact-receiving chamber may have two channels separated by a rail for receiving the two contact retention members on the pair of body sections.  
           [0011]    The main advantageous feature of certain embodiments of the invention is that the contact can be securely installed in the connector housing. The contact cannot move freely within the connector housing. The connector housing with the contact can be dropped onto a printed circuit board without the contact moving relative to the connector housing, thus, allowing solder tails of the contact to properly fit into corresponding holes on the printed circuit board. Also, the contact remains fixed in place during wave soldering of the solder tails to the printed circuit board, allowing for good solder connections that easily can be identified by visual inspection. Additionally, because the contact remains fixed in place, there is less wear and tear of the power contact from normal forces during mating and unmating of connector housings.  
           [0012]    These and other features and embodiments of the present invention are discussed or apparent in the following detailed description of embodiments of the invention. 
       
    
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS  
       [0013]    [0013]FIG. 1 illustrates a top front perspective view of a connector housing with installed signal contacts and power contacts formed in accordance with an embodiment of the present invention.  
         [0014]    [0014]FIG. 2 illustrates a bottom front perspective view of a power contact formed in accordance with an embodiment of the present invention.  
         [0015]    [0015]FIG. 3 illustrates a top back perspective view of a portion of a connector housing with installed signal contacts, installed power contacts, and one uninstalled power contact formed in accordance with an embodiment of the present invention.  
         [0016]    [0016]FIG. 4 illustrates a top back perspective view of a portion of a connector housing formed in accordance with an embodiment of the present invention.  
         [0017]    [0017]FIG. 5 illustrates a top front perspective view of a portion of a connector housing formed in accordance with an embodiment of the present invention.  
         [0018]    [0018]FIG. 6 illustrates a cross-sectional view taken along line  6 - 6  in FIG. 1 of a connector housing with an installed power contact formed in accordance with an embodiment of the present invention.  
         [0019]    [0019]FIG. 7 illustrates a cross-sectional view taken along line  7 - 7  in FIG. 1 of a connector housing with two installed power contacts formed in accordance with an embodiment of the present invention.  
         [0020]    [0020]FIG. 8 illustrates a cross-sectional view taken along line  7 - 7  in FIG. 1 of a connector housing with one installed power contact formed in accordance with an embodiment of the present invention.  
         [0021]    FIGS.  9 - 13  illustrate bottom front perspective views of power contacts in accordance with embodiments of the present invention. 
     
    
       [0022]    The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the present invention is not limited to the arrangements and instrumentality shown in the attached drawings.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0023]    [0023]FIG. 1 illustrates a connector housing  100  with a plurality of signal contacts such as signal contact  102  and a plurality of power contacts such as power contact  104  installed therein in accordance with an embodiment of the present invention. The connector housing  100  includes a top surface  106 , a bottom surface  108 , a front face  110 , and a back face  112 . The front face  110  includes mating chambers, such as mating chamber  114 , defined therein. The mating chamber  114  has a bottom wall  116  that includes ribs  118 ,  120  extending away from a bottom edge  122  in a direction perpendicular to the front face  110  and parallel to the bottom surface  108 .  
         [0024]    The connector housing  100  is divided into modules or sections that are arranged side by side such as guide section  124 , power contact retention section  126 , and signal contact retention section  128 . The connector housing  100  includes a plurality of guide sections  124 , a plurality of power contact retention sections  126 , and a plurality of signal contact retention sections  128 . Guide sections  124  include guide holes such as guide hole  130  for receiving a guide probe of a mating connector housing. The guide sections  124  guide the connector housing  100  during mating with a connector housing mate so that power contacts  104  and signal contacts  102  in the connector housing  100  properly engage receiving holes and chambers of the mating connector housing. The guide sections  124  also allow for the connector housing  100  to mate in only a desired mating configuration with the mating connector housing. The signal contact retention sections  128  are occupied by the installed signal contacts  102 . The power contact retention sections  126  include notches and windows such as notch  132  and window  134 , respectively, located on the top surface  106  of the connector housing  100 . The notches  132  and windows  134  allow for enhanced heat dissipation during use.  
         [0025]    [0025]FIG. 2 illustrates a power contact  104  formed in accordance with an embodiment of the present invention. The power contact  104  includes two body sections  202 ,  204  generally of rectangular shape and arranged parallel to one another. The body sections extend parallel to and on opposite sides of a center plane  205  that includes axes  206 ,  208 . The body sections  202 ,  204  are mirror images of each other and are located symmetrically about the center plane  205 . Given to similar structure, only one body section  202  is explained hereafter.  
         [0026]    The body section  202  includes a tail end  210  located at the rear of the body section  202  and a lead end  211  located at the front thereof. The body section  202  includes a top edge  212  running from the tail end  210  to the lead end  211 . The top edge  212  includes a stabilizing projection  214  projecting upward from a middle of the top edge  212 . A rear adjoining strip  216  is located proximate the tail end  210  and a front adjoining strip  218  is located proximate the lead end  211 . The adjoining strips  216 ,  218  join and hold the two body sections  202 ,  204  in a particular relation to one another. The front adjoining strip  218  includes a latch  220  extending rearward, and at an angle slightly upward, from the front adjoining strip  218 . The latch  220  includes an engaging surface  222  located on the end of the latch  220  distal to the front adjoining strip  218 . The latch  220  helps secure the power contact  104  in the connector housing  100  by extending into the window  134  and engaging the window  134  at the engaging surface  222  of the latch  220 .  
         [0027]    The body section  202  includes a bottom edge  224  running from the tail end  210  to the lead end  211 . The bottom edge  224  includes four solder tails such as solder tail  226  along the bottom edge  224  spaced at intervals such as interval  228  and extending downward in a direction perpendicular to the bottom edge  224  and parallel to the center plane  205 . The bottom edge  224  includes a positioning projection  230  protruding downward therefrom. The body section  204  also includes a positioning projection  232 .  
         [0028]    The body sections  202 ,  204  include contact retention members  234 ,  236  located along and just above the bottom edge  224  proximate the lead end  211 . The contact retention member  234  includes a series of bulge portions  238 - 240  forming a wave along the bottom edge  224 . The bulges  238 - 240  are created by a stamping process. A first bulge  238  and a third bulge  240  protrude from the body section  202  inward toward the body section  204 . A second bulge  239  protrudes from the body section  202  outward in a direction opposite of the direction in which the first and third bulges  238 ,  240  protrude. The contact retention member  236  includes a series of bulges that mirror the contact retention member  234 .  
         [0029]    The power contact  104  includes two lead sections  250 ,  252  that mirror each other and are located symmetrically about the center plane  205 . The power contact  104  includes a gap  254  between the two lead sections  250 ,  252 . The lead sections  250 ,  252  are attached to and extend forward from the lead ends  211  of the body sections  202 ,  204 . The lead sections  250 ,  252  are attached to the lead ends  211  so that the lead sections  250 ,  252  are displaced upward from the bottom edges  224  of the body sections  202 ,  204  by a step  257 . The lead sections  250 ,  252  include a transition flange  256  and a blade  258 . The transition flange  256  is attached to the lead end  211  of the body section  202 . The transition flange  256  extends forward from the lead end  211  bending initially toward the center plane  205  and then away from the center plane  205 . The blade  258  includes a rear end  260  and a front end  262 . The blade  258  is attached to the transition flange  256  at the rear end  260  of the blade  258 . The front end  262  is shorter than the rear end  260 .  
         [0030]    [0030]FIG. 3 illustrates a rear view of a portion of the connector housing  100  with installed signal contacts such as signal contact  302 , installed power contacts  304 ,  306 , and uninstalled power contact  104 . The body section  202  includes a right exterior surface  308  and a right interior surface  310 . The body section  204  includes a left exterior surface  312  and a left interior surface  314 . The body sections  202 ,  204  are separated by a width  316 .  
         [0031]    [0031]FIGS. 4 and 5 illustrate a portion of the connector housing  100  in which the power contact  104  is to be installed. Each power contact retention section  126  includes a contact-receiving chamber  402  located therein and having a rear wall  404  opening onto a loading end  406  located at the rear of the power contact retention section  126 . Power contacts  104  are loaded through the loading end  406 . The contact-receiving chamber  402  is defined by inner walls  408 ,  410 , a top wall  411 , and a bottom wall  412 . The bottom wall  412  includes a rear edge  413 . A rail  414  is provided along the bottom wall  412  of the contact-receiving chamber  402  and is spaced from the inner walls  408 ,  410  to define channels  416 ,  418  running along opposite sides of the rail  414  for receiving contact retention members  234 ,  236 . The rail  414  includes a general rail width  420  and a narrower loading-end rail width  422  to form a general channel width  424  and a wider loading-end channel width  426  for each of the channels  416 ,  418 .  
         [0032]    FIGS.  6 - 8  illustrate side and end sectional views of the power contact  104  loaded into the connector housing  100 . The body sections  202 ,  204  have a predetermined thickness  802 . The bulges  238 - 240  define a lateral envelope  804  for the contact retention members  234 ,  236  that is greater than the predetermined thickness  802  of the body sections  202 ,  204 . The lateral envelope  804  also is thicker than the general channel width  424  of the channels  416 ,  418 .  
         [0033]    The power contact  104  is loaded into the contact-receiving chamber  402  through the loading end  406  so that the lead sections  250 ,  252  of the power contact  104  protrude forward into the contact-receiving chamber  402  toward the front face  110 . Because the lead sections  250 ,  252  are displaced upward from the bottom edge  224  of the body sections  202 ,  204  by a step  257 , the lead sections  250 ,  252  freely pass above the rail  414  and the channels  416 ,  418  during loading of the power contact  104 . As the power contact  104  is loaded in the direction of arrow A, the contact retention members  234 ,  236  are guided into the channels  416 ,  418  through the wider loading-end channel width  426 . The power contact  104  moves forward into the contact-receiving chamber  402  until the positioning projections  230 ,  232  of the body sections  202 ,  204  engage the rear edge  413  of the bottom wall  412  to stop advancement of the power contact  104 . During loading of the power contact  104 , because the latch  220  is angled slightly upward from the front adjoining strip  218 , the latch  220  must deflect downward in order to travel under the top wall  411  of the contact-receiving chamber  402 . The latch  220  remains deflected downward until entering the window  134 . The notch  132  allows the power contact  104  to be loaded into the contact-receiving chamber  402  with less resistance because the notch  132  reduces the distance along the underside of the top wall  411  that the latch  220  must travel deflected downward. Once loaded, the latch  220  is accessible through the window  134  in the power contact retention section  126 . The engaging surface  222  of the latch  200  engages the window  134 , helping secure the power contact  104  within the connector housing  100 .  
         [0034]    Upon installation, the contact retention members  234 ,  236  frictionally engage the rail  414  and inner walls  408 ,  410  of the contact-receiving chamber  402 . Friction between the contact retention members  234 ,  236 , the rail  414 , and the inner walls  408 ,  410  secures the power contact  104  in the connector housing  100 . Also upon installation, the stabilizing projections  214  are positioned just below the top wall  411  of the contact-receiving chamber  402 . The stabilizing projections  214  prevent the power contact  104  from displacing upward and, therefore, prevent the contact retention members  234 ,  236  from rising up out of the channels  416 ,  418 .  
         [0035]    Optionally, because the contact retention members  234 ,  236  sufficiently secure the power contact  104  in the connector housing  100 , the latch  220  is not necessary and may be removed. Removal of the latch  220  allows for greater cooling through the window  134  during operation.  
         [0036]    [0036]FIG. 9 illustrates a power contact  900  in accordance with an embodiment of the present invention. The power contact  900  includes two lead sections  902 ,  904 . Each of the lead sections  902 ,  904  include four beams such as beam  906 .  
         [0037]    [0037]FIG. 10 illustrates a power contact  1000  in accordance with an embodiment of the present invention. The power contact  1000  includes two body sections  1001 ,  1002 . The body sections  1001 ,  1002  include contact retention members  1003 ,  1004 . The contact retention member  1003  includes only one bulge  1006  that protrudes from the body section  1002  in a direction away from both of the body sections  1001 ,  1002 . The contact retention member  1004  includes a bulge that mirrors the contact retention member  1003 .  
         [0038]    [0038]FIG. 11 illustrates a power contact  1100  in accordance with an embodiment of the present invention. The power contact  1100  includes two body sections  1101 ,  1102 . The body sections  1101 ,  1102  include contact retention members  1103 ,  1104 . The contact retention member  1103  includes a series of bulges  1105 ,  1106 . A first bulge  1105  protrudes from the body section  1102  inward toward the body section  1101 . A second bulge  1106  protrudes from the body section  1102  outward in a direction opposite of the direction in which the first bulge  1105  protrudes. The contact retention member  1104  includes a series of bulges that mirrors the contact retention member  1103 .  
         [0039]    [0039]FIG. 12 illustrates a power contact  1200  in accordance with an embodiment of the present invention. The power contact  1200  includes two body sections  1201 ,  1202 . The body section  1202  includes a contact retention member  1203 . The contact retention member  1203  is located along a tail end  1204  of the body section  1202  proximate an upper edge  1206  of the body section  1202 . The contact retention member  1203  includes a series of bulges  1208 - 1210 . A first bulge  1208  and a third bulge  1210  protrude from the body section  1202  inward toward the body section  1201 . A second bulge  1209  protrudes from the body section  1202  outward in a direction opposite of the direction in which the first and third bulges  1208 ,  1210  protrude.  
         [0040]    [0040]FIG. 13 illustrates a power contact  1400  in accordance with an embodiment of the present invention. The power contact  1400  includes two body sections  1401 ,  1402 . The body section  1402  includes two contact retention members  1404 ,  1406 . The contact retention member  1404  is located along a tail end  1408  of the body section  1402  proximate an upper edge  1410  of the body section  1402 . The contact retention member  1406  is located along a bottom edge  1412  of the body section  1402  proximate a lead end  1414  of the body section  1402 .  
         [0041]    While certain embodiments of the present invention employ the power contacts having two body sections, other embodiments may include the power contacts with only one body section or more than two body sections.  
         [0042]    While certain embodiments of the present invention employ the contact retention members having one bulge, two bulges, and three bulges, the number of bulges is in no way limited to one, two, or three.  
         [0043]    While certain embodiments of the present invention employ contact retention members positioned at certain locations on the power contact, other embodiments may include contact retention members positioned at other locations on the power contact.  
         [0044]    While certain embodiments of the present invention employ body sections having one contact retention member and body sections having two contact retention members, other embodiments may include body sections with three or more contact retention members.  
         [0045]    While certain embodiments of the present invention employ bulges that are rectangular in shape, the shape of the bulges is in no way limited to a rectangular shape.  
         [0046]    While certain embodiments of the present invention employ solder tails, alternatively, press-fit tails could be employed. Press-fit tails can be press-fitted into a pattern of corresponding receiving holes on a printed circuit board. Frictional forces retain the press-fit tails in the corresponding pattern of receiving holes in the printed circuit board.  
         [0047]    While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. 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. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.