Connector assembly

A connector assembly for electrically connecting a plurality of wires to a circuit board is described. The connector assembly includes a vertical connector that includes an insulative base having pluralities of substantially parallel first and second base channels formed on respective opposing first and second major surfaces of the base. The vertical connector further includes pluralities of first and second terminals in registration with the respective first and second base channels, each first and second terminal including a contact portion for making contact with a wire, and a press-fit portion for being inserted into a conductive via of a circuit board. At least a majority length of each first and second terminal is disposed outside the housing. Each first and second terminal is secured in the connector at least in part by virtue of making physical contact with a corresponding wire.

BACKGROUND

Coaxial cables may be attached to a circuit board by various methods. Such methods may include soldering the cable directly to the circuit board, using RF (radio frequency) style connectors, or attaching the cable to a paddle card which mates with the circuit board.

SUMMARY

In some aspects of the present description, a connector assembly for electrically connecting a plurality of wires to a circuit board is provided. The connector assembly includes a vertical connector that includes an insulative housing having a cable receiving face and an opposite mounting face for mounting the vertical connector onto a circuit board. The housing includes an insulative base including pluralities of substantially parallel first and second base channels formed on respective opposing first and second major surfaces of the base. The vertical connector further includes pluralities of first and second terminals in registration with the respective first and second base channels, each first and second terminal including a contact portion for making contact with a wire, and a press-fit portion for being inserted into a conductive via of a circuit board. At least a majority length of each first and second terminal is disposed outside the housing beyond the mounting face. The connector assembly further includes a plurality of first wires, each first wire disposed in a corresponding first base channel and terminated at the contact portion of a corresponding first terminal; and a plurality of second wires, each second wire disposed in a corresponding second base channel and terminated at the contact portion of a corresponding second terminal. Each first and second terminal is secured in the connector at least in part by virtue of making physical contact with a corresponding wire.

DETAILED DESCRIPTION

Connector assembles according to the present description allow a plurality of wires to be electrically connected to a circuit board. The plurality of wires may be, for example, wires in an electrical ribbon cable (e.g., a coaxial ribbon cable), such as twin axial cables available from 3M Company (St. Paul, Minn.). Connector assemblies of the present description include connectors in which one or more terminals are secured in the connector at least in part by virtue of making physical contact with corresponding one or more wires of the connector assembly. For example, each terminal may be attached to a wire in the connector assembly and this attachment may hold, or help hold, the terminal in place at a mating surface of the connector. The terminals may be attached to the wires by any known attachment method such as solder, ultrasonic, induction, or crimp attachment. The connector assemblies may include a vertical connector having an insulative housing which includes an insulative base and may also include first and second insulative covers, which may be used to hold the wires in place in the insulative base. The connector assemblies may be attached to a circuit board to provide a separable electrical connection.

FIGS. 1A and 1Bare top perspective and bottom-front perspective views of a portion of a connector including insulative base110having first and second base channels112and114formed on respective opposing first and second major surfaces113and117. The connector also includes pluralities of first and second terminals122and124in registration with the respective first and second base channels112and114and disposed at exit openings121. Each terminal having a length L and including a contact portion123for making contact with a wire, and a press-fit portion128for being inserted into a conductive via of a circuit board. The contact portion123may also include a groove portion129for receiving an end portion of a corresponding wire. The groove portion129may terminate in one or more shoulder portions126which extend laterally and rests on a mounting face of the housing. Although not illustrated inFIGS. 1A-1B, the connector assembly would typically include wires disposed in the first and second base channels112and114that are attached to first and second terminals122and124. In some embodiments, wires attached to the first and second terminals122and124would hold the terminals in place or contribute to holding the terminals in place. As described elsewhere herein, covers may be applied to the insulative base110. The covers may help keep the wires and terminals in position.

The insulative housing, including the insulative base and insulative covers, can be made from any suitable material, such as, for example, insulative polymers. The insulative material used for the insulative housing may be chosen based on processability, mechanical properties, electrical resistivity and/or dielectric properties. Suitable insulative materials includes liquid crystal polymer (LCP), epoxy resins or other electrically insulating resins. The insulative housing, including the insulative base and insulative covers, can be made, for example, by injection molding.

The connector includes face115which is a mounting face of insulative base110, or a mounting face or a portion of a mounting face of an insulative housing that includes insulative base110. In some embodiments, at least a majority length (a majority of the length L) of each first and second terminal122and124is disposed outside the housing beyond the mounting face. In some embodiments, a portion of the terminals may be disposed inside the housing. In some embodiments, at least 70 percent, or at least 80 percent, or at least 90 percent of the length of each first and second terminal122and124is disposed outside the housing beyond the mounting face. In some embodiments, each first and second terminal122and124is completely outside the housing, and the contact portion123of the terminal is perpendicular to and rests on a mounting face of the insulative housing. In the embodiment illustrated inFIGS. 1A-1B, the first and second terminals122and124are completely outside the insulative base110with the contact portion123of the terminals perpendicular to and resting on face115. Any suitable terminals can be used with the connectors of the present description. In some embodiments, the terminals are press-fit terminals which may include compliant pin contacts. Suitable terminal types include straight pin styles and leaf spring styles.

FIG. 2is a perspective top-front view of a portion of a connector assembly including insulative base210having face215, a plurality of first wires232, and first and second terminals222and224, each terminal including a contact portion223, shoulder portions226, a press-fit portion228and a groove portion229. Each first wire232is disposed in a first base channel and terminated at a contact portion223of a corresponding first terminal222. An end portion239of each first wire232may be received in a groove portion229of the corresponding first terminal222. The connector also includes a plurality of second wires (not illustrated), each second wire disposed in a second base channel and terminated at a contact portion223of a corresponding second terminal224. Each first and second terminal222and224includes shoulder portions226which extend laterally and rest on face215of insulative base210, and includes a press-fit portion228for being inserted into a conductive via of a circuit board. The first and second terminals222and224may be held in place at face215by being attached to the first wires232or to second wires, and the wires may be held in place in the insulative base210using first and second covers as described elsewhere herein.

Any or all of the wires used in the connector assemblies of the present description may include a dielectric material (e.g., polymeric dielectrics) surrounding or substantially surrounding a metallic (e.g., copper) core. Any of the wires used in the connector assemblies of the present description may include a metallic foil coating. A foil coating may be applied to a wire with an adhesive layer between the wire and the foil coating. A metallic foil may be applied to a dielectric layer of a wire with an adhesive layer between the dielectric layer and the metallic foil. In some embodiments, the foil coatings may be electrically grounded. Instead of, or in addition to the adhesive layer, the foil coating may be mechanically bonded to the wire with an ultrasonic weld (e.g., a 40 kHz ultrasonic weld). In some embodiments, a wire may be ultrasonically bonded to a foil and the wire with foil may be used as a drain wire. In some embodiments, a wire with a dielectric layer with a foil coating over the dielectric layer may be used as a signal wire. Configurations that include wires having a metallic core, a dielectric layer and a foil coating, and include wires not including the dielectric layer have been found to enable electronic signaling at high frequencies (e.g., up to 25 GHz). An example wire that is suitable for use in the connector assemblies of the present description is illustrated inFIG. 6, which is a cross sectional view of a wire632that may be used as one or more of the first and/or second wires. Wire632includes a conductor671, which may be an insulated conductor, and a metallic foil673surrounding or substantially surrounding the conductor671. The metallic foil673may be ultrasonically bonded to conductor671. In the illustrated embodiment, conductor671includes a metallic core675and a dielectric layer677surrounding the metallic core675with the dielectric layer677, which may be an insulating layer, disposed between the metallic foil673and the metallic core675. In other embodiments, conductor671includes a metallic core675but no dielectric layer677surrounding the metallic core675.

In some embodiments, the plurality of first wires alternate between wires having a metallic core, a dielectric layer and a foil coating, and wires not including the dielectric layer. Similarly, in some embodiments, the plurality of second wires alternate between wires having a metallic core, a dielectric layer and a foil coating, and wires not including the dielectric layer. In other embodiments, all or none of the wires include a metallic core, a dielectric layer and a foil coating.

FIG. 3is a perspective top view of a connector assembly including insulative base310, a plurality of first wires332and a plurality of second wires334. First wires332are disposed in corresponding first base channels (not illustrated) and second wires334are disposed in corresponding second base channels (not illustrated). InFIG. 3, the first and second base channels of insulative base310, which correspond to the first and second base channels112and114ofFIGS. 1A-1B, respectively, are covered by first and second ribbon cables366and367which include the pluralities of first and second wires332and334, respectively. First wires332are terminated at the contact portions of first terminals322and second wires334are terminated at the contact portions of second terminals324. Insulative base310includes face316which may be a cable receiving face of insulative base310for receiving pluralities of first and second wires332and334, or a cable receiving face or a portion of a cable receiving face of an insulative housing that includes insulative base310.

FIG. 4Ais an exploded perspective view of connector assembly451including insulative base410, and first and second insulative covers433and435. InFIG. 4A, connector assembly451is disposed proximate circuit board440that includes vias443.FIG. 4Bis a perspective view of connector assembly451, including vertical connector450, disposed proximate circuit board440, andFIG. 4Cis a perspective view of connector assembly451connected to circuit board440. Insulative housing455includes the insulative base410and the first and second insulative covers433and435. First insulative cover433includes a plurality of first cover channels436and second insulative cover435includes a plurality of second cover channels438. Insulative base410includes a plurality of first base channels (corresponding to first base channels112) and an opposing plurality of second base channels (corresponding to second base channels114). Connector assembly451includes a plurality of first wires432and a plurality of second wires434. The first insulative cover433is assembled to a first major surface of the insulative base410and the plurality of first cover channels436is in registration with corresponding first base channels, each corresponding pair of first cover channels436and first base channels defining a first input opening453at the cable receiving face416for receiving one or more wires, and a first exit opening (corresponding to an exit opening121) at the mounting face415of the insulative housing455. The second insulative cover435is assembled to a second major surface of the insulative base410opposite the first major surface and the plurality of second cover channels438is in registration with corresponding second base channels, each corresponding pair of second cover channels438and second base channels defining a second input opening454at the cable receiving face416for receiving one or more wires, and a second exit opening (corresponding to an exit opening121) at the mounting face of the insulative housing455. Each first wire432is received through a corresponding first input opening453and is disposed in a corresponding first cover and base channel, and each first terminal422is disposed at a corresponding first exit opening. Each second wire434is received through a corresponding second input opening454and is disposed in a corresponding second cover and base channel, and each second terminal424is disposed at a corresponding second exit opening.

In some embodiments, the first insulative cover433includes one or more pegs472and insulative base410includes one or more corresponding holes477for accepting the pegs472. Such features may be included to aid the proper alignment of the first insulative cover433with the insulative base410. Similarly, in some embodiments, the second insulative cover435may include one or more pegs which may be accepted into holes477of the insulative base410. The first and/or second insulative covers may also include latches474that mate with corresponding features479of the insulative base410.

FIG. 5is a perspective cutaway view of vertical connector550attached to circuit board540. Vertical connector550includes terminals524which are inserted into vias543of circuit board540. Vias543may be electrically conductive by virtue of conductive features disposed in the vias543. For example, vias543may be plated through-holes having a metallic (e.g., including copper, silver, gold, or PdNi.) plating which contacts terminals524when vertical connector550is connected to circuit board540.

The following is a list of exemplary embodiments of the present description.Embodiment 1 is a connector assembly for electrically connecting a plurality of wires to a circuit board, comprising:a vertical connector comprising:an insulative housing having a cable receiving face and an opposite mounting face for mounting the vertical connector onto a circuit board, the housing comprising:an insulative base comprising pluralities of substantially parallel first and second base channels formed on respective opposing first and second major surfaces of the base; andpluralities of first and second terminals in registration with the respective first and second base channels, each first and second terminal comprising a contact portion for making contact with a wire, and a press-fit portion for being inserted into a conductive via of a circuit board, at least a majority length of each first and second terminal disposed outside the housing beyond the mounting face;a plurality of first wires, each first wire disposed in a corresponding first base channel and terminated at the contact portion of a corresponding first terminal; anda plurality of second wires, each second wire disposed in a corresponding second base channel and terminated at the contact portion of a corresponding second terminal, each first and second terminal secured in the connector at least in part by virtue of making physical contact with a corresponding wire.Embodiment 2 is the connector assembly of embodiment 1, wherein each first and second terminal is completely outside the housing, the contact portion of the terminal perpendicular to and resting on the mounting face.Embodiment 3 is the connector assembly of embodiment 1, wherein the contact portion of each first and second terminal comprises a groove for receiving an end portion of a corresponding wire, the groove terminating in one or more shoulder portions of the contact portion extending laterally and resting on the mounting face of the housing.Embodiment 4 is the connector assembly of embodiment 1 further comprising:a first insulative cover assembled to the first major surface of the base and comprising a plurality of first cover channels formed therein in registration with corresponding first base channels, each corresponding pair of first cover and base channels defining a first input opening at the cable receiving face for receiving one or more wires, and a first exit opening at the mounting face, each first wire received through a corresponding first input opening and disposed in a corresponding first cover and base channels, each first terminal disposed at a corresponding first exit opening;a second insulative cover assembled to the second major surface of the base and comprising a plurality of second cover channels formed therein in registration with corresponding second base channels, each corresponding pair of second cover and base channels defining a second input opening at the cable receiving face for receiving one or more wires, and a second exit opening at the mounting face, each second wire received through a corresponding second input opening and disposed in a corresponding second cover and base channels, each second terminal disposed at a corresponding second exit opening.Embodiment 5 is the connector assembly of embodiment 1, wherein at least some of the first or second wires comprise a conductor and a metallic foil substantially surrounding the conductor and ultrasonically bonded to the conductor.Embodiment 6 is the connector assembly of embodiment 5, wherein the conductor comprises a metallic core.Embodiment 7 is the connector assembly of embodiment 6, wherein the conductor comprises a dielectric layer substantially surrounding the metallic core, the dielectric layer disposed between the metallic foil and the metallic core.