Systems having an actuator forcing a resilient retainer through a compressor to secure electrical contacts in an electrical component

A system for securing one or more electrical contacts within an electrical component includes a main housing defining a contact-retaining chamber, a base fixed within the contact-retaining chamber, a resilient retainer supported on the base and positioned around at least a portion of the one or more electrical contacts, a compressor within the contact-retaining chamber, wherein the resilient retainer is positioned between the base and the compressor, and a moveable actuator configured to be moved into a retaining position in which a retaining force is exerted into the compressor. The retaining force is translated into the resilient retainer to securely retain the electrical contact(s) within the electrical component.

BACKGROUND OF THE DISCLOSURE

Embodiments of the present disclosure generally relate to systems and methods for retaining electrical contacts within electrical components, such as high density electrical connector assemblies.

Various communication or computing systems use electrical connectors to transmit data signals between different components of the systems. An electrical connector may electrically and mechanically connect one electrical component, such as a circuit board, server, or the like to another electrical component.

As data processing demands continue to increase, electrical connectors have been developed with an increased number of electrical contacts. In many applications, a high density pattern of electrical contacts is desired. A high density pattern of electrical contacts is one in which a center-to-center spacing of neighboring electrical contacts creates a thin insulative material between the neighboring contacts.

However, high density contact applications may not provide sufficient space for known contact retention systems and methods to securely retain the electrical contacts. For example, known molded contact retention systems and known retention clip retainer systems are typically too bulky for various high density applications.

A need exists for a practical system and method of efficiently retaining electrical contacts within a high density array or pattern.

BRIEF DESCRIPTION OF THE DISCLOSURE

Certain embodiments of the present disclosure provide a system for securing one or more electrical contacts within an electrical component. The system may include a main housing defining a contact-retaining chamber, a base fixed within the contact-retaining chamber, a resilient retainer supported on the base and positioned around at least a portion of the electrical contact(s), a compressor within the contact-retaining chamber, wherein the resilient retainer is positioned between the base and the compressor, and a moveable actuator configured to be moved into a retaining position in which a retaining force is exerted into the compressor. The retaining force is translated into the resilient retainer to securely retain the electrical contact(s) within the electrical component. In at least one embodiment, the resilient retainer securely retains the electrical contact(s) by deforming and flowing into or otherwise filling one or more interstices of the electrical contact(s) in response to the moveable actuator moving into the retaining position. The resilient retainer may be formed of rubber, for example.

The system may include an actuator track that moveably retains the moveable actuator. The moveable actuator may be configured to slide over the compressor into the retaining position. In another embodiment, the moveable actuator may be or include a plunger that is configured to be pushed into the compressor. In still another embodiment, the moveable actuator is configured to be pulled into the compressor.

In at least one embodiment, the actuator is configured to be rotated into the retaining position. For example, the actuator may include a rotatably cap that is threadably secured to the main housing.

Each of the electrical contacts may include a barrel secured to one or more leads. The electrical component may be or include an electrical connector assembly.

Certain embodiments of the present disclosure provide a method for securing one or more electrical contacts within an electrical component. The method may include defining a contact-retaining chamber within a main housing, fixing a base to or within the contact-retaining chamber, supporting a resilient retainer on the base, positioning the resilient retainer around at least a portion of the electrical contact(s), positioning a compressor in relation to the resilient retainer, wherein the positioning the compressor includes positioning the resilient retainer between the base and the compressor, and engaging an actuator into a retaining position with respect to the compressor. The engaging operation may include exerting a retaining force into the compressor, and translating the retaining force into the resilient retainer to securely retain the one or more electrical contacts within the electrical component. The method may also include disengaging the actuator from the retaining position. The disengaging operation releases the one or more resilient retainer from securely retaining the one or more electrical contacts within the electrical component.

DETAILED DESCRIPTION OF THE DISCLOSURE

Embodiments of the present disclosure provide systems and methods for retaining electrical contacts within an electrical component, such as an electrical connector assembly, a circuit board, a server, and/or the like. A contact-retaining system may include a resilient retainer that is configured to be urged into or around a portion of an electrical contact, such as an outer longitudinal portion or shaft of the electrical contact. For example, an actuator may urge a compressor, such as a rigid layer of hard plastic, into the resilient retainer. As the resilient retainer is urged toward and/or into the electrical contact, the resilient retainer is blocked by a base that prevents the resilient retainer from passing further therein. The resilient retainer is trapped between the compressor and the base. Because the resilient retainer is confined within a fixed volume of space between the compressor and the base, the force exerted by the actuator into the compressor forces the resilient retainer to deform and flow into or otherwise fill interstices or other such gaps, spaces, or the like of at least portions of the electrical contact, thereby securely retaining the electrical contact in place. For example, in at least one embodiment, the interstices may be features within an electrical contact, such as crimp detents in a wire barrel that are configured to secure a wire to a contact.

FIG. 1illustrates a perspective front view of an electrical connector assembly100, according to an embodiment of the present disclosure. The electrical connector assembly100includes a main housing or shell102that includes a contact-retaining chamber104. The main housing102may include one or more actuator tracks106that are configured to moveably retain one or more actuators108aand108b. The contact-retaining chamber104houses a plurality of electrical contacts110.

As shown inFIG. 1, a portion of the main housing102is removed to show internal components. For example, the contact-retaining chamber104includes opposed lateral walls112integrally connected to opposed end walls114, a face116, and an opposite surface118from the face116. The lateral walls112, end walls114, and face116, for example, may be formed of a metal, for example aluminum, and may include an insulating layer. The face116includes contact openings120that provide passages to ends122of the electrical contacts110. Opposite ends124of the electrical contacts110may be exposed through the rear surface118.

A compressor130may be positioned within the contact-retaining chamber104around the ends124of the electrical contacts110. The compressor130may be a layer, beam, strip, sheet, or the like of hard, rigid, non-resilient plastic or metal, for example. As shown, the compressor130may be exposed through the rear surface118.

A deformable, resilient retainer132is positioned between the compressor130and a fixed, rigid base134, which may be an integral base portion of the main housing102. The retainer132may be formed of a resilient material, such as rubber or another elastomeric material that is configured to deform, flow, or otherwise move when a compressive force is exerted therein.

Each actuator108aand108bmay include lateral beams140that integrally connect to a cross handle142. The cross handle142may connect the lateral beams140together such that a space144is defined therebetween. Each lateral beam140may include a tapered protuberance146, such as an ridge, rib, or the like extending along its length. As the actuators108aand108bare urged into a retaining position, the lateral beams140slide over portions of the compressor130. During this movement, the protuberances146force the compressor130toward the retainer132, which moves toward the base134. The base134forms a barrier past which the compressor130is unable to pass. In short, the retainer132is confined or trapped within a space between the compressor130and the base134. Accordingly, as the actuator108is urged over the compressor130is urged into the retainer132between the compressor130and the base134. During the compressive sandwiching, the retainer132deforms and flows into or otherwise fills interstices of at least portions of the electrical contacts110, thereby securely retaining the electrical contacts110within the contact-retaining chamber104. In short, as the actuator108aor108bis urged into a retaining position over the compressor130, the retainer132is compressively sandwiched between the hard and rigid compressor130and the base134, which forces portions of the retainer132to move into interstices of at least portions of the electrical contacts110, thereby securely retaining the electrical contacts110in position.

The actuators108aand108bare configured to slide over the compressor130in the directions A and A′, respectively, in order to exert a retaining force B into the compressor130. The directions A and A′ are orthogonal to the direction of the exerted retaining force B.

As shown inFIG. 1, the actuator108ais in a disengaged position. The actuator108ais not in contact with the compressor130. In contrast, the actuator108b(although portions of the actuator108aare not shown in order to show the internal components of the electrical connector assembly100) is shown in an engaged position over a portion of the compressor130. In order to move the actuator108ainto an engaged position, the cross handle142of the actuator108ais pushed in the direction of arrow A. Conversely, in order to move the actuator108binto a disengaged position, the cross handle142of the actuator108bis pulled in the direction of arrow A.

The electrical connector assembly100may include more or less actuators than shown. For example, instead of two opposed actuators, the electrical connector assembly100may include a single actuator that is configured to slide over the length of the compressor130. Alternatively, the electrical connector assembly100may include various other actuators, such as plungers, that are configured to be directly urged into and away from the compressor130.

While the electrical connector assembly100is shown, embodiments of the present disclosure may be used with various other electrical components. For example, embodiments of the present disclosure may be used with respect to electrical contacts in any type of electrical connector assembly, a circuit board, server, and/or the like. Further, embodiments of the present disclosure may be used with electrical connector assemblies having various shapes and sizes other than shown. For example, the electrical connector assembly100may house more or less electrical contacts than shown. In at least one embodiment, the electrical connector assembly100may include more or less rows or electrical contacts than shown. Additionally, the shape of the electrical connector assembly100may be other than rectangular, square, or linear. For example, the contact-retaining chamber1045may have an arcuate shape, such as circular, elliptical, or the like. In at least one embodiment, the electrical connector assembly100may have a circular shape, which may allow compression to be performed through a threaded backshell and/or threaded retainer.

FIG. 2illustrates a perspective front view of an actuator200in relation to a compressor202and a retainer204, according to an embodiment of the present disclosure. As shown, the actuator200may be positioned directly over the compressor202. For example, the actuator200may be aligned and coaxial with the compressor202. In order to force the compressor into the retainer204, the compressor202may be urged directly into the compressor202in the direction of arrow B, instead of sliding over a surface of the compressor202.

The actuator200is pushed into the compressor202in the same direction B as the retaining force that is exerted into the compressor202. As such, the direction of movement of the actuator200and the direction of force exerted into the compressor202are the same or otherwise parallel.

FIG. 3illustrates a simplified lateral view of an actuator300in relation to a compressor302and a retainer304, according to an embodiment of the present disclosure. In this embodiment, the compressor302may hook over portions of the compressor302. For example, the compressor302may include a handle306connected to outer beams308that hook onto outer edges310of the compressor302. In order to securely retain electrical contacts through deformation of the retainer304, the handle306of the actuator300is pulled in the direction of arrow B.

The actuator300is pulled into the compressor302in the same direction B as the retaining force that is exerted into the compressor302. As such, the direction of movement of the actuator300and the direction of the force exerted into the compressor302are the same or otherwise parallel.

FIGS. 1-3show and describe examples of actuators. It is to be understood that various other types of actuators that urge a compressor into a retainer may be used.

FIG. 4illustrates an axial cross-sectional view of an electrical connector assembly400having an unsecured electrical contact402, according to an embodiment of the present disclosure. The electrical connector assembly400includes a main housing or shell404that defines an internal contact-retaining chamber406. The main housing404may include one or more actuator tracks408that are configured to moveably retain one or more actuators. An actuator is not within the actuator track408at the position shown inFIG. 4. Instead, the actuator is in a disengaged position (in relation to a compressor410). The contact-retaining chamber406houses the electrical contact402. For the sake of clarity, only one electrical contact402is shown inFIG. 4. However, it is to be understood that various other electrical contacts402may be housed within the contact-retaining chamber406.

The electrical contact402may include a barrel412integrally connected to a reduced diameter stud414. One or more electrical leads416are secured to the stud414, such as through soldering, bonding, or the like. The barrel412includes an open-ended internal chamber418that is configured to receive a reciprocal feature of another electrical contact (not shown). Various other types of electrical contacts other than shown may be used. For example, the electrical contact may be or include an eye-of-the-needle contact, a deflectable contact beam, a pin, socket, and/or the like.

The contact-retaining chamber406includes opposed lateral walls420integrally connected to opposed end walls (not shown inFIG. 4), a face422, and an opposite surface424from the face422. A compressor430may be positioned within the contact-retaining chamber406. The compressor430may be formed of a rigid, non-deformable material, such as a hard plastic or metal. The compressor430includes an exposed surface432having a width that is generally as wide as the internal diameter of an opening434of the contact-retaining chamber406. The exposed surface432connects to outer edges436that connect to an internal peripheral shoulder438that connects to a reduced width retainer-contacting beam440. As shown, a contact channel442is formed through the compressor430. The electrical contact402is positioned within the contact channel442.

A deformable, resilient retainer450is positioned between the compressor430and a fixed, rigid base460, which may be integrally formed with the main housing404. As shown, the base460includes a pocket462into which the retainer450seats. The retainer450is confined or trapped within the pocket462between the compressor430and the base460. The base460may be formed of a rigid, non-deformable material such as a hard plastic, metal, or the like. Outer ledges466of the base460are positioned around an outer edge of the retainer450. The outer ledges466seat on (or are integrally formed with) an internal ridge468of the main housing404. In the disengaged position, a bottom surface470of the peripheral shoulder438of the compressor430is separated from a top surface480of the outer ledges466of the base460by a space482.

The retainer450may be formed of a resilient material, such as rubber or another elastomeric material. As shown, the retainer450includes a contact channel490into which a portion of the electrical contact402is positioned. The electrical contact402includes one or more interstices494. In the disengaged position, the retainer450is not disposed within the interstices494.

FIG. 5illustrates an axial cross-sectional view of the electrical connector assembly400having a securely retained electrical contact402, according to an embodiment of the present disclosure. In order to securely retain the electrical contact402within the contact-retaining chamber406, an actuator500, such as any of those described above, is moved into or otherwise within the actuator track408so that the actuator500exerts an inwardly-directed force502into the compressor420. The force502exerted into the compressor420is translated into the retainer450, which is trapped within the pocket462of the base460. Because the base460is rigid and fixed in position, the force502exerted into the retainer450by the compressor420causes the resilient retainer450to deform. For example, an internal diameter portion of the retainer450that defines contact channel490flows into or otherwise fills the interstices494of the electrical contact402(as the retainer450is compressively squeezed), thereby providing a positive lock with the electrical contact402. In this manner, the electrical contact402is unable to retreat in the direction of arrow510, because the electrical contact402is securely fixed in place by the deformed portions of the retainer450that are disposed within the interstices494. As such, the electrical contact402is securely retained in position without the need for a bulky molded retention feature or the like.

The actuator500may be disengaged to release the electrical contact from secure engagement with the retainer. For example, as shown inFIG. 5, the actuator500may be released. As such, the compressor420retreats in the direction opposite to the arrows502, and the electrical contact402is no longer securely retained by the retainer450.

FIG. 6illustrates a perspective top view of a retainer600, according to an embodiment of the present disclosure. The retainer600may include a main body602formed of a resilient material, such as rubber. The main body602may be sized and shaped to fit within a pocket of a base. The main body602may include a plurality of contact channels604that are configured to receive portions of electrical contacts. The number of contact channels604may equal the number of electrical contacts within an electrical component, such as an electrical connector assembly. Alternatively, the number of contact channels604may be less than a total number of electrical contacts within an electrical component. The retainer600may include more or less contact channels604than shown.

FIG. 7illustrates a perspective top view of a retainer700, according to an embodiment of the present disclosure. The retainer700may include a plurality of retainer elements702, each having a contact channel704. Thus, for each electrical contact within an electrical component, a separate and distinct retainer element702may be used. The retainer700may include more or less retainer elements702than shown.

FIG. 8illustrates a flow chart of a method of retaining electrical contacts within an electrical component, according to an embodiment of the present disclosure. At800, an actuator is urged into a surface of a compressor. As the actuator is urged into the compressor, at802, the exerted force of the actuator is translated into a resilient retainer that is trapped or otherwise sandwiched between the compressor and a base, such as within a pocket of the base. In response to the compressor being forced into the retainer, the retainer deforms at804through the translated force and fills one or more interstices of an electrical contact. At806, the electrical contact is securely retained in position through the deformed portion of the retainer within the one or more interstices of the electrical contact.

FIG. 9illustrates a front view of an electrical connector assembly900, according to an embodiment of the present disclosure.FIG. 10illustrates an axial cross-sectional view of the electrical connector assembly900. Referring toFIGS. 9 and 10, the electrical connector assembly900includes a main housing or shell902that includes a contact-retaining chamber904that houses a plurality of electrical contacts910. As shown, the main housing902may include a cylindrical shaft having one or more threaded outer surfaces911.

An actuator912, in the form of a threaded cap, may be threadably secured to an upper portion of the main housing902. The actuator912may include, or be connected to, a compressor914positioned over a deformable, resilient retainer916, which, in turn, may be positioned over a fixed, rigid base918, which may be an integral base portion of the main housing902. In order to securely.

As the actuator912is rotatably engaged in the direction of arc920, for example, the threadable interface between the actuator912and the main housing902moves the actuator912downward in the direction of arrow922, which forces the compressor914into the retainer916. As the retainer916is compressed between the actuator912and/or the compressor914and the base918, the retainer916securely retains the contacts910, as described above. Accordingly, the electrical connector assembly900shown inFIGS. 9 and 10may be rotatably engaged to secure the electrical contacts910is a retained position.

As described above, the retainer is configured to be deformed when compressively sandwiched between the compressor and the base, such as when the actuator is urged into the compressor. As the retainer deforms, the deformed portion of the retainer fills or otherwise moves into the one or more interstices formed on or in outer portions of the electrical contact, thereby securely locking the electrical contact in position. The deformed portion of the retainer within the interstice(s) of the electrical contact provides a resistive force that prevents or otherwise resists the electrical contact from dislodging out of an electrical component. Alternatively, the retainer may not be positioned in relation to one or more interstices of an electrical contact. Instead, the force exerted into the retainer by the compressor may simply cause the retainer to compressively constrict around an outer portion of the electrical contact, thereby securely retaining the electrical contact in position.

Thus, embodiments of the present disclosure provide practical systems and methods of efficiently retaining electrical contacts within a high density array or pattern, for example.

While various spatial terms, such as upper, bottom, lower, mid, lateral, horizontal, vertical, and the like may be used to describe embodiments of the present disclosure, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like.