SINGLE ELEMENT WIRE TO BOARD CONNECTOR

A single element electrical connector includes a single conductive contact element formed into a cage structure having a wire insert end and a wire contact end along a longitudinal centerline axis of the connector. The cage structure defines an upper pick-up surface having a surface area suitable for placement of a suction nozzle of a vacuum transfer device, as well as a pair of contact tines biased towards the centerline axis to define a contact pinch point for an exposed core of a wire inserted into the connector. A contact surface is defined by a member of the cage structure for electrical mating contact with a respective contact element on a component on which the connector is mounted.

DETAILED DESCRIPTION

Reference will now be made to various embodiments, one or more examples of which are illustrated in the figures. The embodiments are provided by way of explanation of the invention, and are not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to yield still a further embodiment. It is intended that the present application encompass these and other modifications and variations as come within the scope and spirit of the invention.

Exemplary embodiments of an electrical connector10according to various embodiments are illustrated inFIGS. 1 through 8. The electrical connector10is configured for connecting the conductive core of an insulated wire to any manner of electrical component, such as a printed circuit board (PCB). For ease of explanation and illustration, the electrical connector10is illustrated and referred to herein in the context of connecting wires to a PCB. In addition, the electrical connector10is depicted in the figures as a “single-way” connector in that it includes only a single wire position. It should be appreciated that the electrical connector10is not limited by the number of wire positions, and multi-way embodiments are contemplated within the scope and spirit of the invention. For example, in alternative embodiments, the cage structure may be formed into a two-way or a three-way connector in addition to the illustrated single-way connector.

Referring to the figures in general, the electrical connector10is depicted as a single element electrical connector in accordance with various illustrative embodiments. The electrical connector10is particularly suited for connecting a wire12to any manner of electrical component, such as a PCB. The wire12may be a stranded or solid core wire having a core14surrounded by an insulation material16. Prior to insertion of the wire12into the electrical connector10, a section of the insulation material16is stripped away from the core14adjacent to the end of the wire12, as depicted inFIGS. 1 and 2.

As mentioned above, the electrical connector10is a “single element” connector in that it is formed from a single conductive element18. The single conductive element18may be any suitable conductive metal material having a gauge and other physical characteristics suitable for maintaining the shape of the electrical connector10in the mounting process, as well as in the operating environment of the electrical component to which the electrical connector10is mounted.

The single conductive element18is formed into a cage-like structure20as depicted inFIG. 1. In an embodiment, the single conductive element18is formed by bending a single piece of conductive material into the cage-like structure20. The cage-like structure20includes a wire insert end22that defines an inlet opening28for insertion of the wire12into the electrical connector10. The cage-like structure20also defines a wire contact end24(FIG. 1), which is the end of the cage-like structure20at which the exposed conductive core14of the wire12is contacted by the single conductive element18. The wire insert end22and wire contact end24are aligned along a central longitudinal axis26of the electrical connector10, as depicted inFIGS. 1 and 2.

In an embodiment, the cage-like structure20includes a wall structure30that essentially surrounds the wire12. The wall structure30may include any number and configuration of walls, such as a circular wall, semicircular wall components, and so forth. At least a portion of the wall structure30defines a pick-up surface32. The pick-up surface32has a surface area that is suitable for placement of a suction nozzle of a vacuum transfer device so that the electrical connector10may be transferred to an electrical component, such as a PCB, in a conventional pick-and-place process, as is understood by those skilled in the art. In a desirable embodiment, the electrical connector10is supplied in tape form that is fed to a conventional vacuum transfer device in the pick-and-place process.

The cage-like structure20includes a pair of contact tines34that are biased towards the central longitudinal axis26of the electrical connector10downstream of the wall structure30in the insertion direction of the wire12into the electrical connector10. These contact tines34are defined by sections or cutouts of the single conductive element18and define a contact pinch point36(FIG. 3) for contact against the exposed core14of the wire12. The contact pinch point36also serves as a clamp point to prevent inadvertent removal of the wire12from the electrical connector10.

The electrical connector10includes a contact surface38that may be defined by any member or section of the cage-like structure20. The contact surface38is provided for electrical mating contact with a respective contact element on the electronic component. For example, the contact surface38may be defined by any section of the bottom portion or wall of the cage-like structure30that mates with a corresponding contact pad on the PCB, wherein the electrical connector10may be surface mounted directly onto the contact pad of the PCB.

In an embodiment, the electrical connector10and the single conductive element18are formed from a single electrically-conductive sheet material that is bent or otherwise formed into the cage-like structure20. Any manner of cuts, reliefs, or other structures may be cut or stamped into the single conductive element18to facilitate forming the single conductive element18into the overall configuration of the electrical connector10as described herein.

In an embodiment, the wall structure30includes a plurality of walls that are bent into a box-like structure40having a top wall42, bottom wall44, and opposite side walls46. The top wall42defines the pick-up surface32discussed above. It should also be appreciated that any one of the other walls may also define the pick-up surface32. The box-like structure40may be defined by the walls in various ways. For example, in an embodiment, the side walls46are components that are bent upwardly relative to the bottom wall44, while the top wall42is defined by an extension of one of the side walls46that is bent towards the opposite side wall46.

Certain embodiments of the electrical connector10may also include guide surfaces within the cage-like structure20that serve to physically contact and align the wire12within the cage-like structure20. In an embodiment, for example, an upper wire guide48is defined by an angled portion of the top wall42. This upper wire guide48is angled from the generally parallel top wall (parallel to the bottom wall44) towards the center longitudinal (or centerline) axis26, as illustrated inFIGS. 2 and 3. Similarly, the bottom wall44, which may be parallel to the top wall42, may have a forward portion that is angled towards the center longitudinal axis26to define a lower wire guide50, as illustrated inFIGS. 2,6, and7.

As mentioned, the contact tines34may be variously configured within the cage-like structure20. In the illustrated embodiment, the contact tines34are defined by forward portions of each of the side walls46that are bent or angled towards the center longitudinal axis26to the pinch point36. In this manner, the contact tines34are biased towards each other (and the center longitudinal axis26). The contact tines34separate and engage against the core14of the wire as the wire inserted through the contact tines34.

In various embodiments, e.g.,FIGS. 3 and 5, it may be desired to include one or more release tabs52defined on each of the contact tines34generally forward of the pinch point36. The release tabs52provide a location for insertion of a tool between the contact tines34in order to open the contact tines34for removal of the wire12if desired. The release tabs52may be variously configured. In the illustrated embodiment, the release tabs52include generally forwardly extending tabs that are substantially parallel to the center longitudinal axis26with the wire12removed from the electrical connector10, as depicted inFIG. 5.

In various embodiments, it may also be desired to include a wire stop wall54relative to the wire contact end24of the cage-like structure20. The wire stop wall54provides a surface against which the conductive core14of the wire12may abut in the completely inserted position of the wire12, as depicted inFIG. 2. The wire stop wall54may be variously configured. In an embodiment, the wire stop wall54is formed from a bent-up portion of the bottom wall44. The wire stop wall54may further include an overhang or lip58that extends back towards the pinch point36of the contact tines34. This overhang or lip58may serve to prevent inadvertent removal of the wire12in a vertical direction relative to the electrical connector10.

As mentioned, the contact surface38may be defined by any portion of the bottom wall44(or any other wall) that aligns with a mating contact pad on a PCB. According to such an embodiment, the electrical connector10may be configured for conventional surface mount processes.

In an alternative embodiment depicted inFIG. 8, the electrical connector10may be configured for a thru-board connection wherein the connector extends through a hole in a PCB. Contact feet56are provided for mating against a contact pad on either side of the thru-hole in the PCB. Similarly, the contact feet56may serve for surface mounting of the electrical connector10on a PCB wherein the electrical connector10assumes a relatively vertical (i.e., perpendicular) orientation relative to the PCB. In the embodiment depicted inFIG. 8, the contact feet56are defined by outwardly bent portions of each side wall46. In an alternative embodiment, the contact feet56may also be defined by outwardly bent portions of the bottom wall44and top wall42.

FIG. 9depicts an electrical connector110in accordance with an illustrative embodiment. In an embodiment, the electrical connector110is a “single element” connector in that it is formed from a single conductive element. The single conductive element may be any suitable conductive metal material having a gauge and other physical characteristics suitable for maintaining the shape of the electrical connector110in the mounting process, as well as in the operating environment of the electrical component to which the electrical connector110is mounted. In an embodiment, the electrical connector110does not have an insulating component.

The electrical connector110includes an opening128that is configured to receive a wire or other electrically-conductive component inserted into the electrical connector110. The electrical connector110includes a pair of contact tines134. The pair of contact tines134are biased toward a central longitudinal axis of the electrical connector110downstream of the opening128in an insertion direction of a wire or other electrically-conductive component into the electrical connector110. The contact tines134may be formed from portions of the single conductive element that are bent or angled toward the central longitudinal axis to form a pinch point136. The contact tines134are configured to contact an exposed core or portion of a wire or other electrically-conductive component inserted into the electrical connector110. The contact tines134may be configured to separate and engage against the core of the wire or other electrically-conductive component as the wire or other electrically-conductive component is inserted between the contact tines134. In this way, the contact pinch point136may also perform a clamping mechanism to prevent inadvertent removal of the wire or other electrically-conductive component from the electrical connector110. In various embodiments, it may be desirable to include one or more release tabs defined on each of the contact tines134to provide a location for insertion of a tool between the contact tines134in order to open the contact tines134for selective removal of the wire or other electrically-conductive component.

In various alternative embodiments, electrical connector110may include one or more additional contact tines134. The contact tines134may be formed from sections or cutouts of the single conductive element.

In addition, one or more of contact tines134may include one or more release tabs182a,182b. In an embodiment, release tabs182a,182bare defined on one or more of the contact tines134generally forward of the pinch point136. For example, the release tabs182a,182bmay include extensions of a main body of the contact tines134. The release tabs182a,182bprovide a location for insertion of a tool between the contact tines134in order to open the contact tines134for removal of a wire if desired. The release tabs182a,182bmay be variously configured. In the illustrated embodiment, the release tabs182a,182binclude generally forwardly extending tabs that are substantially parallel to a center longitudinal axis that extends through the opening128.

The electrical connector110also includes contact surfaces138and140that may be defined by any member or section of the single conductive material. The contact surfaces138and140are configured to electrically couple to respective contact elements on an electrical component such as a PCB or other electrical device. In an embodiment, the electrical connector110may be surface mounted directly onto the contact pad of the PCB or other electrical device.

FIG. 10adepicts a bottom view of a rear mounting configuration for the electrical connector110in accordance with an illustrative embodiment. In an embodiment, the electrical connector110is mounted to a surface of a PCB150. The electrical connector110includes the contact surfaces138and140which are electrically coupled to contacts pads152and154, respectively, of the PCB150.

FIG. 10bdepicts a top view of the rear mounting configuration for the electrical connector110in accordance with an illustrative embodiment. As mentioned above, the electrical connector110is mounted to a surface of the PCB150. The PCB150includes an opening158that is configured to receive a wire or other electrically-conductive component to be inserted into the electrical connector110.

FIG. 10cdepicts another bottom view of the rear mounting configuration for the electrical connector110in accordance with an illustrative embodiment. A wire160includes an exposed conductive core162. As discussed above, the PCB150includes the opening158which is configured to receive the exposed conductive core162. The exposed conductive core162of the wire160may thus be inserted through the opening158of the PCB150into the electrical connector110such that the exposed conductive core162may be seated between the contact tines134of the electrical connector110, thereby forming an electrical connection between the wire160, the electrical connector110, and the contact pads152and154.

FIG. 11adepicts a top view of a thru-board mounting configuration for the electrical connector110in accordance with an illustrative embodiment. In an embodiment, the electrical connector110is secured to a first surface of the PCB150and extends through the opening158in the PCB150. The electrical connector110includes the contact surfaces138and140which are electrically coupled to contacts pads152and154, respectively, on the first surface of the PCB150. The contact tines134of the electrical connector110extend thru the opening158in the PCB150such that the contact tines134extend outward a distance from a second surface of the PCB150that is opposite the first surface.

FIG. 11bdepicts a bottom view of the thru-board mounting configuration for the electrical connector110in accordance with an illustrative embodiment. As mentioned above, the electrical connector110is mounted to a first surface of the PCB150. The PCB150includes the opening158through which the contact tines134extend.

FIG. 11cdepicts another top view of the thru-board mounting configuration for the electrical connector110in accordance with an illustrative embodiment. The wire160includes the exposed conductive core162. As discussed above, the electrical connector includes the opening128which is configured to receive the exposed conductive core162of the wire160. The exposed conductive core162of the wire160may thus be inserted through the opening128of the electrical connector110. In turn, the exposed conductive core162is inserted between the contact tines134and through the opening158in the PCB150such that the exposed conductive core162may be seated between the contact tines134of the electrical connector110. In this way, upon fully seating the wire160within the electrical connector110, the wire160will extend through the opening158in the PCB150.

FIG. 12depicts an electrical connector210in accordance with an illustrative embodiment. In an embodiment, the electrical connector210is a “single element” connector in that it is formed from a single conductive element as discussed in additional detail above. The single conductive element may be any suitable conductive metal material having a gauge and other physical characteristics suitable for maintaining the shape of the electrical connector210in the mounting process, as well as in the operating environment of the electrical component to which the electrical connector210is mounted.

The electrical connector210includes contact surfaces238and240that may be defined by any member or section of the single conductive material. The contact surfaces238and240are configured to electrically couple to respective contact elements on an electrical component such as a PCB or other electrical device. In an embodiment, the electrical connector210may be surface mounted directly onto the contact pad of the PCB or other electrical device. The contact surfaces238and240are connected to a main body portion of the electrical connector210by raised portions270and272, respectively. Raised portions270and272extend away from contact surfaces238and240, respectively, at an angle such that a main body portion of the electrical connector210which includes an opening228is located at a different height from a mounting surface relative to the contact surfaces238and240. Such embodiments allow the electrical connector210to be mounted to either side of a PCB. For example, the electrical connector210may be top mounted or rear mounted, thereby providing the option of connecting a wire from either side of the PCB and not restricting on which side of the PCB additional circuitry may be located.

The opening228is configured to receive a wire or other electrically-conductive component inserted into the electrical connector210. The electrical connector210includes a pair of contact tines234that extend from a surface in which the opening228is formed in a direction away from contact surfaces238and240. In various alternative embodiments, electrical connector210may include one or more additional tines234. The contact tines234may be formed from sections or cutouts of the single conductive element. The contact tines234are biased towards a central longitudinal axis of the electrical connector210downstream of the opening228in the insertion direction of a wire or other electrically-conductive component into the electrical connector210. For example, the contact tines234may be formed from portions of the single conductive element that are bent or angled towards the central longitudinal axis to form a pinch point236. The contact tines234are configured to contact an exposed core or portion of a wire or other electrically-conductive component inserted into the electrical connector210. The contact tines234may be configured to separate and engage against the core of the wire or other electrically-conductive component as the wire or other electrically-conductive component is inserted between the contact tines234. In this way, the pinch point236may also serve as a clamp point to prevent inadvertent removal of the wire or other electrically-conductive component from the electrical connector210. In various embodiments, it may be desirable to include one or more release tabs defined on each of the contact tines234to provide a location for insertion of a tool between the contact tines234in order to open the contact tines234for selective removal of the wire or other electrically-conductive component.

In addition, one or more of contact tines234may include one or more release tabs282a,282b. In an embodiment, release tabs282a,282bare defined on one or more of the contact tines234generally forward of the pinch point236. For example, the release tabs282a,282bmay include extensions of a main body of the contact tines234. The release tabs282a,282bprovide a location for insertion of a tool between the contact tines234in order to open the contact tines234for removal of a wire if desired. The release tabs282a,282bmay be variously configured. In the illustrated embodiment, the release tabs282a,282binclude generally forwardly extending tabs that are substantially parallel to a center longitudinal axis that extends through the opening228.

FIG. 13adepicts a bottom view of a top mounting configuration for the electrical connector210in accordance with an illustrative embodiment. In an embodiment, the electrical connector210is mounted to a surface of a PCB250. The electrical connector210includes the contact surfaces238and240which are electrically coupled to contacts pads252and254, respectively, of the PCB250. The raised portions270and272extend away from the contact surfaces238and240, respectively, at an angle such that portion of the electrical connector210in which the opening228is formed is located at an increased distance from a surface of the PCB250.

FIG. 13bdepicts a top view of the top mounting configuration for the electrical connector210in accordance with an illustrative embodiment. As mentioned above, the electrical connector210is mounted to a surface of the PCB250. The PCB250includes an opening258that is configured to receive a wire or other electrically-conductive component to be inserted into the electrical connector210.FIG. 13cdepicts another bottom view of the top mounting configuration for the electrical connector210in accordance with an illustrative embodiment. A wire260includes an exposed conductive core262. As discussed above, the PCB250includes the opening258which is configured to receive the exposed conductive core262. The exposed conductive core262of the wire260may thus be inserted through the opening258of the PCB250into the electrical connector210such that the exposed conductive core262may be seated between the contact tines234of the electrical connector210.

FIG. 14depicts an electrical connector310in accordance with an illustrative embodiment. In an embodiment, the electrical connector310is a “single element” connector in that it is formed from a single conductive element as discussed in additional detail above. The electrical connector310includes contact surfaces338and340that may be defined by any member or section of the single conductive material. The contact surfaces338and340are configured to electrically couple to respective contact elements on an electrical component such as a PCB or other electrical device. In an embodiment, the electrical connector310may be surface mounted directly onto the contact pad of the PCB or other electrical device. The contact surfaces338and340are connected to a main body portion of the electrical connector310by raised portions370and372, respectively. Raised portions370and372extend away from contact surfaces338and340, respectively, at an angle such that a main body portion of the electrical connector310which includes an opening328is located at a different height from a mounting surface relative to the contact surfaces338and340. Once again, such embodiments allow the electrical connector310to be mounted to either side of a PCB. For example, the electrical connector310may be top mounted or rear mounted, thereby providing the option of connecting a wire from either side of the PCB and not restricting on which side of the PCB additional circuitry may be located.

The opening328is configured to receive a wire or other electrically-conductive component inserted into the electrical connector310. The electrical connector310includes a pair of contact tines334that extend from the surface in which the opening328is formed in a direction back toward the contact surfaces338and340. In various alternative embodiments, electrical connector310may include one or more additional tines334. The contact tines334may be formed from sections or cutouts of the single conductive element. The contact tines334are biased towards a central longitudinal axis of the electrical connector310downstream of the opening328in the insertion direction of a wire or other electrically-conductive component into the electrical connector310. For example, the contact tines334may be formed from portions of the single conductive element that are bent or angled towards the central longitudinal axis to form a pinch point336. The contact tines334are configured to contact an exposed core or portion of a wire or other electrically-conductive component inserted into the electrical connector310. The contact tines334may be configured to separate and engage against the core of the wire or other electrically-conductive component as the wire or other electrically-conductive component is inserted between the contact tines334. In this way, the pinch point336may also serve as a clamp point to prevent inadvertent removal of the wire or other electrically-conductive component from the electrical connector310. In various embodiments, it may be desirable to include one or more release tabs defined on each of the contact tines334to provide a location for insertion of a tool between the contact tines334in order to open the contact tines334for selective removal of the wire or other electrically-conductive component.

In addition, one or more of contact tines334may include one or more release tabs382a,382b. In an embodiment, release tabs382a,382bare defined on one or more of the contact tines334generally forward of the pinch point336. For example, the release tabs382a,382bmay include extensions of a main body of the contact tines334. The release tabs382a,382bprovide a location for insertion of a tool between the contact tines334in order to open the contact tines334for removal of a wire if desired. The release tabs382a,382bmay be variously configured. In the illustrated embodiment, the release tabs382a,382binclude generally forwardly extending tabs that are substantially parallel to a center longitudinal axis that extends through the opening328.

FIG. 15adepicts a top view of a thru-board mounting configuration for the electrical connector310in accordance with an illustrative embodiment. In an embodiment, the electrical connector310is secured to a first surface of the PCB350and extends through the opening358in the PCB350. The electrical connector310includes the contact surfaces338and340which are electrically coupled to the contacts pads352and354, respectively, on the first surface of the PCB350. The contact tines334of the electrical connector310extend thru the opening358in the PCB350such that the contact tines334extend a distance above a second surface of the PCB350that is opposite the first surface.

FIG. 15bdepicts a bottom view of the thru-board mounting configuration for the electrical connector310in accordance with an illustrative embodiment. As mentioned above, the electrical connector310is mounted to a first surface of the PCB350. The PCB350includes the opening358through which the contact tines334extend.FIG. 15cdepicts another top view of the thru-board mounting configuration for the electrical connector310in accordance with an illustrative embodiment. The wire360includes the exposed conductive core362. As discussed above, the electrical connector includes the opening328which is configured to receive the exposed conductive core362of the wire360. The exposed conductive core362of the wire360may thus be inserted through the opening328of the electrical connector310. In turn, the exposed conductive core362is inserted between the contact tines334and through the opening358in the PCB350such that the exposed conductive core362may be seated between the contact tines334of the electrical connector310. In this way, upon fully seating the wire360within the electrical connector310, the wire360will extend through the opening358in the PCB350.

It should be readily appreciated by those skilled in the art that various modifications and variations can be made to the embodiments of the invention illustrated and described herein without departing from the scope and spirit of the invention. It is intended that such modifications and variations be encompassed by the appended claims.