A number of board-to-board array connectors are described. An example connector includes a receptacle assembly and a plug assembly. The receptacle assembly includes a receptacle housing and a receptacle interface assembly. The plug assembly includes a plug housing and a plug interface assembly. The plug interface assembly includes a plug contact blade having a cantilevered blade beam. The cantilevered blade beam can be centrally positioned within the plug contact blade in one example. The cantilevered blade beam can be cantilevered toward a contact blade end of the cantilevered blade beam and extends toward a mount end of the cantilevered blade beam. The receptacle interface assembly includes a receptacle contact having a pair of contact beams. The cantilevered blade beam is configured to bend as the pair of contact beams electrically contact and slide along surfaces of the cantilevered blade beam.

BACKGROUND

Connectors, connector assemblies, and housings for connectors are important structural and functional components in many computing and data interconnect systems. A number of different types and styles of connectors are known and used to electrically transfer data and radio frequency signals among interconnected boards and systems. Board-to-board connectors are relied upon to electrically couple data signals, radio frequency signals, and power between various types of printed circuit boards and other electrical and electro-mechanical assemblies. With the continued increase in the number of features and capabilities of electronics and related devices, such as cellular phones, computers, tablets, and other devices, many devices now include several printed circuits boards and related assemblies in a common housing.

SUMMARY

A number of board-to-board array connectors are described. An example connector includes a receptacle assembly and a plug assembly. The receptacle assembly includes a receptacle housing and a receptacle interface assembly. The plug assembly includes a plug housing and a plug interface assembly. The plug interface assembly includes a plug contact blade having a cantilevered blade beam. The cantilevered blade beam can be centrally positioned within the plug contact blade in one example. The cantilevered blade beam can be cantilevered toward a contact blade end of the cantilevered blade beam and extends toward a mount end of the cantilevered blade beam. The receptacle interface assembly includes a receptacle contact having a pair of contact beams. The cantilevered blade beam is configured to bend as the pair of contact beams electrically contact and slide along surfaces of the cantilevered blade beam.

Another example connector includes a receptacle assembly. The receptacle assembly includes a receptacle housing and a receptacle interface assembly. The receptacle interface assembly includes a receptacle shield body having a compliant extension contact. The compliant extension contact includes a cantilevered shield arm. The cantilevered shield arm can be cantilevered toward a contact end of the receptacle shield body extends toward a mount end of the receptacle shield body. The cantilevered shield arm can include a compliant arm and a shield paddle. The shield paddle is separated from the receptacle shield body by a shield clearance area, and the shield paddle is configured to bend from a position further toward the center of the receptacle shield body to a position further away from the center of the receptacle shield body.

DETAILED DESCRIPTION

Connectors, connector assemblies, and housings for connectors are important structural and functional components in many computing and data interconnect systems. A number of different types and styles of connectors are known and used to electrically transfer data and radio frequency (RF) signals among interconnected systems. Board-to-board connectors are relied upon to electrically couple data signals, RF signals, and power between various types of printed circuit boards (PCBs) and other electrical and electro-mechanical assemblies. With the continued miniaturization of electronics and related devices, such as cellular phones, computers, tablets, and other devices, engineers are working to package many different PCBs closely together in a common housing. One limitation for arranging PCBs into closer proximity with each other, however, is the size of the board-to-board and other connectors and contactors used to electrically communicate the data and RF signals among them.

In the context outlined above, a number of board-to-board array connectors are described. An example connector includes a receptacle assembly and a plug assembly. The receptacle assembly includes a receptacle housing and a receptacle interface assembly. The plug assembly includes a plug housing and a plug interface assembly. The plug interface assembly includes a plug contact blade having a cantilevered blade beam. The cantilevered blade beam can be centrally positioned within the plug contact blade in one example. The cantilevered blade beam can be cantilevered toward a contact blade end of the cantilevered blade beam and extends toward a mount end of the cantilevered blade beam. The receptacle interface assembly includes a receptacle contact having a pair of contact beams. The cantilevered blade beam is configured to bend as the pair of contact beams electrically contact and slide along surfaces of the cantilevered blade beam. Another example connector includes a receptacle assembly. The receptacle assembly includes a receptacle housing and a receptacle interface assembly. The receptacle interface assembly includes a receptacle shield body having a compliant extension contact. The compliant extension contact includes a cantilevered shield arm. The cantilevered shield arm can be cantilevered toward a contact end of the receptacle shield body extends toward a mount end of the receptacle shield body. The cantilevered shield arm can include a compliant arm and a shield paddle. The shield paddle is separated from the receptacle shield body by a shield clearance area, and the shield paddle is configured to bend from a position further toward the center of the receptacle shield body to a position further away from the center of the receptacle shield body.

Turning to the drawings,FIG.1Aillustrates a perspective view of an example board-to-board array connector10(also “connector10”) according to various embodiments of the present disclosure.FIG.1Billustrates a first side view of the board-to-board array connector10, andFIG.1Cillustrates a second side view of the board-to-board array connector10. The connector10shown inFIGS.1A-1Cis representative, not drawn to any particular scale, and is illustrated to provide context for the concepts of the board-to-board array connectors described herein. The connectors described herein can be formed in a range of different shapes, styles, and sizes, although certain sizes and shapes are described and illustrated. The connectors described herein can be used in a range of interconnect applications, although board-to-board interface applications are described in some examples.

The connector10can be relied upon as a type of board-to-board connector for electrically coupling signals, including but not limited to RF signals, for example, between two different PCBs, as described herein. The connector10includes receptacle assembly100and a plug assembly200. The connector10is positioned between two PCBs. Particularly, the receptacle assembly100is mechanically and electrically coupled to the PCB12, and the plug assembly200is mechanically and electrically coupled to the PCB14. Conductive signal paths and traces on the PCB12, carrying RF signals, are electrically coupled through the connector10to conductive signal paths and traces on the PCB14.

Among other components described below, the receptacle assembly100includes a housing102. The housing102includes a keyway104formed in and extending along one side of the housing102. The housing102also includes a housing base106, which is seated upon a surface of the PCB12in the example shown. The housing102can be formed as an integral part or piece in one example, although the housing102can also be formed from two or more separate parts or pieces in some cases. The housing102can be formed from an insulating material, such as a plastic or polymer, a thermoplastic resin, a liquid crystal polymer (LCP), a glass fiber epoxy compound, Polytetrafluoroethylene (PTFE), polyimide, or other insulating material(s). The housing102can be plated with a conductive plating material in some examples. Thus, the housing102can be embodied as a plated plastic in some cases.

The plug assembly200includes a housing202. The housing202also includes a mating bonnet208at one end, and the housing102of the receptacle assembly100can be inserted into the plug assembly200using the mating bonnet208to guide the alignment of the receptacle assembly100with the plug assembly200. One end of the housing202is seated upon a surface of the PCB14in the example shown. The housing202can be formed as an integral part or piece in one example, although the housing202can also be formed from two or more separate parts or pieces in some cases. The housing202can be formed from an insulating material, such as a plastic or polymer, a thermoplastic resin, a liquid crystal polymer (LCP), a glass fiber epoxy compound, Polytetrafluoroethylene (PTFE), polyimide, or other insulating material(s). The housing202can be plated with a conductive plating material in some examples. Thus, the housing202can be embodied as a plated plastic in some cases.

Referring toFIGS.1B and1C, the housing102includes positioning posts106A and106B, which extend off the housing base106. The positioning posts106A and106B extend through apertures in the PCB12, to align the housing102with conductive pads, traces, or other features on the PCB12. In other examples, the positions or locations of the positioning posts106A and106B can vary as compared to that shown, the housing102can include additional positioning posts at other positions, or one or both of the positioning posts106A and106B can be omitted. Additionally, the positioning posts106A and106B can vary in size (e.g., in diameter, length, width, etc.), in shape (e.g., circular, oval, square, rectangular, etc.), or in both size and shape as compared to each other in some cases. Such variations among the positioning posts106A and106B can provide a type of polarizing or orienting mechanism, to ensure the intended orientation of the housing102with respect to the PCB12.

The housing102also includes ground legs121A and121B, among others. The ground legs121A and121B extend from shield bodies positioned within the housing102, as described below. The ground legs121A and121B extend through apertures or vias in the PCB12. The ground legs121A and121B can be press- or interference-fit through the apertures, in one example, or the ground legs121A and121B can extend through the apertures with a clearance. The apertures through the PCB12for the ground legs121A and121B can also be plated in some cases, such as plated vias in one example, and the ground legs121A and121B can be soldered or otherwise electrically connected to the plated vias or other conductive traces on the PCB12.

The housing202includes positioning posts206A and206B, which extend off the housing202. The positioning posts206A and206B extend through apertures in the PCB14, to align the housing202with conductive pads, traces, or other features on the PCB14. In other examples, the positions or locations of the positioning posts206A and206B can vary as compared to that shown, the housing202can include additional positioning posts at other positions, or one or both of the positioning posts206A and206B can be omitted. Additionally, the positioning posts206A and206B can vary in size (e.g., in diameter, length, width, etc.), in shape (e.g., circular, oval, square, rectangular, etc.), or in both size and shape as compared to each other in some cases. Such variations among the positioning posts206A and206B can provide a type of polarizing or orienting mechanism, to ensure the intended orientation of the housing202with respect to the PCB14.

The plug assembly200also includes ground legs221A and221B, among others. The ground legs221A and221B extend from shield bodies positioned within the housing202, as described below. The ground legs221A and221B extend through apertures or vias in the PCB14. The ground legs221A and221B can be press- or interference-fit through the apertures, in one example, or the ground legs221A and221B can extend through the apertures with a clearance. The apertures through the PCB14for the ground legs221A and221B can be plated, such as plated vias in one example, and the ground legs221A and221B can be soldered or otherwise electrically connected to the plated vias or other conductive traces on the PCB14.

When interfaced with each other between the PCBs12and14, the connector10has a total height “H” between the PCBs12and14, as shown inFIGS.1B and1C. The receptacle assembly100has a length “L1” and a width “W1.” The plug assembly200has a length “L2” and a width “W2.” The “L1” and “W1” dimensions of the receptacle assembly100are smaller than the “L2” and “W2” dimensions of the plug assembly200, so that the receptacle assembly100can fit and be inserted within the plug assembly200, as also described below. The connector10can be manufactured to a range of sizes. Example dimensions of “H” can range from 10-40 mm, but the connector10can be formed to larger or smaller sizes in some cases. Thus, the connector10can be tailored to accommodate a range of board-to-board spacings between PCBs. Example dimensions of “L1” and “W1” can range from 10-20 mm, from 10-30 mm, from 10-40 mm, from 10-50 mm, or larger ranges. Similarly, example dimensions of “L2” and “W2” can range from 10-20 mm, from 10-30 mm, from 10-40 mm, from 10-50 mm, or larger ranges. Overall, the “L1,” “L2,” “W1,” and “W2” dimensions can vary depending on the number of RF signals being passed through the connector10. The connector10is designed to electrically couple six (6) different RF signals, with sufficient electromagnetic isolation between, but other connectors can be designed to couple eight, ten, twelve, or more RF signals. The shape and size of the connector10can thus range depending on the design needs for a particular application.

FIG.2Aillustrates a perspective view of the receptacle assembly100of the connector10shown inFIGS.1A-1C.FIG.2Billustrates a top-down view of the receptacle assembly100. The plug assembly200is omitted from view inFIGS.2A and2B. The housing102of the receptacle assembly100includes a receptacle body103and the housing base106. The receptacle body103extends from the top surface107of the housing base106to the end surface109of the housing102. The receptacle assembly100can be inserted into the plug assembly200, with the end surface109of the housing102being inserted into the plug assembly200first. The dimension of “H1” of the housing102can range, depending on the overall design and height “H” for the connector10(seeFIGS.1B and1C).

The keyway104is formed in and extends along one side of the receptacle body103. The housing102includes one keyway104in the example shown, but the housing102can include other keyways at other positions. Overall, the number and positions of any keyways of the housing102can vary among the embodiments. The keyway104polarizes or orients the housing102with the housing202of the plug assembly200, to ensure the correct mechanical and electrical coupling between them when they are connected or assembled with each other.

A number of openings, including the openings109A and109B, among others, are formed in the end surface109of the housing102. The openings109A and109B extend through the housing102, from the end surface109of the housing102to and through the housing base106. A receptacle interface assembly is positioned within each of the openings. Example receptacle interface assemblies110and111are identified inFIGS.2A and2B, positioned respectively within the openings109A and109B. The receptacle interface assemblies110and111, among others, are described in further detail below. The receptacle interface assemblies110and111are oriented the same way as each other in the example shown, as are the receptacle interface assemblies in the other openings of the housing102. However, one or both of the receptacle interface assemblies110and111, among others, can be rotated (e.g., by 90°) as compared to that shown, and the receptacle assembly100can include a mixture of receptacle interface assemblies having different orientations. The receptacle assembly100includes a total of six (6) openings in the end surface109of the housing102in the example shown, but other connectors with receptacle assemblies having more or less than six openings are within the scope of the embodiments.

FIG.3Aillustrates a perspective view of the plug assembly200of the connector10shown inFIGS.1A-1C.FIG.3Billustrates a top-down view of the plug assembly200. The receptacle assembly100is omitted from view inFIGS.3A and3B. The housing202of the plug assembly200includes a plug body203and the mating bonnet208. The plug body203extends from one end of the housing202to the mating bonnet208. The mating bonnet208is outwardly tapered away from outer surfaces of the plug body203, until reaching the end surface209of the housing202. The dimension “H2” of the housing202can range, depending on the overall design and height “H” for the connector10(seeFIGS.1B and1C).

The housing202includes a central opening or cavity209A. The cavity209A is sized to permit insertion of the receptacle body103of the housing102(seeFIG.2) within the cavity209A, with a nominal clearance for movement between them. The receptacle body103of the housing102can be inserted to a varying extent (i.e., to a varying distance) into the cavity209A of the housing202. Receptacle contacts of the receptacle assembly100can make electrical contact with plug contact blades of the plug assembly200over a range of insertion, when the receptacle assembly100is inserted into the plug assembly200, as described below. Thus, the connector10can facilitate a range of dimensions or spacings between PCBs, such as the PCBs12and14, to account for design tolerances, manufacturing tolerances, and other considerations.

A plug ridge204extends along an inner surface within the housing202, as shown inFIGS.3A and3B. The housing202includes one plug ridge204in the example shown, but the housing202can include other ridges at other positions. Overall, the number and positions of any ridges of the housing202can vary among the embodiments. The plug ridge204polarizes or orients the housing202of the plug assembly200with the housing102of the receptacle assembly100, to ensure the correct mechanical and electrical coupling between them when they are connected together. Particularly, the plug ridge204of the housing202is designed and sized to slide within the keyway104of the housing102when they are connected or assembled with each other.

The plug assembly200also includes a number of plug interface assemblies, such as the plug interface assemblies210and211, among others, as shown inFIGS.3A and3B. The plug interface assemblies210and211are oriented the same way as each other in the plug assembly200shown, as are the other plug interface assemblies. However, one or both of the plug interface assemblies210and211, among others, can be rotated (e.g., by 90°) as compared to that shown, and the plug assembly200can include a mixture of plug interface assemblies having different orientations. In any case, among the receptacle assembly100and the plug assembly200, the receptacle interface assemblies and the corresponding plug interface assemblies can be oriented with respect to each other so that the receptacle contacts in the receptacle interface assemblies are oriented for insertion into the plug contact blades in the plug interface assemblies.

When the receptacle assembly100is inserted into the plug assembly200, the plug interface assemblies210and211of the plug assembly200extend into the openings109A and109B of the receptacle assembly100. The plug interface assemblies210and211engage and contact with the receptacle interface assemblies110and111, respectively, when the receptacle assembly100is inserted into the plug assembly200. One RF signal is electrically coupled between the PCBs12and14via the connector10, through the plug interface assembly210and the receptacle interface assembly110. Another RF signal is electrically coupled between the PCBs12and14via the connector10, through the plug interface assembly211and the receptacle interface assembly111. Other RF signals are also coupled between the PCBs12and14through other interface assemblies of the connector10as described herein.

FIG.4Aillustrates the cross-sectional view of the connector10designated A-A inFIG.1A, with the receptacle assembly100separated from the receptacle assembly200. As shown, the receptacle assembly100can be positioned and centered with the plug assembly200, and the receptacle body103of the receptacle assembly100can be inserted into the cavity209A of the receptacle assembly100by movement of the receptacle assembly100generally in the direction “D”. Alternatively, the receptacle assembly100can be positioned and centered with the plug assembly200, and the central cavity209A of the plug assembly200can be fitted over the receptacle body103by movement of the of the plug assembly200generally in the direction “D”. The receptacle assembly100and the plug assembly200can also be positioned and moved, respectively, in some cases, to connect them together.

It is not necessary that the receptacle assembly100and the plug assembly200be perfectly centered or aligned with each other before the mating or connecting process proceeds. The mating bonnet208includes tapered internal surfaces, such as the tapered surfaces208A and208B, among others. Thus, even if the receptacle assembly100and the plug assembly200are not perfectly aligned with each other along the centerline “C,” the tapered surfaces208A and208B will help to channel or funnel the receptacle body103of the housing102into the cavity209A of the housing202. The keyway104of the housing102will also interface with the plug ridge204of the housing202during the mating or connecting process to ensure the correct orientation of the receptacle assembly100with respect to the plug assembly200.

As the receptacle assembly100and the plug assembly200are mated, the end surface109of the housing102will be directed towards the center of the cavity209A as it approaches the insertion point “P1.” The insertion of the receptacle body103of the housing102to the point “P1” completes a first or primary phase of alignment of the receptacle assembly100with the plug assembly200. At that point (i.e., when the end surface109of the housing102reaches the point “P1” within the cavity209A of the housing202), the plug interface assemblies210and211of the receptacle assembly200, among others, still have not been inserted into (and do not extend into) the openings109A and109B, among others, in the housing102. The connector10includes additional features that help to further align the plug interface assemblies of the receptacle assembly200with the receptacle interface assemblies of the plug assembly100, as described below.

FIG.4Billustrates the cross-sectional view designated A-A inFIG.1A, with the receptacle assembly100inserted into the plug assembly200to the same extent as that shown inFIG.1A. As shown inFIG.4B, the end surface109of the housing102has been inserted into and reached the point “P2” within the cavity209A of the housing202. The plug interface assemblies210and211of the plug assembly200, among others, have also been inserted into (and extend into) the openings109A and109B, among others, in the housing102of the receptacle assembly100inFIG.4B. Thus, the plug interface assemblies210and211of the plug assembly200have also mated and made electrical contact with the receptacle interface assemblies110and111(seeFIGS.2A and2B), which are positioned within the openings109A and109B in the receptacle assembly100. It is not necessary that the end surface109of the housing102reach the point “P2,” however, before electrical contact occurs between the plug interface assemblies and the receptacle interface assemblies of the receptacle assembly100and the plug assembly200. Electrical contact between them occurs over a range of insertion, before the end surface109of the housing102reach the point “P2,” as described below.

FIG.5illustrates the plug interface assemblies and the receptacle interface assemblies of the connector10shown inFIG.1A. The housings102and202of the connector10are omitted from view inFIG.5, as is the PCB14, so that the interface assemblies are visible. Six plug and receptacle interface assemblies are shown inFIG.5. Among others, the receptacle interface assembly110and the plug interface assembly210are shown and separately referenced inFIG.5, and additional interface assemblies are also illustrated (but not separately referenced).

The receptacle interface assembly110includes a receptacle shield body120. The plug interface assembly210includes a plug shield body220. The other receptacle and plug interface assemblies each include identical or similar shield bodies. In the configuration shown, the plug shield body220has been inserted into and makes electrical contact with the receptacle shield body120. The plug shield body220includes the ground legs221A and221B, and the receptacle shield body120includes the ground legs121A and121B (see alsoFIGS.1B and1C). The shield bodies120and220can be formed from an electrically-conductive, metallic material, such as aluminum, copper, or other conductive metals or alloys thereof. In one example, the shield bodies120and220can be stamped or sheared out from a sheet of the electrically-conductive, metallic material, and then be bent or otherwise formed into the shapes shown inFIG.5, although the shield bodies120and220can also be formed in other suitable ways.

A receptacle contact150(seeFIG.8), including contact beams, extends within the receptacle interface assembly110. A plug contact blade250(seeFIG.9), including a cantilevered blade beam, extends within the plug interface assembly210. The receptacle contact150is electrically insulated from the receptacle shield body120, and the plug contact blade250is electrically insulated from the plug shield body220. However, the receptacle contact150makes electrical contact with the plug contact blade250inside the shield bodies120and220, as also described below. The receptacle contact150and the plug contact blade250provide an electrical pathway for an RF signal, and the shield bodies120and220provide an electrical shield (e.g., an electromagnetic interference (EMI) shield) for the RF signal.

FIG.6Aillustrates the receptacle interface assembly110of the connector10shown inFIG.1A.FIG.6Billustrates a contact end of the receptacle interface assembly110shown inFIG.6A, andFIG.6Cillustrates a mounting end of the receptacle interface assembly110shown inFIG.6A. The components shown inFIGS.6A-6Care representative, not drawn to any particular scale, and are illustrated to provide context for the concepts of the board-to-board array connectors described herein. The components can be formed in a range of different shapes, styles, and sizes, although certain sizes and shapes are described and illustrated.

Referring amongFIGS.6A-6C, the receptacle interface assembly110includes the receptacle shield body120, a receptacle body insulator130(seeFIG.6D), a receptacle contact insulator140, and a receptacle contact150(see alsoFIG.8). The receptacle body insulator130and receptacle contact insulator140are described in further detail below with reference toFIG.6D, and the receptacle contact150is described in further detail below with reference toFIGS.8and10.

The receptacle shield body120can be formed from an electrically-conductive, metallic material, such as aluminum, copper, or other conductive metals or alloys thereof. In one example, the receptacle shield body120can be stamped or sheared out from a sheet of the electrically-conductive, metallic material, and then be bent or otherwise formed into the shape shown inFIGS.6A-6C. The receptacle shield body120is generally formed as a hollow, rectangular cuboid, with rounded corners. The receptacle shield body120includes a number of housing detents, such as the detents124A and124B. The number and positions of the detents are illustrated as a representative example inFIGS.6A-6C. In other cases, the number and positions of the detents can vary as compared to that shown. Additionally, the size, shape, and form of the detents can vary. For example, the detents can be shaped as teeth, posts, pins, or other types of projections. The detents can be relied upon to secure the receptacle interface assembly110, among others, within the housing102of the receptacle assembly100. Thus, the receptacle interface assembly110, among others, can be inserted and secured within the housing102using a mechanical interference, friction-based, or related type of fit or interface. The detents can also be relied upon to help secure the receptacle body insulator130within the receptacle shield body120in some cases.

The receptacle shield body120includes the ground legs121A and121B at the mounting end shown inFIG.6C. The ground legs121A and121B are illustrated as examples. In other cases, the receptacle shield body120can include additional or fewer ground legs than that shown inFIGS.6A and6C. The positions of the ground legs can also be varied as compared to that shown. The receptacle shield body120also includes a number of compliant extension contacts122A-122D at a contact end shown inFIG.6B. Each of the compliant extension contacts122A-122D extends from one side surface of the receptacle shield body120.

The plug shield body220of the plug interface assembly210(seeFIG.5) can be inserted into the receptacle shield body120at the contact end, and the inner surfaces of the compliant extension contacts122A-122D will contact the outer surfaces of the plug shield body220, making an electrical contact between them. The compliant extension contacts122A-122D bend outwardly at the leading contact end and can help to align the plug shield body220with the receptacle shield body120, as the plug shield body220is inserted into the receptacle shield body120. For example, if the plug shield body220is offset or off-center (e.g., in the range of tenths or hundredths of a millimeter) with the receptacle shield body120, the compliant extension contacts122A-122D are designed to contact and apply centering forces to the plug shield body220as it is inserted into the receptacle shield body120. The shield bodies120and220provide an EMI shield for the RF signal carried on the receptacle contact150.

Referring toFIG.6B, the receptacle contact150includes contact circlets157A and157B positioned, respectively, at the distal ends of contact beams155A and155B (seeFIG.8) of the receptacle contact150. The contact circlets157A and157B are separated, with a clearance between them, and are positioned within channels formed in the receptacle contact insulator140. A contact channel160(see alsoFIG.6A) extends between the contact circlets157A and157B, the contact beams155A and155B, and within the receptacle contact insulator140. A plug contact blade250(seeFIG.9) of the plug interface assembly210can be inserted into the contact channel160. An electrical contact can be formed between the receptacle contact150and the plug contact blade250within the contact channel160, as described in further detail below. As noted above, the compliant extension contacts122A-122D bend outwardly and can help with alignment of the plug shield body220into the receptacle shield body120. Thus, the compliant extension contacts122A-122D can also help with alignment of the plug contact blade250into the contact channel160and between the contact beams155A and155B of the receptacle contact150.

The receptacle body insulator130can be formed from an insulating material, such as a plastic or polymer, a thermoplastic resin, LCP, a glass fiber epoxy compound, PTFE, polyimide, or other insulating material(s). The receptacle body insulator130electrically insulates and isolates the receptacle contact150from the receptacle shield body120. The receptacle body insulator130can be molded (e.g., injection molded, over-molded, etc.) around the receptacle contact150, at least in part, in one example. More particularly, the receptacle body insulator130can be molded around the receptacle contact150, with the contact beams155A and155B (or at least some portion thereof) being exposed and extending out from the contact end of the receptacle body insulator130, as also described below with reference toFIG.6E. A mount contact153of the receptacle contact150can also be exposed and extend out from the mounting end of the receptacle body insulator130, as shown inFIG.6C. After the receptacle body insulator130is molded around the receptacle contact150, the molding assembly can be sheared out from a larger lead frame including the receptacle contact150, among others.

The receptacle contact insulator140can be separately formed from an insulating material, such as a plastic or polymer, a thermoplastic resin, LCP, a glass fiber epoxy compound, PTFE, polyimide, or other insulating material(s). The receptacle contact insulator140can be placed over the contact beams155A and155B of the receptacle contact150. This assembly, which is shown inFIG.6D, can be inserted and fitted within the receptacle shield body120. In other cases, rather than the receptacle contact insulator140being formed separately from the receptacle body insulator130, the receptacle body insulator130and the receptacle contact insulator140can be integrally formed, as one molded piece.

Referring toFIG.6C, the mount contact153of the receptacle contact150is exposed and extends out from the mounting end of the receptacle interface assembly110. When the receptacle interface assembly110is mounted to the PCB12, the mount contact153can be electrically contacted and connected (e.g., soldered, welded, etc.) to a conductive trace or pad on the PCB12. The mount contact153is tailored for a surface mount connection, but the connector concepts described herein are not limited to surface mount contacts or couplings. The receptacle contact150can include a through-mount contact in place of the mount contact153in other cases. The ground legs121A and121B extend through apertures or vias in the PCB12. The ground legs121A and121B can be press- or interference-fit through the apertures, in one example, or the ground legs121A and121B can extend through the apertures with a clearance. The apertures through the PCB12for the ground legs121A and121B can be plated, such as plated vias in one example, and the ground legs121A and121B can be soldered or otherwise electrically connected to the plated vias or other conductive traces on the PCB12.

FIG.6Dillustrates the receptacle interface assembly110shown inFIG.6A, with the shield body120omitted from view.FIG.6Eillustrates the receptacle interface assembly110shown inFIG.6A, with the shield body120and the receptacle contact insulator140omitted from view. As noted above, the receptacle body insulator130can be formed from an insulating material and electrically isolates the receptacle contact150from the receptacle shield body120. The receptacle body insulator130also mechanically supports and centrally positions the receptacle contact150within the receptacle shield body120. As best shown inFIG.6E, the receptacle body insulator130can be molded around the receptacle contact150, with the contact beams155A and155B of the receptacle contact150being exposed and extending out from the contact end of the receptacle body insulator130. After the receptacle body insulator130is molded around the receptacle contact150, the receptacle contact150and receptacle body insulator130can be sheared out from a larger lead frame including the receptacle contact150, among others.

The receptacle contact insulator140can be separately formed from an insulating material. The receptacle contact insulator140includes a base141, one or more positioning joints, including the joint142, that extend off the back of the base141, and beam covers144A and144B. A contact beam channel146A is formed in the beam cover144A to provide a clearance for the contact beam155A to extend within the receptacle contact insulator140. Similarly, a contact beam channel146B is formed in the beam cover144B to provide a clearance for the contact beam155B to extend within the receptacle contact insulator140. The beam cover144A includes a chamfered or tapered corner145A at the contact end of the beam cover144A, and the beam cover144B includes a chamfered or tapered corner145B at the contact end of the beam cover144B. The tapered corners145A and145B help to channel or divert the plug contact blade250into the contact channel160and between the contact beams155A and155B of the receptacle contact150.

The receptacle contact insulator140is separately formed and fitted over the contact beams155A and155B of the receptacle contact150to arrive at the assembly shown inFIG.6D. The joint142of the receptacle contact insulator140, for example, can be positioned into a notch134formed in the receptacle body insulator130to help position them with respect to each other. The assembly shown inFIG.6Dcan then be inserted and fitted within the receptacle shield body120. The receptacle body insulator130can also include a number of positioning extensions, one of which is referenced as the positioning extension132inFIGS.6D and6E. The positioning extensions can be fitted into body notches formed in the mounting end of the receptacle shield body120. An example body notch126of the receptacle shield body120is illustrated inFIG.6C, with the positioning extension132seated in the body notch126. That and other mechanical interferences or mating features can be relied upon to secure the receptacle body insulator130, the receptacle contact insulator140, and the receptacle contact150into the receptacle shield body120.

FIG.7Aillustrates the plug interface assembly210of the connector10shown inFIG.1A.FIG.7Billustrates a contact end of the plug interface assembly210shown inFIG.7A, andFIG.7Cillustrates a mounting end of the plug interface assembly210shown inFIG.7A. The components shown inFIGS.7A-7Care representative, not drawn to any particular scale, and are illustrated to provide context for the concepts of the board-to-board array connectors described herein. The components can be formed in a range of different shapes, styles, and sizes, although certain sizes and shapes are described and illustrated. Referring amongFIGS.7A-7C, the plug interface assembly210includes the plug shield body220, a plug body insulator230(seeFIG.7D), and a plug contact blade250(see alsoFIG.9). The plug body insulator230is described in further detail below with reference toFIG.7D, and the plug contact blade250is described in further detail below with reference toFIGS.9and10.

The plug shield body220can be formed from an electrically-conductive, metallic material, such as aluminum, copper, or other conductive metals or alloys thereof. In one example, the plug shield body220can be stamped or sheared out from a sheet of the electrically-conductive, metallic material, and then be bent or otherwise formed into the shape shown inFIGS.7A-7C. The plug shield body220is generally formed as a hollow, rectangular cuboid, with rounded corners. The plug shield body220includes a number of housing detents, such as the detents224A and224B. The number and positions of the detents are illustrated as a representative example inFIGS.7A-7C. In other cases, the number and positions of the detents can vary as compared to that shown. Additionally, the size, shape, and form of the detents can vary. For example, the detents can be shaped as teeth, posts, pins, or other types of projections. The detents can be relied upon to secure the plug interface assembly210, among others, within the housing202of the plug assembly200. Thus, the plug interface assembly210, among others, can be inserted and secured within the housing202using a mechanical interference, friction-based, or related type of fit or interface.

The plug shield body220includes the ground legs221A and221B at the mounting end shown inFIG.7C. The ground legs221A and221B are illustrated as examples. In other cases, the plug shield body220can include additional or fewer ground legs than that shown inFIGS.7A and7C. The positions of the ground legs can also be varied as compared to that shown. The contact end of the plug shield body220(seeFIG.7B) can be inserted into the contact end of the receptacle shield body120(seeFIG.6B). In that arrangement, the outer surfaces of the plug shield body220can contact the inner surfaces of the compliant extension contacts122A-122D of the receptacle shield body120, making an electrical contact between them. The shield bodies120and220provide an EMI shield for the RF signal carried on the receptacle contact150and the plug contact blade250.

Referring toFIG.7B, the blade end255of the plug contact blade250is positioned within the plug shield body220, with the plug shield body220extending around it. The front edge of the blade end255can be recessed within the plug shield body220in some cases. When the contact end of the plug shield body220(seeFIG.7B) is inserted into the contact end of the receptacle shield body120(seeFIG.6B), the blade end255of the plug contact blade250can be inserted into the contact channel160. The blade end255will then extend between the contact circlets157A and157B and the contact beams155A and155B of the receptacle contact150, as also shown inFIG.10. The circlets157A and157B will contact opposing side surfaces of the plug contact blade250. An electrical contact will thus be formed between the receptacle contact150and the plug contact blade250within the contact channel160, as described in further detail below with reference toFIG.10.

Referring toFIG.7C, the mount contact253of the plug contact blade250is exposed and extends out from the mounting end of the plug interface assembly210. When the plug interface assembly210is mounted to the PCB14, the mount contact253can be electrically contacted and connected (e.g., soldered, welded, etc.) to a conductive trace or pad on the PCB14. The connector concepts described herein are not limited to surface mount contacts or couplings, however, and the plug contact blade250can include a through-mount contact in place of the mount contact253in other cases. The ground legs221A and221B extend through apertures or vias in the PCB14. The ground legs221A and221B can be press- or interference-fit through the apertures, in one example, or the ground legs221A and221B can extend through the apertures with a clearance. The apertures through the PCB14for the ground legs221A and221B can also be plated in some cases, such as plated vias in one example, and the ground legs221A and221B can be soldered or otherwise electrically connected to the plated vias or other conductive traces on the PCB14.

FIG.7Dillustrates the plug interface assembly210shown inFIG.7A, with the shield body220omitted from view. The plug body insulator230can be formed from an insulating material, such as a plastic or polymer, a thermoplastic resin, LCP, a glass fiber epoxy compound, PTFE, polyimide, or other insulating material(s). The plug body insulator230electrically insulates and isolates the plug contact blade250from the plug shield body220. The plug body insulator230also mechanically supports and centrally positions the plug contact blade250within plug shield body220. The plug body insulator230can be molded around the plug contact blade250, at least in part, in one example. More particularly, the plug body insulator230can be molded around the plug contact blade250, with the blade end255(or at least some portion thereof) being exposed and extending out from the contact end of the plug body insulator230. The mount contact253of the plug contact blade250can also be exposed and extend out from the mounting end of the plug body insulator230, as shown inFIG.6C. After the plug body insulator230is molded around the plug blade contact250, the molding assembly can be sheared out from a larger lead frame including the plug blade contact250, among others.

The plug body insulator230may also include a number of insulating finger extensions, such as in the example shown, two of which are referenced as the insulating finger extensions234A and234B inFIG.7D. The insulating finger extensions234A and234B extend from the plug body insulator230at the contact end of the plug body insulator230. The insulating finger extensions234A and234B are separated from each other, with a space between them. When the plug shield body220is inserted into the receptacle shield body120, the beam covers144A and144B of the receptacle contact insulator140(seeFIG.6D) will fit between the insulating finger extensions234A and234B.

FIG.8illustrates an example of the receptacle contact150in the receptacle interface assembly110shown inFIG.6A. The receptacle contact150is representative and not drawn to any particular scale. The receptacle contact150can vary as compared to that shown in some cases, such as in length, width, or other aspects. The receptacle contact150can be formed from an electrically-conductive, metallic material, such as aluminum, copper, or other conductive metals or alloys thereof. In one example, a number of receptacle contacts, including the receptacle contact150, can be stamped or sheared out from a sheet of the electrically-conductive, metallic material, forming a lead frame assembly of receptacle contacts. A number of receptacle body insulators, including the receptacle body insulator130, can be molded around the lead frame assembly of receptacle contacts. After molding, individual contact and body insulator assemblies can be sheared out from the lead frame, andFIG.6Eillustrates an example of one such assembly.

The receptacle contact150includes a mount contact153at the mounting end152, a contact beam154, and a contact head158. The contact head158extends to the contact end151of the receptacle contact150. The contact beam154extends between the mount contact153and the contact head158. The contact beam154includes lead frame extensions154A and154B, which are formed when the contact and body insulator assemblies are sheared out from a larger lead frame, as described above. The contact beam154also includes a flow-through aperture154C. When the receptacle body insulator130is molded around the receptacle contact150, the insulating material of the receptacle body insulator130can flow through the flow-through aperture154C and cure, so that the receptacle body insulator130is secured with the receptacle contact150.

The contact head158of the receptacle contact150includes the contact beams155A and155B and the contact circlets157A and157B at the ends of the contact beams155A and155B, respectively. A beam channel156extends between and separates the contact beams155A and155B along their length of extension. The contact head158includes also includes barbs159A and159B. The receptacle contact insulator140(seeFIG.6D) can engage (e.g., snap or fit over) the barbs159A and159B, to help hold the receptacle contact insulator140in place over the contact head158.

FIG.9illustrates an example of the plug contact blade250in the plug interface assembly210shown inFIG.7A. The plug contact blade250is representative and not drawn to any particular scale. The plug contact blade250can vary as compared to that shown in some cases, such as in length, width, or other aspects. The plug contact blade250can be formed from an electrically-conductive, metallic material, such as aluminum, copper, or other conductive metals or alloys thereof. In one example, a number of plug contact blades, including the plug contact blade250, can be stamped or sheared out from a sheet of the electrically-conductive, metallic material, forming a lead frame assembly of plug contact blades. A number of plug body insulators, including the plug body insulator230, can be molded around the lead frame assembly of plug blade contacts. After molding, individual contact and body insulator assemblies can be sheared out from the lead frame, andFIG.7Dillustrates an example of one such assembly.

The plug contact blade250includes a mount contact253at the mounting end252, a contact beam254, and the blade end255. The blade end255extends to the contact end251of the plug contact blade250. The contact beam254extends between the mount contact253and the blade end255. The contact beam254includes lead frame extensions254A and254B, which are formed when the contact blade and body insulator assemblies are sheared out from a larger lead frame, as described above. The contact beam254also includes a flow-through aperture254C. When the plug body insulator230is molded around the plug contact blade250, the insulating material of the plug body insulator230can flow through the flow-through aperture254C, so that the plug body insulator230is secured with the plug contact blade250.

The blade end255of the plug contact blade250includes the cantilevered blade beam257. The cantilevered blade beam257is cantilevered within the blade end255and separated from the remainder of the blade end255by the beam clearance area256. The cantilevered blade beam257is centrally positioned within the blade end255of the plug contact blade250in the example shown, along a longitudinal axis of the plug contact blade250. The cantilevered blade beam257is cantilevered starting from a position toward the contact end251of the plug contact blade250and extends toward the mounting end252of the plug contact blade250.

FIG.10illustrates the receptacle contact150shown inFIG.8and the plug contact blade250shown inFIG.9, in electrical contact with each other. The arrangement shown inFIG.10is representative of how the receptacle contact150and the plug contact blade250interface with each other, when the connector10is arranged as shown inFIG.1A. As shown, the contact circlets157A and157B contact opposing surfaces of the cantilevered blade beam257. The blade end255of the plug contact blade250extends into the beam channel156between the contact beams155A and155B. AlthoughFIG.10illustrates the contact circlets157A and157B at one position on the cantilevered blade beam257, the contact circlets157A and157B can also contact the cantilevered blade beam257at other locations. For example, depending on how far the receptacle assembly100is inserted into the plug assembly200, the contact circlets157A and157B can also contact the cantilevered blade beam257at other positions.

The cantilevered blade beam257is flexible and can bend to some extent based on forces presented by the contact circlets157A and157B. Thus, the cantilevered blade beam257can help to facilitate misalignments, manufacturing tolerances, and other conditions that may result in forces being presented on the plug contact blade250by the contact circlets157A and157B. Overall, the cantilevered blade beam257is configured to elastically bend to some extent, if needed, as the pair of contact circlets157A and157B electrically contact and slide along surfaces of the cantilevered blade beam257.

FIG.11illustrates the cross-sectional view designated B-B inFIG.5according to various embodiments of the present disclosure. Particularly,FIG.5illustrates a cross-sectional view of the receptacle interface assembly110and the plug interface assembly210, when they are mated together. The arrangement shown inFIG.11is representative of how the receptacle interface assembly110and the plug interface assembly210interface with each other, when the connector10is arranged as shown inFIG.1A.

Turning to other aspects of the embodiments,FIG.12Aillustrates a perspective view of another example receptacle interface assembly310that can be used in a board-to-board array connector according to various embodiments of the present disclosure.FIG.12Billustrates a side view of the receptacle interface assembly310shown inFIG.12A. The receptacle interface assembly310is not drawn to any particular scale and is illustrated to provide context for the concepts of the board-to-board array connectors described herein. The receptacle interface assembly310can be formed in a range of different shapes, styles, and sizes, although certain sizes and shapes are described and illustrated. The receptacle interface assembly310shown inFIG.12Ais similar to the receptacle interface assembly110shown inFIG.6A, although the receptacle interface assembly310includes cantilevered shield arms, among other features described below. The receptacle interface assembly310is also relatively shorter than the receptacle interface assembly110, as the board-to-board array connectors can vary in size according to the embodiments.

The receptacle interface assembly310includes a receptacle shield body320, a receptacle body insulator positioned within the receptacle shield body320, a receptacle contact insulator340, and a receptacle contact350that extends within the receptacle shield body320. The receptacle body insulator and the receptacle contact150are similar to the receptacle body insulator130and the receptacle contact150described above.

The receptacle shield body320can be formed from an electrically-conductive, metallic material, such as aluminum, copper, or other conductive metals or alloys thereof. In one example, the receptacle shield body320can be stamped or sheared out from a sheet of the electrically-conductive, metallic material, and then be bent or otherwise formed into the shape shown inFIGS.12A and12B. The receptacle shield body320is generally formed as a hollow, rectangular cuboid, with rounded corners. The receptacle shield body320includes the ground legs321A and321B at a mounting end. The receptacle shield body320also includes a number of compliant extension contacts322A-322D at a contact end. Each of the compliant extension contacts322A-322D extends from one side surface of the receptacle shield body320.

The plug shield body220of the plug interface assembly210(seeFIG.5), for example (or a similar plug interface assembly), can be inserted into the receptacle shield body320at the contact end, and the inner surfaces of the compliant extension contacts322A-322D will contact the outer surfaces of the plug shield body220, making an electrical contact between them. The shield bodies320and220provide an EMI shield for the RF signal carried on the contacts within them.

The receptacle shield body320also includes a number of cantilevered shield arms. As examples, the cantilevered shield arms325B and325C of the receptacle shield body320are shown inFIG.12A. Although not visible inFIGS.12A or12B, the receptacle shield body320includes cantilevered shield arms corresponding to each of the compliant extension contacts322A-322D. The cantilevered shield arm325B includes a compliant arm323B and a shield paddle324B. The cantilevered shield arm325B is cantilevered at a position within the compliant extension contact322B and extends toward the mounting end of the receptacle shield body320. Similarly, the cantilevered shield arm325C includes a compliant arm323C and a shield paddle324C. The cantilevered shield arm325C is cantilevered at a position within the compliant extension contact322C and extends toward the mounting end of the receptacle shield body320.

The compliant arm323B includes a bend326B. Starting from the end closest to the contact end of the receptacle shield body320, the compliant arm323B generally extends parallel to (or in the same plane as) the compliant extension contact322B until meeting the bend326B. After the bend326B, the compliant arm323B angles to extend further toward the center of the receptacle shield body320. The shield paddle324B joins the compliant arm323B at the distal end of the compliant arm323B. A shield clearance area327B separates the cantilevered shield arm325B from the remainder of the receptacle shield body320, so that the cantilevered shield arm325B can bend. The cantilevered shield arm325B, and other cantilevered shield arms of the receptacle shield body320, are similarly formed.

The shield paddle324B is cut out (i.e., separated) from the side320A of the receptacle shield body320. The shield paddle324C, among shield paddles, are also cut out from other sides of the receptacle shield body320. The shield paddles324B and324C, among others, are positioned around the receptacle contact insulator340, which is positioned within the receptacle shield body320. Generally, the shield paddle324B is located closer to the center of the receptacle shield body320than the side320A of the receptacle shield body320, and the shield paddle324C is also located closer to the center of the receptacle shield body320. Overall, the shield paddles of the cantilevered shield arms can help to provide improved return loss performance in some cases as compared to other designs.

The plug shield body220of the plug interface assembly210(seeFIG.5), for example (or a similar plug interface assembly), can be inserted into the receptacle shield body320at the contact end. In that case, the inner surfaces of the compliant extension contacts322A-322D of the receptacle shield body320will contact the outer surfaces of the plug shield body220, making an electrical contact between them. Additionally, depending upon the extent (e.g., distance) that the plug shield body220is inserted into the receptacle shield body320, the outer surfaces of the plug shield body220will contact the inner surfaces of the cantilevered shield arms325B and325C, among those of other cantilevered shield arms. The cantilevered shield arms325B and325C are flexible and can bend to some extent based on forces presented by the outer surfaces of the plug shield body220. In turn, the shield paddles324B and324C, among others, may move from the position shown inFIG.12A. Particularly, if the plug shield body220is inserted far enough into the receptacle shield body320, the shield paddles324B and324C may be pushed further out from the center of the receptacle shield body320.

Terms such as “top,” “bottom,” “side,” “front,” “back,” “right,” and “left” are not intended to provide an absolute frame of reference. Rather, the terms are relative and are intended to identify certain features in relation to each other, as the orientation of structures described herein can vary. The terms “comprising,” “including,” “having,” and the like are synonymous, are used in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Also, the term “or” is used in its inclusive sense, and not in its exclusive sense, so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list.

Combinatorial language, such as “at least one of X, Y, and Z” or “at least one of X, Y, or Z,” unless indicated otherwise, is used in general to identify one, a combination of any two, or all three (or more if a larger group is identified) thereof, such as X and only X, Y and only Y, and Z and only Z, the combinations of X and Y, X and Z, and Y and Z, and all of X, Y, and Z. Such combinatorial language is not generally intended to, and unless specified does not, identify or require at least one of X, at least one of Y, and at least one of Z to be included.

The terms “about” and “substantially,” unless otherwise defined herein to be associated with a particular range, percentage, or related metric of deviation, account for at least some manufacturing tolerances between a theoretical design and a manufactured product or assembly, such as the geometric dimensioning and tolerancing criteria described in the American Society of Mechanical Engineers (ASME®) Y14.5 and the related International Organization for Standardization (ISO®) standards. Such manufacturing tolerances are still contemplated, as one of ordinary skill in the art would appreciate, although “about,” “substantially,” or related terms are not expressly referenced, even in connection with the use of theoretical terms, such as the geometric “perpendicular,” “orthogonal,” “vertex,” “collinear,” “coplanar,” and other terms.

The above-described embodiments of the present disclosure are merely examples of implementations to provide a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiments without departing substantially from the spirit and principles of the disclosure. In addition, components and features described with respect to one embodiment can be included in another embodiment. All such modifications and variations are intended to be included herein within the scope of this disclosure.