Composite general purpose rectangular connector

An electrical connector assembly is disclosed that includes a receptacle connector and plug connector. The receptacle connector includes a receptacle housing having a top surface and a bottom surface, a support plate, spacers configured to retain the support plate adjacent to the top surface, and a post retained against the support plate by a spring and a fastener configured to releasable assemble the post and the support plate. The receptacle connector is less complex, lighter, and less expensive than receptacle connectors entirely made of a unitary composite, metal, or metallized composite.

FIELD OF THE INVENTION

The present invention relates to electrical connector assemblies. More specifically, the present invention relates to an electrical connector assembly having a receptacle connector with a threaded insert, support plate and spacer.

BACKGROUND OF THE INVENTION

Electrical connector assemblies typically include a plug connector and a receptacle connector configured to mate with the plug connector. The plug connector generally includes a plug housing containing contacts, and the receptacle connector generally a receptacle housing containing contacts configured to mate with the corresponding plug contacts. When the plug connector and receptacle connector are mated, the corresponding contacts mate to form an electrical connection.

In many applications, the receptacle connector utilizes machined components. The machined components can include mounting ears and spacers, which can be complex, heavy, and expensive to manufacture into the connector.

Therefore, there is an unmet need to provide an electrical connector assembly having a receptacle connector that is less complex, lighter, less expensive, and less susceptible to receptacle housing breakage than prior connector.

SUMMARY OF THE INVENTION

In one embodiment, an electrical connector assembly is disclosed that includes a receptacle connector and plug connector. The receptacle connector includes a receptacle housing having a top surface and a bottom surface, a support plate, spacers configured to retain the support plate adjacent to the top surface, and a post retained against the support plate by a spring and a fastener. The spring and fastener are configured to releasably assemble the post and the support plate to the receptacle housing. The receptacle connector is configured to mate with the plug connector by releasably engaging the post of the receptacle connector to the plug connector.

In another embodiment, a receptacle connector is disclosed that includes a receptacle housing having a top surface and a bottom surface, a support plate, spacers configured to retain the support plate adjacent to the top surface, and a post retained against the support plate by a spring and a fastener configured to releasably assemble the post and the support plate.

Further aspects of the method and system are disclosed herein. The features as discussed above, as well as other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1shows an exemplary embodiment of an electrical connector assembly100according to the disclosure. The electrical connector assembly100includes a plug connector101and a receptacle connector102. The plug connector101is configured to mate with the receptacle connector102. The plug connector101and receptacle connector102include corresponding mating terminals (not shown) disposed therewithin, which mate to form an electrical connection upon mating of the plug connector101and receptacle connector102as would be appreciated by one of ordinary skill in the art.

FIGS. 2-5show an exemplary embodiment of a receptacle connector102according to the disclosure. The receptacle connector102includes a receptacle housing104, a support plate118, a post120, spacers122, a fastener124, and a spring126. The receptacle connector102further includes a plurality of electrical terminals (not shown) disposed therewithin, which have not been shown to simplify the inventive elements of the disclosure. The receptacle connector102may be formed of metals, metal alloys, plastics, composites, polymers and any combination thereof. For example, the receptacle connector may be formed of a light weight metal alloy, for example a magnesium-aluminum alloy. The light weight metal alloy may be machined or molded to form the various components. In another example, the receptacle connector102may be formed of engineered composites including reinforcing material. For example, the reinforcing material may include carbon, glass, carbon nanotubes, and micro-spheres.

The receptacle housing104includes a base portion106and a receiver shroud portion108. The base portion106includes a top surface112, end surfaces114and a bottom surface116. The top surface112includes a support plate recess133configured to receive support plate118. The bottom surface116includes spacer recesses117configured to receive spacers122.

The receiver shroud portion108is configured to receive a portion of a corresponding plug connector (not shown). The receiver portion108includes grounding tabs110for releasably engaging plug connector101(FIG. 1). The grounding tabs110include contact portions111. In another embodiment, the receiver portion108may not include grounding tabs110. In this exemplary embodiment, the receiver portion108is offset in relationship to the base portion106. In another embodiment, the receiver portion108may be symmetrically positioned in relationship to the base portion106.

The support plate118includes countersunk through-holes128, a slot130, and positioning tabs132. The support plate118is received in a recess133in the top surface112of the receptacle housing104. The recess133includes insert holes134and a post hole136configured to align with the tapered through-holes128and slot130, respectively, when assembled. The support plate118is retained in the recess133against the receptacle housing by the spacers122as will be discussed in detail below.

The post120includes an upper portion138, a support plate140, and a lower portion142. The upper portion138includes pins143. The lower portion142includes fastener feature144. The support plate140is configured to be positioned over and in contact with slot130between tabs132of support plate118, so as to fixedly position the locking post with respect to the support plate118and prevent the locking post120from rotating within the post hole136when the locking post120is releasably assembled with the support plate118by spring126and fastener124as shown inFIG. 3. The posts120are configured to be releasably engaged by the plug connector101(FIG. 1) so as to releasably mate the plug connector101and the receptacle connector102.

The spacers122include an insertion portion146and a spacer portion148. In this exemplary embodiment, the spacers122are a single unit body including both the insertion portion146and the spacer portion148. The spacer portion148extends away from the bottom surface162a predetermined distance D as shown inFIG. 2. In this exemplary embodiment, the spacers122are a unitary body. The spacers122may be formed by molding or other similar forming method. In another embodiment, the spacers122may be formed from an insertion portion146and a spacer portion148that are joined by know methods such as, but not limited to, thermal welding and adhesive bonding.

As shown inFIG. 5, the spacers122further include a through-hole150traversing from a top end152to a bottom end154. The through-hole150includes spacer portion through-hole302and an insertion portion through-hole308. In this exemplary embodiment, as shown inFIG. 5, the insertion portion through-hole308includes an non-threaded surface311, and the spacer portion through-hole302includes internal threads303. The spacers122may be used to attach the receptacle connector102at a predetermined distance from a substrate (not shown). In one embodiment, the substrate may be a printed circuit board (PCB). The spacers122may be used to attach the receptacle connector102to a substrate by receiving a fastener (not shown) in the spacer portion148, where the fastener is further attached to the substrate. The fastener may be a screw or other similar threaded fastener.

In another embodiment shown inFIG. 5A, a spacer122includes an insertion portion through-hole308including internal threads309. In this embodiment, the internal threads309of the insertion portion through-hole308are different than the internal threads303of the spacer portion through-hole302. The internal threads309,303may differ by pitch, count, or other thread feature. In this embodiment, a screw (not shown) may be received in the insertion portion through-hole146to further securely assemble the spacers122, support plate118, and receptacle housing104.

In yet another embodiment shown inFIG. 5A, a spacer122includes an insertion portion through-hole308including a non-threaded surface309and a spacer portion through-hole302including a non-threaded surface310.

Referring again toFIGS. 2-5, the insertion portion146has a generally circular exterior cross-sectional geometry, and the spacer portion148has a generally square exterior cross-sectional geometry. In another embodiment, the insertion portion146and spacer portion148may have other cross-sectional geometry. For example, the insertion portion146and spacer portion148may have a generally circular or hexagonal exterior cross-section.

The spacers122are shown including a flare156at the top end152. The flare156is formed on the top end152after the insertion portion146has been received in insert holes134to securely assemble the spacers122to the receptacle housing104. The flare156may be formed by a flaring tool as would be appreciated by one of ordinary skill in the art. The spacer portion148of the spacers122is received in spacer recesses117in the bottom surface116of the receptacle housing104when the receptacle connector102is assembled.

The spring126is sized to be compressedly disposed in post hole136between the support plate118and the fastener124when the receptacle connector102is assembled as shown inFIG. 2. The compressibility of the spring26is selected to securely retain the post120against the support plate118and to securely assemble the receptacle connector102to the plug connector101(FIG. 1).

The fastener124includes a slot158configured to receive fastener feature144of post120. The fastener124further includes a bottom surface160having a recess162configured to receive fastener feature144after the fastener feature has passed through the slot158and the fastener124has been rotated as shown inFIG. 1B. The fastener124compresses the spring126against the support plate118when assembled as shown inFIG. 3B.

FIGS. 6 and 6Ashow another exemplary embodiment of spacers122. In this embodiment, spacers122are formed from a separate insertion portion146and spacer portion148. The insertion portion146includes internal threads309and external threads610. External threads610are configured to engage internal threads314of the spacer portion. The insertion portion146includes flare156. In this exemplary embodiment, the flare156may be formed prior to assembling the receptacle connector102(FIG. 2). In such a manner, the insertion portion146may be assembled with the spacer portion148having the flare156already formed so as to retain the support plate118(FIG. 2) when assembled. In another embodiment, the insertion portion310is received in insert holes134and then the flare156is formed.

In this exemplary embodiment, the insertion portion146is only received for a part of the length of the spacer portion148. In other words, the external threads610do not extend the entire length of the internal threads314.

In this exemplary embodiment, the insertion portion146has internal threads309for substantially the length of the insertion portion146. In another embodiment, the insertion portion146may have internal threads for only a partial portion of the length of the insertion portion146. In still another embodiment, the insertion portion146may have no internal threads309. For example, the internal threads309may be included in the portion of the insertion portion146received in the spacer portion148or may have internal threads only in the portion of the insertion portion146not received in the spacer portion148.

In another embodiment, not shown, the insertion portion146does not include external threads610and the spacer portion148does not include internal threads314in the portion of the spacer portion148receiving the insertion portion146. The portion of the spacer portion148not receiving the insertion portion146may or may not be threaded. In this exemplary embodiment, the insertion portion146and the spacer portion148may be press-fit together to form the spacer122.

FIG. 6Bshows yet another exemplary embodiment of spacers122. In this exemplary embodiment, the spacers122are formed from a separate insertion portion146and spacer portion148, and the spacer portion148includes a threaded protrusion615configured to engage the internal threads309of the insertion portion146. In this exemplary embodiment, the flare156may be formed before or after the insertion portion146is received in insert holes132.

In the embodiments having the spacer122formed by a separate insertion portion146and spacer portion148, the insertion portion146and the spacer portion148may be further secured joined by thermal welding, adhesive bonding or other joining methods.

FIGS. 7,8,9and10show another exemplary embodiment of the receptacle connector102. In this exemplary embodiment, the receptacle connector102includes yet another exemplary embodiment of spacers122. In this exemplary embodiment, the spacers122include an insertion portion146and a spacer portion148. The spacer portion148has a length d′ to position a bottom181of the spacer portion148(seeFIG. 10) approximately parallel with the bottom116of the receptacle housing104. In this exemplary embodiment, the spacers122further include a through hole150that includes internal threads304covering substantially the length of the through hole150. In another embodiment, the internal threads304may extend only a partial length of the through hole150. In yet another embodiment, the internal threads304may be omitted.

Furthermore, in this exemplary embodiment, the spacers122are a unitary body. In another embodiment, the spacers122may include a separate insertion portion146and a spacer portion148that are joined as discussed above.

FIG. 11shows two other exemplary alternative embodiments of spacers122. In a first exemplary alternative embodiment, spacer122aincludes an insertion portion146that does not include a flare156after assembly. The spacer122aincludes a through hole150having internal threads152. In this embodiment, the spacer122ais assembled to the receptacle housing104and support plate118with a fastener180as shown. In this exemplary embodiment, the fastener180is a screw, however, other similar fasteners may be used. In another embodiment, the fastener180may include a post or a through-hole, which may be threaded.

In this exemplary embodiment, the insertion portion146and spacer portion148are a single component, however, in other embodiments as discussed above, the insertion portion146and spacer portion148may be separate components. Furthermore, in this exemplary embodiment, the spacer portion148has a bottom surface181(FIG. 10) that is substantially parallel with the bottom surface116(FIG. 10) of the housing104. In another embodiment, the spacer122amay include a spacer portion148that extends away from the bottom surface181of the housing104as discussed above.

FIG. 11also shows another exemplary alternative embodiment of a spacer122b. In this embodiment, the spacer122bincludes an insertion portion148having internal threads309and a spacer portion149having external threads149aconfigured to engage the internal threads152of the insertion portion146. As can be seen inFIG. 11, the spacer portion148does not include a through hole, but is a solid body. In this exemplary embodiment, the insertion portion146includes a flare156which may be formed prior to or during assembly of the connector102. In another embodiment, the spacer122bmay include a spacer portion149that extends away from the bottom surface181of the housing104as discussed above.