Connector insert for preventing contamination

A connector insert for protecting contacts within a receptacle housing of a connector assembly from becoming contaminated. The connector insert includes a body portion having an exterior configured to correspond to at least a portion of the interior of the receptacle housing of the connector assembly. The body portion of the insert includes an opening which extends into the body portion to receive the contacts and protect the contacts from the exterior environment surrounding the receptacle housing when at least a portion of the body portion is received within the receptacle housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present U.S. application is related to U.S. design application entitled “CONNECTOR INSERT”, to the same inventors, which is incorporated herein by reference, and having been filed concurrently with the present application.

TECHNICAL FIELD

The present invention relates to the field of connectors and, more particularly, relates to preventing contamination of the contacts of the connector during the manufacturing process.

BACKGROUND OF THE INVENTION

Electronic devices typically include various types of receptacle-type connector assemblies which are installed during the manufacturing of the electronic device. For example, a computer or set-top box may include 1394 ports, sometimes referred to as “firewire” ports, or USB ports. Also, a newer connector, referred to as a HDMI (High Definition Multimedia Interface) connector assembly, integrates audio and video information into a single digital interface to be used with, for example, digital video disc (DVD) players, digital television (DTV), high definition TV (HDTV), set-top boxes, and other audio and/or video devices. Connectors such as these include contacts within the receptacle housing of the connector assembly. These contacts are typically made of gold and may easily become contaminated during the manufacturing of the electronic device. The HDMI connector, in particular, allows contamination to pass into the receptacle housing of the connector assembly through openings in the bottom of the receptacle housing. These openings in the bottom of the receptacle housing define resilient tabs that are utilized to retain the corresponding plug-type connector within the receptacle housing. This contamination often occurs from liquid flux, paste or solder that seeps, bubbles, wicks or splashes into the connector assembly through these openings or elsewhere in the receptacle housing while the connector assembly is soldered to an electrical board.

Consequently, these electronic devices fail because of the contaminated connector assemblies. The contaminated connector assemblies require replacing by hand which results in a costly rework of the electronic device. Therefore, what is needed is a means to protect the connector assembly's contacts from contamination during the manufacturing process.

DETAILED DESCRIPTION

The present invention will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which an exemplary embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, the embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The present invention is described more fully hereinbelow.

FIG. 1illustrates a perspective view of one embodiment of an insert10to be received and retained within a receptacle housing12of a connector assembly14. The connector assembly14inFIGS. 1–3generally depict a HDMI connector assembly which is for illustrative purposes only. The insert10of the present invention may be used with any type of connector assembly where it is desirable to prevent contacts within a receptacle housing from becoming contaminated.FIGS. 2 and 3illustrate the insert10received and retained within the receptacle housing12of the connector assembly14to prevent contamination of electrical contacts20.

As best shown inFIG. 1, the electrical contacts20are positioned along both sides of a central tongue portion24. The tongue portion24is interposed between the contacts20. The distal ends of the contacts20correspond with the distal end of the tongue portion24. The receptacle housing12also includes a plurality of outwardly extending feet26which are utilized to secure the connector assembly14to an electrical board (not shown). Once these feet26are positioned in corresponding openings in an electrical board during the manufacturing process, the electrical board is passed through a hot bath of solder where the solder and liquid flux may pass through openings30defined on the top and bottom of the receptacle housing12of the connector assembly14. Typically, these openings30define resilient tabs32which are used to retain the corresponding plug-type connector (not shown) within the receptacle housing12of the connector assembly14. However, contamination other than solder and liquid flux may contaminate the contacts20which may pass into the receptacle housing12through other means during the manufacturing process as well as during shipment of the electrical devices.

The insert10may itself be referred to as a plug or connector, but the insert10does not have electrical components to make an electrical connection with any connector assembly such as connector assembly14. The insert10is preferably made of Pollybutylene Terephalateor, commonly referred to as PBT (30% glass filled), with a UL rating of UL94V-0, or some other suitable material such as a heat resistant plastic. As best shown inFIG. 4, at least part of a body portion40of the insert10is configured or keyed to be received within the receptacle housing12and also has a central opening42configured or keyed to protect at least portions of the contacts20around the central tongue portion24. Preferably, the exterior of the body portion40conforms to the inner confines of the receptacle housing12and the opening42of the body portion40conforms to the contacts20.

In one embodiment, the body portion40obstructs contaminates from passing through the openings30as well as through the front face of the connector assembly14when the body portion40is within the receptacle housing12. In another embodiment, the body portion40is configured to be received and retained only within a lower portion of the receptacle housing12below the tongue portion24such that any openings30on the bottom of the receptacle house12are blocked to prevent contamination, while any openings30on the top of the receptacle housing12above the tongue portion24remain unobstructed.

For example, in one embodiment, if the connector assembly14is a HDMI connector, the bottom edges of the body portion40are truncated or arched inward as best seen from the end view shown inFIG. 4. The bottom edges of the opening42are preferably also truncated or arched inward in order to accommodate the contacts20and tongue portion24while the exterior of the insert10mattingly corresponds with the interior of the receptacle housing12. However, the opening42and the exterior of the body portion40of the insert10may be configured differently depending upon the type of the connector assembly the insert is intended to be used with.

In one embodiment for use with a HDMI connector assembly, the body portion40has a height x of approximately 0.175 inches which allows the insert10to be received and retained within the receptacle housing12in a secure manner. The depth of the opening42through the body portion40could be any depth suitable for receiving the contacts20and central tongue portion24. For example, the depth of the opening42could be approximately 0.275 inches. Also, for example, the height y of the opening42could be approximately 0.054 inches in order to satisfactorily accommodate the contacts20and the central tongue portion24.FIG. 4best illustrates the proximal end of the insert10having height x and an opening with height y.

FIGS. 4 and 5also illustrate a width w of the body portion40. In one embodiment, such as when the insert10is used with a HDMI connector, the overall width of the body portion40is approximately 0.547 inches. The opening42, on the other hand, has a width z as shown inFIG. 4which is approximately 0.452 inches.

In one embodiment, when the insert10is received and retained within the receptacle housing12of the connector assembly14, the body portion40has a length which allows it to extend outward from the face of the connector assembly14as shown inFIGS. 1–3. This allows the insert10to be more easily withdrawn from the connector assembly14by allowing the body portion12itself to be grasped by hand or by a tool. Preferably, however, the insert10also includes an elongated portion46as best shown inFIG. 5which outwardly extends from the body portion40to facilitate withdrawal of the insert10from the connector assembly14. The elongated portion46may be any length, but is preferably a length which permits itself to be grasped by hand or by a tool.FIG. 5also illustrates the elongated portion46having a width d relative the body portion40. The width d could be, for example, approximately 0.25 inches. The elongated portion46may be also utilized for facilitating the insertion of the insert10within the receptacle housing12in a secured manner.

In another embodiment, the insert10may include only the body portion40and therefore have no elongated portion46. In such case, the body portion40may include a recessed portion or other means suitable for allowing the body portion40to be hooked or otherwise grasped with a tool so that the insert10may be withdrawn from the connector assembly14. In yet another embodiment, the insert may include a withdraw strap that outwardly extends from the body portion40. In any case, to facilitate a low profile design, nothing extends significantly beyond the exterior of the connector assembly14, such as an electrical cord, when the connector assembly14with insert10is installed in an electrical device.

The elongated portion46may include one or more friction bearing surfaces to further facilitate the withdrawal of the insert10from the connector assembly14. For example, one or more divots48on the surface of the elongated portion46may allow the insert10to be more easily grasped by the fingers.FIGS. 1–3and5show a pair of divots48displaced from one another, on one side of the elongated portion46, and adjacent the distal end of the elongated portion46.

The foregoing has broadly outlined some of the more pertinent aspects and features of the present invention. These should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by modifying the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.