Electrical contact stabilizer assembly

Abstract: An electrical contact stabilizer assembly includes support and positioning means (22, 24) to sandwich an electronic leadframe (10) between opposing interconnecting members which maintain the contact leads of the leadframe in predetermined spaced relationship during the molding process by which the leadframe is encapsulated in a housing. Opposing members are integrally formed of an insulative material and include cooperative connecting means and spacers to hold the contact leads in the intended spaced relation to each other.

Description: This invention relates to electrical contact assemblies and more particularly to the support and positioning of a plurality of contacts. It is well known to provide a plurality of leads on a lead frame and to encapsulate such leads in a plastic housing. An example of such an assembly is disclosed in DE-A-3611224 Typically, an electronic circuit, such as a thick film hybrid circuit, is mounted on the leadframe prior to encapsulation. During the encapsulating process, the leads are often subject to forces which result in the leads becoming mis-aligned, deformed or out of relative position with respect to each other. As a result, the leads do not correctly align with mating contacts of an associated device. In prior attempts to avoid such mis-alignment, the leads of a lead frame have been pre-molded with a plastic member intended to position the leads in intended alignment. The lead frame with the pre-molded member is thereafter fully molded into a completed housing. This pre-molding operation does not wholly eliminate the problem of mis-alignment as the pre-molding process itself can cause mis-alignment of the leads. In brief, the present invention provides a support and positioning means for the plural leads of a lead frame. The present invention accurately positions the leads relative to each other and maintains precise alignment of the leads during the encapsulating molding process. The support and positioning means comprises first and second integral insulative members, preferably formed of a molded plastic, and having constituents cooperative with portions of the lead frame and also cooperative with portions of the other member to sandwich and secure the leads in intended aligned position when the insulative members are snapped together. This assembly, formed by the lead frame and the cooperative support members, is then molded into a housing and does not suffer the deleterious consequences of mis-alignment of the leads occasioned by the molding process. A more complete understanding of the invention and its various features, objects, and advantages may be obtained from the following detailed description when taken in conjunction with the attached drawings in which: Fig. 1 is a top view of a typical electronic lead frame; Fig. 2 is an exploded view of the opposing members of the present invention and an electronic leadframe; Figs. 3A and 3B are pictorial views of the opposing members of the present invention; Fig. 4 is a top perspective view of the members of the present invention connected to the leadframe; Fig. 5 is a bottom perspective view of the members of the present invention connected to the leadframe; Fig. 6 is a top view, partly cutaway, of the leadframe and supporting members encapsulated in the housing; and Fig. 7 is an exploded view of the base plate and cover of the molded housing containing a thick film circuit. The electronic leadframe 10 of Fig. 1 includes a plurality of leads 12 each terminating in a respective contact 14. The leadframe is formed of a conductive metal or alloy and has a central portion 16 and a plurality of contact pads 20 for connection to corresponding contact points on an electronic device such as a thick film hybrid circuit. Fig. 2 illustrates the leadframe 10 of Fig. 1 and the opposing members 22, 24 of the present invention in exploded view. Opposing members 22, 24 are molded to accept the lead frame 10 in snug-fit when the leadframe 10 is sandwiched therebetween. Figs. 3A and 3B illustrate opposing members 22,24 respectively. Integrally formed press-fit connectors 26,28 are cooperative with apertures 27 and 29 respectively to interconnect opposing members 22,24 with leadframe 10 securely held in position therebetween. Integrally formed spacers 30 and 33 and spacing boss 31 are dimensioned for insertion between selected portions of contact leads 12 to maintain contact leads 12 in predetermined spaced relationship when opposing members 22,24 are interconnectably mounted on leadframe 10. Aperture 35 of opposing member 22 is dimensioned to receive spacing boss 31 to enhance the stability of the assembly. Orifice 37 in opposing member 22 and orifice 39 in opposing member 24 allow flow-through of molten plastic during the final encapsulation of the assembly into its housing. Figs 4 and 5 illustrate leadframe 10 and opposing members 22,24 after assembly. In the embodiment illustrated, opposing members include opposing elongated stabilizers 32,34 which hold flimsy lengths of contact leads 36, illustrated in Fig. 1, in stable spaced relation to each other. Opposing end sections 38,40 maintain the array of contact leads 12 in predetermined stable spaced relation to each other. Integral stand-off bosses 41 conform to top and bottom halves of the mold tool (not shown) and prevent mold squeeze, thereby reducing the likelihood of leadframe deformation during assembly. Fig. 6 illustrates the assembled leadframe and opposing members after encapsulation into housing 50. Part of the housing has been cut away to illustrate the array of contacts 14 which have survived the encapsulation process, typically plastic injection molding, in intended predetermined spaced relation. By maintaining the intended spacing between adjacent contact leads 12, and between adjacent contacts 14, opposing members 22,24 of the present invention prevent electrical shorts between leads 12 and contacts 14 and ensure that contacts 14 are correctly positioned for interconnection with mating contacts of an associated device. In the embodiment illustrated in Fig. 6, leadframe 10 comprises three pins 52 which are interconnected by tie bar 54. After leadframe 10 is encapsulated into housing 50, tie bar 54 is removed to expose pins 52 for connection to an associated electrical component. In addition, cuts are made either before or after the encapsulating process, for example along the dotted lines shown in Fig. 6, and central portion 16 is removed permitting connection of contact pads 20 to an electronic device. Referring now to Fig. 7, film circuits are disposed at sites 56 and 57 on base plate 58. The base plate is mounted to housing 50, with the circuits 66 (only one being visible) disposed in the cavity of the housing. The base plate 58 is retained on the housing 50 by cooperative heat strokes 62 (also shown in Fig. 6) and apertures 64. Other featuring means can be employed to secure the base plate to the housing. Film circuit 66 is illustrated connected to housing 50. Contact pads 20 have been bent for electrical connection to intended contacts of film circuit 66. After electrical connection between contact pads 20 and film circuit 66 has been achieved, the surface of film circuit 66 and contact pads 20 may be covered with a potting material or seal gel to reduce the likelihood of disconnection during handling and use. Cover 68 is connectably mounted on lip 70 of housing 50 to enclose film circuit 66 within housing 50. Pins 52 are shown with tie-bar 54 removed.

Claims: An electrical contact assembly comprising a leadframe (10) having at least one plurality of leads (12) disposed in spaced relationship each terminating at one end in a respective contact (14), and terminating at an opposite end in a plurality of contact pads (20) at a site for mounting an electronic circuit to which the leads (12) are connected, characterised in that it further comprises : first and second integral members (22, 24) of electrically insulative material, at least one of which includes at least one element (30, 31, 33) cooperative with said at least one plurality of leads (12) for positioning and maintaining said leads (12) in intended relative alignment; and said first and second integral members (22, 24) are disposed on respective opposite sides of the leadframe (10) and have cooperative elements (26, 27, 28, 29) for retaining the members in locking engagement with the leadframe (10) sandwiched therebetween. The electrical contact assembly of claim 1 wherein said leadframe (10) further includes at least one detent (35) in at least one of said plurality of leads (12) for receiving pre-selected ones of said at least one positioning and maintaining cooperative elements (30, 31, 33). The electrical contact assembly of claim 1 wherein said cooperative elements for retaining said opposing members (22, 24) in locking engagement include interlocking male (26, 28) and female connecting elements (27, 29). The electrical contact assembly of claim 3 wherein said female connecting elements include male connecting element receiving apertures (27, 29) and said male connecting elements include locking detents (26, 28) cooperative with said female connecting element receiving apertures (27, 29) to maintain each of said female elements in locking engagement with a respective corresponding male element. The electrical contact assembly of claim 1 wherein at least one of said cooperative positioning and maintaining elements (30, 31, 33) includes at least one integrally formed raised member (31) dimensioned for insertion between portions of selected ones of said at least one plurality of leads (12). The electrical contact assembly of claim 1 wherein at least one of said first and second integral members (22, 24) includes an aperture (37, 39) to permit flow of a molten housing material. The electrical contact assembly of claim 1 wherein at least one of said first and second integral members (22, 24) includes at least one integrally formed stand-off boss (41). The electrical contact assembly of claim 7 wherein selected ones of said plurality of contacts (14) depend from said leadframe (10). The electrical contact assembly of claim 1, wherein: said first integral member (22) further includes: an end section (38); a stabilizer (32) extending from said end section; and at least one connecting element; and said second integral member (24) further includes: an end section 40 ; a stabilizer (34) extending from said end section; at least one integrally formed raised element (41) extending from said end section and dimensioned for insertion between selected adjacent ones of said plurality of leads (12); an integrally formed ridge extending substantially the length of said stabilizer and dimensioned for insertion between selected adjacent ones of said plurality of leads (12); and at least one connecting element cooperative with said at least one connecting element of said first integral member (22) to interconnect said first and second integral members with said leadframe sandwiched therebetween. The electrical contact assembly of claim 9, wherein at least one of said first and second integral members (22, 24) further includes at least one integral stand-off boss (41). The electrical contact assembly of claim 9, wherein at least one of said first and second integral members (22, 24) further includes an aperture (37, 39) to permit flow of a molten plastic material. The electrical contact assembly of claim 9 wherein said first integral member (22) further includes at least one aperture (27, 29) dimensioned to receive a corresponding one of said at least one integrally formed raised elements (26, 28) of said second integral member (24). The electrical contact assembly of claim 9 wherein said first and second integral member end sections (38, 40) are disposed substantially perpendicularly to said first and second integral member stablizers (32, 34) respectively. The electrical contact assembly of claim 9 wherein said first integral member (22) further includes at least one integrally formed raised element (41) extending from said first integral member end section (38) and dimensioned for insertion between selected adjacent ones of said plurality of leads (12).

Inventors: MALO CHARLES J, PETERSON RICHARD W, MALO, CHARLES J., PETERSON, RICHARD W.
Applicants: ALTAIR INT INC, ALTAIR INTERNATIONAL, INC.
Application year: 1989
Main classification: H01R43
IPC codes: H05K3, H01R43, H01R13