High deflection, high density single sided electrical connector

Abstract: This specification discloses a zero or low insertion force single or multiple contact electrical connector with single sided spring contacts with inherent high deflection contact capability upon insertion of a printed circuit board into the connector. The connector comprises a plurality of spring single sided contacts generally rectangularly shaped mounted in slots formed along an elongated cavity in a connector housing. Each contact pair includes two single sided deflectable contacting portions (86, 88) for engaging the conductive strips disposed on opposite sides of the insertable edge of the printed circuit board (12). The opposed contacting portions define an opening (130) through which the edge of the printed circuit board may be inserted in the cavity with zero or low insertion force. Subsequently the printed circuit board is pivoted or rotated through an angle into a final contacting position, in which position the conductor strips on the printed circuit board engage and deflect the contacting portions of the spring contacts with a relatively high contact force. A staggered, alternating pattern of conductive pad contacts on both sides of the printed circuit board yields up to doubling of the number of contacts in a given amount of space along the edge of the board as compared to contacts having traditional double-sided contacts that grip both sides of the board.

Description: Field of the Invention The present invention relates to a zero or low insertion force electrical connector for connecting one printed circuit board to another. More particularly, this invention relates to a zero insertion force connector that yields greater densities and that allows greater deflection of the connector contacts. Prior Art There are many types of electrical connectors in the prior art for making electrical connections to conductive strips dispersed along opposing sides on the elongated edge of a printed circuit board. One such type is called a "zero insertion force" connector, which allows a circuit board to be inserted into the connector without any substantial insertion force. The board is thus inserted into the connector to make an electrical connection without any urging and potentially harmful friction force against the delicate electrical contacts on the opposing sides of the edge of the board. Examples of these types of connectors are shown in US-A-3,701,071, 3,920,303, 3,848,952, and 4,575,172. While these prior art connectors have provided low insertion force connectors for printed circuit boards, they have deficiencies. One problem is the limited beam deflection these connectors allow. These prior art connectors have typically employed C- or U-shaped contacts supported by a central attachment point. Depending on the location of the attachment joint, one or the other or both of the two contact arms have a shortened beam length. This shortened beam length limits the range that the contact can deflect without plastic deformation of the contact. Since many boards are or become warped through use, the limited deflection allowed by such a connector limits the utility of the connector for some significantly warped boards. Another problem with the prior art connectors is the limited density of the electrical connections the connectors can accommodate between the boards they connect. C- or U-shaped contacts necessarily grip the board on two sides. This means one contact, i.e., one electrical connection, occupies a certain amount of contact pad space on both sides of the board. Since adjacent contact pads must be separated by a certain minimum distance given tecnnological constraints, C-or U-shaped connectors cannot achieve a greater density than minimum distance allowed between contacts on one side of the board. The present invention is as claimed in the claims. OBJECTS OF THE INVENTION It is therefore an object of this invention to provide a zero or low insertion force connector that accommodates boards that are warped to a degree that would not be easily or adequately received by a C- or U-shaped zero-insertion-force connector. The present invention is a low insertion force connector of the type for connecting a first circuit board to a second circuit board, the first circuit board having a board edge, first and second opposed board surfaces abutting the board edge, and at least one board contact on either the first or second opposed board surfaces, the connector comprising in combination a housing having spacing means for maintaining at least a first and a second contact space in the housing, the spacing means having a board cavity bounded by a first cavity side and an opposing second cavity side; a first contact disposed in the first contact space and having only a first contact arm for engaging the first side of the circuit board and first means for supporting the first contact arm adjacent the first cavity side in the board cavity; and a second contact disposed in the second contact space and having only a second contact arm for engaging the second side of the circuit board and second means for supporting the second contact arm adjacent the second cavity side in the board cavity, characterised in that the first cantilevered beam extends across the width of the first housing cavity bounded by the first housing cavity's sides a first distance defined by the junction of said beam with a terminal support base and the furthest length said first beam can extend toward one of said housing cavity sides; and the second cantilevered beam extends across the width of the second housing cavity bounded by the second housing cavity's sides a second distance defined by the junction of said beam with a terminal support base and the furthest length said second beam can extend toward one of said housing cavity sides; so that the sum of said first distance and said second distance is greater than a distance between said opposite cavity walls of either said cavity. BRIEF DESCRIPTION OF THE DRAWINGS The preferred embodiment of the present invention is shown in the accompanying drawing wherein: Figure 1 is a perspective view of preferred embodiment of the electrical connector as used to connect to a printed circuit board; and Figure 2 is a cross-sectional view of the electrical connector of Figure 1, taken along line 2-2 of Figure 1, depicting the right contact beam in its free state in the preferred electrical connector; and Figure 3 is a cross-sectional view of the novel electrical connector of Figure 1, taken along line 3-3 of Figure 1, depicting the left contact arm in its free state in the preferred electrical connector. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring initially to Figure 1 of the drawing, the preferred embodiment of the electrical connector, generally 10, is used to connect a conventional printed circuit board, generally 12, to a base circuit board (not shown) on which the connector 10 is mounted. The electrical connector 10 is suitable to connect a single printed circuit board 12 or a plurality of two or more such printed circuit boards to a base circuit board. The electrical connector 10 includes an elongated housing 14, formed from any suitable insulating thermoplastic, having a pair of elongated, spaced part, board access cavities 16, 18 on the access side 20 of an elongated base 22 in the housing 14. Four upstanding circuit board retention posts 24, 26, 28, 30 extend outwardly from the access side 20. Two of the posts 24, 28 are at opposing ends of the first access cavity 16, and the other two 26, 30 are at opposing ends of the second access cavity 18. Each of the posts 24, 26, 28, 30 includes an integrally-formed, resilient or yieldable board latch 32, 34, 36, 38 formed at the upper end of the posts 24, 26, 28, 30 respectively. The board latches 32, 34, 36, 38 yieldably retain a printed circuit board in a mounted contact position between associated pairs of the posts 24, 28 and 26, 30. More specifically, each latch, 36 for example, has an elongated tapered surface 40 formed at its free end opposite the access side 20 of the elongated base 22. The tapered surface 40 is outwardly deflectable upon contact with one of the opposing lateral edges 42, 44 of the printed circuit board 12. The tapered surface 40 terminates in a thickened section 41 abutting a board edge retention cavity 44 extending along the length of the post 28. When the printed circuit board 12 is mounted within the board edge retention cavities 44, 46, formed in the opposing pair of posts 28, 24, the associated resilient latches 36, 32, return to their nondeflected position to retain the printed circuit board 12 in its mounted contact position, shown in phantom in Figures 2 and 3. Referring back to Figure 1, each access cavity, 16 for example, includes a plurality of generally parallel, spaced apart, transversely oriented contact slots 46, 48 disposed along substantially its entire length. Connector spring contacts 50, 52 are disposed in the slots 48, 46 respectively. If desired, the right spring contact 50 disposed in the second slot 48 may be electrically short circuited to the left spring contact 52 disposed in the adjacent first slot 46. This may be achieved by forming the adjacent spring contacts 50, 52 in the slots 48, 46 as integral portions of a single electrically conductive metallic strip, the interconnecting portion of which (not shown) would extend along the mounting surface 54 of the elongated base 22 opposite the access side 20 of the base 22. Alternatively, the spring contacts 50, 52 may be electrically insulated from each other by the insulating wafers 56, 58, 60 between the contacts 50, 52 and forming the slots 48, 46 in the housing. Each of the slots, 48 for example, formed by adjacent wafers 58, 60 includes an inclined shoulder 61, an elongated, inclined insertion wall 62, a bottom edge 64, an inwardly inclined shoulder 66, and a vertically projecting flatted stop wall 68 disposed between the inclined wall 62 and the inclined shoulder 66. Referring now to Figure 2, the right spring contact 50 is shown as disposed in the second contact slot 48 of Figure 1. In Figure 3, the left spring contact 52 is shown as disposed in the first contact slot 46 of Figure 1. The contacts 50, 52 are stamped and integrally formed from any suitable resilient electrically conductive metallic materials, preferably from a copper alloy such as strip of beryllium copper phosphor bronze or other suitable material having a thickness of approximately 0.003cm (0.012 inch). The two contacts 50, 52 are, to a large degree, mirror images of each other, and thus the description of one applies to the other with this understanding and the exceptions described below. The right spring contact 50 of Figure 2, for example, has a transverse support base 70 extending across the width of the second contact slot 48 adjacent bottom edge 64 of the elongated base 22. First and second housing latch arms 72, 74 extend from the opposing ends 76, 78 of the support base 70 towards the opposed inclined shoulders 66, 61. A cantilever contact bean 80 extends from a junction 82 with the support base 70 intermediate the latch arms 72, 74 but adjacent the first or left contact arm 72. The cantilever beam 80 extends from the junction 82 parallel to the support base 70 toward the right latch arm 74. A contact beam 84 extends perpendicularly from the cantilever beam 80 adjacent the right latch arm 74, and an inclined contact arm 86 extends from the end of the contact beam 84 opposite the cantilever beam 80 toward the left latch arm 72 at an acute angle to the contact beam 84. The contact beam 84 narrows in cross-section from the wider intersection with the cantilever bean 80 toward the intersection with the uniformly narrower contact arm 86. On the side of the support base 70 opposite the cantilever beam 80, a first board contact or lance 90 extends perpendicularly from the base 70 at the right end 92 of the base 70. An optional second board contact or lance 94 may also extend from the support base 70 parallel to the first board contact 90. The board contacts 90, 94 provide electrical and mechanical connection to a base printed circuit board (not shown) when mounted in, and soldered, to the base board in ways well known to those of skill in the art. As shown in Figure 3, the left contact 52 has the identical mirror image instruction with one exception. Rather than having an inclined and narrow contact arm 86 as in Figure 2, the left contact 52 is a thickened contact 88 extending substantially perpendicularly from the contact beam 84. Referring again to Figure 2, the first access or mounting cavity 16 has a deep throat 96 for insertion of the contact bearing end 98 of the printed circuit board 12. The throat 96 is bounded on the right side by first planar side edge 100 extending toward and adjoining the inclined insertion wall 62 of the second insulating wafer 58, and on the left side by a second planar side edge 102 extending toward and perpendicularly adjoining the stop wall 68. A rounded throat bottom 104 interconnects the first and second side edges 100, 102. The opposing planar edges 100, 102 extend substantially perpendicularly to the support base 70 of the right contact 50. A strengthening wall 106 extends perpendicularly from the wafer 58 to rigidly interconnect the wafer 58 with the adjoining wafer 60, as shown in Figure 1. In addition, molded-in recesses 108, 110 penetrate the bottom edge 64 of the wafer 58 to minimize the material necessary to form the wafer 58 while maintaining sufficient strength in the body of the wafer 58. In addition, latching ramps 112, 114 also extend perpendicularly from the surface of the wafer 58 to, as also shown in Figure 1, interconnect the adjacent wafers 58, 60. The latching ramps 112, 114 provide strength and rigidity to the connector 10 and wafers, e.g., 58, while also providing latching surfaces 116, 118 for mating latch clamps 120, 122 on the latch arms 72, 74. Internal inclined ramp surfaces 128, 129 on the ramps 112, 114 urge the mating latch arms 72, 74 inwardly respectively, to center the contact 50 in the access cavity 16 while simultaneously urging the contact 50 to engage the base circuit board (not shown). As shown in Figures 2 and 3, the structure of each contacts 50, 52 is the same. Thus, the contact bearing end 98 of a circuit board 12 is mounted in the connector 10 by inserting the contact bearing end 98 into the deep throat 96 at an acute angle to the parallel planes of the planar side edges 100, 102 of the throat 96, between a mounting gap 130 between the narrow contact arm 86 and thickened contact arm 88 on adjacent right and left contacts 50, 52 respectively. The mounting gap 130 is, at its narrowest point, substantially wider than the width of the insertion edge 132 of the board 12. The board 12 is then rotated into position in the throat 96 so, as shown in phantom, that the opposing sides 140, 142 of the board 12 are parallel to the opposing side edges 100, 102 of the throat 96. When thus mounted in the throat 96, the narrow contact arm 86 is deflected somewhat toward the right latch arm 74. At the same time, the thickened contact arm 88 on an adjacent contact 52 is deflected, as shown in phantom in Figure 2, toward the left latch arm 72. In accordance with an important feature of the present invention, greater contact deflection capability of the contacting portions of the spring contact is inherent in the off-center support of the cantilever beams, which can be significantly lengthened as a result. In addition, because the one-sided contact engages only one side of the board rather than both sides of the board as do traditional C-and U-shaped contacts, the minimum spacing between contacts can be reduced by up to 50% while retaining the same minimum spacing between contact pads on each side of the board. In this manner, a new and improved zero or low insertion force electrical connector is provided for making effective and reliable high contact force electrical connection with a printed circuit board with the capability of greater beam deflection and the use of existing board tab densities for single or double density connectors. A single density will utilize contact pads on only one side of the board. A double density will utilize pads on both sides of the board. Quad densities are achieved by utilizing pads on both sides of the board, each such pad contacting a separate single-sided contact at the doubled-up spacing allowed by the single-sided contact arms. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. For example, the precise configuration of the spring contacts 54, 73 may be modified to achieve desired spring and contact characteristics. Thus, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above.

Claims: A low insertion force connector (10) of the type for connecting a first circuit board (12) to a second circuit board, the first circuit board (12) having a board edge (132), first and second opposed board surfaces (142,140) abutting the board edge (132), and at least one board contact on either the first or second opposed board surfaces (142,140), the connector (10) comprising in combination: A. a housing (14) having a board cavity (16,18) bounded by a first cavity side (100) and an opposing second cavity side (102) having a longitudinal extending centreline, a first and a second contact slot (48,46); B. a first contact (50) disposed in the second contact slot (48) and having only a first contact arm (86) for engaging the first side (142) of the circuit board (12) and first means (84) for supporting the first contact arm (86) in the board cavity (16) adjacent the first cavity side (100); CHARACTERISED BY C. a second contact (52) disposed in the first contact slot (46) and having only a second contact arm (88) for engaging the second side (140) of the circuit board (12) and second means (84) for supporting the second contact arm (88) in the board cavity (16) adjacent the second cavity side (102), and in which a first cantilevered beam (80) of said first contact (50) and a second cantilevered beam (80) of said second contact (52), from both of which extend respectively said first and second means (84) for supporting the contact arm (86, 88), both extend across the centreline of the board cavity (16) from a respective junction (82) with a terminal support base (70), said junction (82) being positioned in the board cavity (16,18) on that side of the centreline which is further from the first and second cavity side, respectively. A low insertion force connector as claimed in Claim 1, characterised in that the first cantilevered section (80) is longer than the width of the board cavity. A low insertion force connector as claimed in Claim 1, characterised in that the second cantilevered section (80) is longer than the width of the board cavity.

Inventors: STANEVICH KENNETH W, STANEVICH, KENNETH W.
Applicants: MOLEX INC, MOLEX INCORPORATED
Application year: 1990
Main classification: H01R23
IPC codes: H01R24, H01R12