Coplanar sliding electrical connector

Abstract: An electrical connector assembly having a front and a back side has an electrically insulating connector housing having a front side and a back side and at least one aperture extending from the front side to the back side, an electrically conductive unitary spring clip connector extending from the front side of the housing through the aperture to the back side of the housing, the spring clip connector having a connecting terminal on one end and a resiliently deflectable spring contact on the other end and an insulating retention plate to retain the spring clip connector in the housing, the retention plate being fastened to and on the back side of the connector housing and having at least one aperture therein with the connecting terminal on one end of the spring clip connector extending therethrough.

Description: The present invention relates to electrical connectors and in particular to a versatile simple inexpensive reliable electrical interface which enables electrical contact in two directions perpendicular to each other. There are many machines in use today wherein a functional module is inserted and withdrawn from the main machine frame. For example, in electrostatographic printing apparatus it is common to have various of the subsystems in the imaging machine be removably mounted in the machine. Accordingly, the individual modules such as, for example, a developer housing or a cleaner housing may be mounted such that it is removably inserted in the machine and can be withdrawn for replenishment, repair, etc. In such applications, typically the developer housing, for example, has to be positioned very close to, if not in contact with the photoreceptor to enable adequate development of the electrostatic latent image formed on the photoreceptor. To minimize damage to the delicate photoreceptor, the developer module is inserted on a track or rail type of arrangement which spaces it slightly from the photoreceptor until it reaches its end position where it is moved into developing engagement with the photoreceptor by being moved in a direction perpendicular to the insertion direction into the main machine. Upon insertion, electrical contact between the developer housing, for example, and the main machine must be made to provide operational power to the developer housing as well as signal level control. It has previously been proposed to provide an electrical connector assembly attached to a module, such as a developer housing, at one end which contacts an electrical power source on the main machine through the use of a spring clip contact in a plastic housing. While the one end of the electrical connector may take the form of a spring clip having a large contact area, typically the other end of the electrical connector is connected to a wire on the module or developer housing by means of a screw, weld or other type of physical connector. In addition, typically the wires connected to such a connector come out the sides of the connectors assembly which constrains the positioning of the connector assembly to the module and more importantly, if the connections are made on both sides of the connector housing, one of the connections must be substantially modified to enable the spring clips to face in the same direction to enable the lateral positioning. Typically, this geometry then requires additional parts and manufacturing operations to provide such a connector. EP-A-214,468 discloses a contacting apparatus 1 for a chip card 2 having card contacts 5 adapted for being brought into contact with the contacting apparatus. A card support 3, which is adapted to receive the chip card, is movably supported in the housing 4. Card contacts 5 can be brought into contact engagement with with contacts 6 which are stationary with respect to the housing 4. EP-A-520,080 (a document falling under Art. 54(3) EPC) discloses an IC card connector 10 including a base member 12 having a plurality of contacts 36 exposed on one side of the base member for engaging a terminal array of the IC card. A cover 14 is hinged to the base member for movement toward and away from the base member. Closing of the cover onto the base member effects engagementof the terminal array with the contacts. In a principle aspect of the present invention a space efficient, low part count, easy to assemble, low cost, spring loaded electrical make break connector for a module, which is insertable into a machine and permits lateral motion to the home position after insertion is provided. The present invention provides an electrical connector assembly having a front and a back side comprising an electrically insulating connector housing having a front side and a back side and at least one aperture therein extending from said front side to said back side, an electrically conductive unitary spring clip connector extending from the front side of said housing through said aperture to the back side of said housing, said spring clip connector having a connecting terminal on one end and a resiliently deflectable spring contact on the other end, and an insulating retention plate to retain said spring clip connector in said housing, said retention plate being fastened to and on the back side of said connector housing and having at least one aperture therein with the connecting terminal on one end of said spring clip connector extending therethrough; characterised by further including a mating and locating feature comprising at least one mounting pin adjacent said at least one aperture in said housing, a mounting hole in said spring clip connector and at least one retention hole in said retention plate, said spring clip being mounted on said mounting pin through said mounting hole and said retention plate being mounted on the top of said spring clip on said mounting pin. Particular embodiments are set out in claim 2 to 9 of the appended claims. Preferably, the connector housing and retention plate are molded insulating plastic and the housing has insulating ribs integrally molded on its front side, separating and electrically isolating adjacent connectors whereby the spring contacts are located in insulating cavities. Preferably, the connector assembly further includes at least one external mounting post to mount said connector assembly to a machine or part thereof. Preferably, all the spring clip connectors are oriented in the same direction. Preferably, the connecting terminals on said spring clip connectors are male connectors having a raised dimple for cooperative engagement with female connectors. For a better understanding of the present invention, attention is now directed to the drawings. Figure 1 is an exploded isometric view of the electrical connector assembly according to the present invention. Figures 2a and 2b are back and front views respectively of the assembled connector. Figures 3a and 3b are isometric views of the electrically conductive unitary spring connector. Figures 4a and 4b are front and back views respectively of the connector housing. Figures 5a and 5b are isometric views of the electrical connector assembly showing the back and front sides respectively. Figure 6 is a representation of a module such as a developer housing being inserted in the side of a machine such as an electrostatographic printing machine and after insertion, moved into operational relationship with the photoreceptor in a lateral direction. As will be apparent from the drawings and the following description, the present invention has three main elements, a connector housing, a spring clip connector and a retention plate. While illustrated as providing a matrix pattern of a plurality of individual connectors it will be understood that the connectors may be placed in any desired pattern and that only a single spring clip connector need be used per cavity. Referring now to the exploded isometric view of Figure 1, as well as the assembled views of Figures 2a and 2b it will be observed that the electrical connecter assembly 10 provides a total of nine electrical contacts 11. Turning now to Figures 4a and 4b, which represent the top view and bottom view of the connector housing, a plurality of apertures 22 extending from the back of the housing through the housing to the front of the housing are provided. Associated with each of these apertures is a mounting pin 24 which is used for mounting the electrical spring clip connector 14 and the retention plate 16 as will be herein after discussed. The connector housing is typically made from a molded plastic such as ABS and provides a matrix pattern for the individual connectors which are separated by insulating ribs 50 (See Figure 5a) and thereby provide insulating cavities 52 on the front of the connector assembly for the spring contact of the spring clip connector. To facilitate lateral movement of the electrical connector assembly when it is positioned in the machine these spring clip connectors 14 in the individual insulating cavities 52 are oriented in the same direction in the connector housing which may have a tapered or inclined portion at the leading end which is being laterally moved. Turning now to Figures 3a and 3b, the electrically conductive unitary spring clip connector 14 is illustrated as being generally U-shaped in construction with the spring contact being one arm 33 of the U and the mounting hole being in the other arm of the U and having at its end an upwardly inclined arm 36 which provides the other connecting terminal. The upwardly inclined arm 36 has a raised dimple 32 with rounded end that provides the male portion of a quick connect/disconnect connector. By the term "quick connect/disconnect connector" it is intended to define a two piece electrical connection comprising a male portion and a female portion which may be quickly and easily joined to complete an electrical connection and just as quickly and easily separated to break the electrical connection. An example of such a connector is the "fast on" connector available from AMP Inc. of Harrisburgh, PA. The dimple increases the overall thickness of the connecting terminal so that it can be used with a standard female quick connect/disconnect connector enabling the appropriate interference with the female terminal. The unitary spring clip connector 14 is made of a conductive resiliently deflectable material to provide electrical contact with a pin contact on the main machine upon insertion and lateral movement into position. Typically, it is made from stainless steel and has a thickness of about 0.2mm to provide the desired spring function as well as to enable formation of a dimple to provide a thickness to enable cooperation with a standard female quick connect/disconnect connector. The mounting holes 34 are used to locate and mount the unitary spring clip connector 14 on the mounting pins 24 in the connector housing 12 so that the spring contacts are positioned in the insulating cavities 52 at the front of the connector housing. As may be observed the retention plate 16 has a plurality of apertures 42 through which the unitary spring clip connector 14 is inserted to provide the connecting terminal 26, which is engageable with the female portion of the quick connect/disconnect connector, on the back of the connector assembly. Associated with each of the apertures 42 are retention holes 44 which engage the mounting pins 24 in the connector housing 12. The connector assembly 10, according to the present invention is capable of robotic top down assembly wherein the unitary spring clip connectors 14 are readily inserted into the apertures 22 in the connector housing while at the same time having their mounting holes 34 placed over the mounting pins 24 in the connector housing 12. Subsequently, the retention plate 16 may be placed on the connector housing 12 having the unitary spring clips 14 so that the spring clips extend through the apertures 42 in the retention plate 16 and the retention holes 44 in the retention plate engage the mounting pins 24 on the connector housing. The retention plate may be fixed to the connector housing by any suitable means such as with an adhesive or by heat staking or spin welding the retention plate to the connector housing. Figures 2a and 2b illustrate the back and the front sides of the assembled connector assembly. Also illustrated are external mounting posts 54 to enable the mounting of the connector assembly to a frame or module which is going to be inserted into the main machine. In use, the male connecting terminals 26 on the connector assembly would be connected to female terminals on the module and then the connector assembly connected by means of the mounting posts directly to the end of a module. With reference to Figure 6 the electrical connector assembly 10 is mounted on the end of the developer module 56 which can then be inserted into the main machine 58 such as an electrostatographic printing machine and once at the end of its insertion path make electrical contact with electrical pin contacts on the main body of the machine and/or the module can be rotated or otherwise moved into its operational position to further complete contact with the electrical pin contacts on the machine. The present design permits subsystem insertion in a main machine by motion in one direction as well as motion in a second direction perpendicular to the first direction. It also provides a simple relatively inexpensive electrical connector with a very small number of parts which is capable of robotic top down assembly. In addition, it is space efficient and provides a matrix of electrical contacts in a variety of configurations. The unique design of the dimple in the spade area of the connecting terminal permits the use male and female portions of quick connect/disconnect of connectors. Further, the design permits access to the mating harness from the rear of the connector which is a more efficient use of space than providing perimeter access to the connector. Furthermore, the connector matrix can be expanded in any direction.

Claims: An electrical connector assembly (10) having a front and a back side comprising an electrically insulating connector housing (12) having a front side and a back side and at least one aperture (22) therein extending from said front side to said back side, an electrically conductive unitary spring clip connector (14) extending from the front side of said housing (12) through said aperture (22) to the back side of said housing, said spring clip connector (14) having a connecting terminal (36) on one end and a resiliently deflectable spring contact (33) on the other end, and an insulating retention plate (16) to retain said spring clip connector (14) in said housing (12), said retention plate (16) being fastened to and on the back side of said connector housing (12) and having at least one aperture (42) therein with the connecting terminal (36) on one end of said spring clip connector (14) extending therethrough; characterised by further including a mating and locating feature comprising at least one mounting pin (24) adjacent said at least one aperture (22) in said housing (12), a mounting hole (34) in said spring clip connector (14) and at least one retention hole (44) in said retention plate (16), said spring clip (14) being mounted on said mounting pin (24) through said mounting hole (34) and said retention plate (16) being mounted on the top of said spring clip (14) on said mounting pin (24). The connector assembly of claim 1, wherein said connecting terminal (36) on said spring clip connector (14) is a male quick connect/disconnect connector having a raised dimple (32) for cooperative engagement with a female quick connect/disconnect connector. The connector assembly of claim 2 wherein the ends of said male connector (36) are rounded. The connector assembly of any of claims 1 to 3, wherein said spring clip connector (14) is generally U-shaped with the spring contact (33) being one arm of the U and the mounting hole (34) being in the other arm of the U and having at its end a downwardly inclined arm with a male quick connect/disconnect connector (36) at the end. The connector assembly of any of the preceding claims, wherein said spring clip connector (14) is stainless steel. The connector assembly of any of the preceding claims, wherein said spring clip connector (14) is about 0.2 mm in thickness. The connector assembly of any of the preceding claims, wherein there are a plurality of apertures (22) in said housing having cooperatively associated therewith unitary spring clip connectors (14) and apertures (42) in said retention plate (16) to form a plurality of electrical connectors (36) on said front and back sides. The connector assembly of claim 7, wherein said plurality of electrical connectors (36) on said front and back sides are electrically insulated from each other. The connector assembly of claim 7 or 8, wherein said plurality of electrical connectors (36) are in a matrix pattern.

Inventors: HALVONIK MARK R, HALVONIK, MARK R.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1993
Main classification: H01R13
IPC codes: H01R13, H01R4