Abstract:
An electrical connector assembly (10) includes at least one signal contact (22) and one grounding structure (16) mounted in a dielectric housing (12) having flat exterior surface portions (19). A filter (32) is associated with each signal contact, if desired, and is in tape form with dielectric material (36) laminated between broad area electrodes (34,38) with the tape attached to the housing exterior surface (14); the dielectric material is selected to have a dielectric constant and thickness to provide a desired capacitance between signal and ground electrodes (34,38). The method includes electrically joining the signal and ground electrodes to the signal contact (22) and grounding structure (16) while pressing the tape filter along and against the exterior housing surfaces (19) between the connections, for the electrodes (34,38) of the filter to be connected between the signal contact and ground structure to effectively insert the filter in the signal path to ground.

Description:
FIELD OF THE INVENTION 
     This invention relates to an electrical article such as a connector and more particularly a method of assembling thereto a filter of a tape, laminated construction, by mounting the tape filter on portions of the exterior surface of the connector housing. 
     BACKGROUND OF THE INVENTION 
     The increasing use of high speed digital pulses for communication has led to the use of sensitive components to receive and manipulate such signals This sensitivity has in turn made the components vulnerable to unwanted frequencies transmitted thereto on the same signal paths as the wanted signal frequencies. To solve the problem caused thereby, a number of developments have led to patents that purport to filter out unwanted frequencies utilizing electrical connectors as the vehicle for accommodating appropriate filters having appropriate characteristics. U.S. Pat. No. 4,695,115 granted Sep. 22, 1987, is drawn to a telephone connector with bypass capacitor and teaches the use of capacitors built into the connector to filter out unwanted frequencies from signals carried on signal contacts of a connector. There, the filters are termed &#34;tombstone capacitors&#34; and means are provided for interconnecting such capacitors between the signal paths and grounding paths. As will be discerned, the filters occupy a considerable volume of the total volume of the connector. 
     U.S. Pat. No. 4,772,224 granted Sep. 20, 1988 represents a modular electrical connector which includes capacitors and additionally, ferrite inductors to provide filtering. As with U.S. Pat. No. 4,695,115, the filter elements take up considerable volume of the device, particularly in terms of the height of the device from a printed circuit board or part of the assembly served by the filtered connector. 
     Accordingly, it is an object of the present invention to provide a connector having a filter that adds minimally to the packaging dimensions of the connector. It is a further object to provide the combination of multi-pin electrical connector in conjunction with a thin tape filter disposed on the exterior surface of the connector housing in an unobtrusive way, generally conforming to the shape of the exterior surfaces while innocuously traversing openings thereinto. It is a still further object to provide a simple, and readily manufacturable filter construction that adapts itself to use on connectors and other electrical articles such as printed circuit boards and transmission cable. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, there is provided a filter assembly consisting essentially of one or more thin foil signal electrodes and one or more grounding electrodes separated by a thin coating of dielectric material with the area of the electrodes, in conjunction with the dielectric constant of the material and the spacing between electrodes, selected to provide a capacitance effectively filtering out unwanted frequency components and allowing desired frequency components to pass through signal transmission circuits. The unwanted frequency components are in essence grounded by the filter through a connection to a grounding means. The filter may include the electrodes and dielectric material laminated together, or additionally, a thin dielectric film utilized as a carrier to hold the assembly of electrodes and dielectric material in a position for manufacturing and application. 
     In one embodiment, the present invention achieves the foregoing objectives through the use of an electrical connector having a plastic housing with an exterior surface essentially of a conventional configuration. The connector includes signal contacts carried by the housing with post portions extending from the bottom of the housing and a grounding contact, including a shield structure over the front or mating face of the connector, with post portions extending down from the bottom or mounting face of the connector, the post portions to be inserted into respective apertures of the printed circuit board of a circuit assembly being soldered thereto. Signals transmitted to the connector by a mating connector are carried by their signal contacts to signal traces on the circuit assembly through printed circuit board conductive traces extending from connections with the contacts at the apertures, to components within the assembly that receive and utilize such signals for communication purposes. The combination is disclosed in U.S. patent application Ser. No. 07/971,028 filed Nov. 3, 1992 and assigned to the assignee hereof. 
     In combination with the connector, which may be in the form of a telephone receptacle that mates with a telephone connector plug, the electrodes of the filter, both signal and ground, have holes therein through which are fitted the contacts of the connector, suitably terminated thereto such as by solder joints, with the filter tape lamination being thereafter folded around from the bottom of the connector housing, over the back and top of the housing with the grounding electrode being joined to the shielding and grounding of the connector as by solder. An insulative layer is provided over the portions of the electrodes except at the soldering sites, such as by spraying of a polymeric coating thereover or lamination to a polymeric film. 
     The invention contemplates application for a broad range of connectors, including at least one signal contact and at least one grounding contact with separate tape structures for separate signal contacts in accordance with the size of the capacitor required or with a common ground and separate electrodes for separate signal contacts. The invention also contemplates, in certain applications, a lamination having a common grounding electrode with separate signal electrodes for the filter capacitor. The filter of the invention being as mentioned tape-like and laminated is, in all events, made quite thin and flexible so as to be foldable over and pressed against substantially flat portions of the outside surface of the connector housing and attached thereto as by adhesive or bonding or structures intended to hold the filter in place on the housing so that the connector/filter assembly can be handled as one element. The filter tapes may be mechanically secured to the connector housing by means of the solder joints with signal and ground contacts of the connector, and optionally further secured by a plastic covering thereover assembled to the connector after soldering. Through this technique, the volumetric change by adding the filter is minimized and the invention is adaptable to existing connector designs, being added thereto in a straightforward assembly technique. 
     The filter of the present invention can also be utilized with other electrical articles such as printed circuit boards, where the signal and ground electrodes could be soldered directly to exposed contact pads of the board&#39;s signal and ground traces, for example. The filter could also be used around a length of shielded signal transmission cable. 
     The method of the present invention includes the steps of providing a tape filter for a particular selected connector, electrically connecting each signal electrode with a portion of corresponding signal terminal of the connector extending from the connector housing or at least exposed along the surface of the housing, wrapping the tape filter along outer surfaces of the connector so that it is disposed adjacent the surfaces thereof, and electrically connecting each ground electrode with a ground shell or shield of the connector. 
     An embodiment of the present invention will now be described by way of example with reference to the accompanying drawings 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view showing an electrical connector positioned above two representative tape filters of the present invention prior to an assembly thereof; 
     FIG. 2 is a view of the elements of FIG. 1 in partial assembly; 
     FIG. 3 is a side, elevation and partially sectioned view of the end of the filter as connected to a contact of the connector; 
     FIG. 4 is an isometric view of the connectors of FIGS. 1 and 2 in the fully assembled condition; 
     FIG. 5 is an isometric view of the end of the filter and the connection to the ground circuit of the connector; 
     FIG. 6 is a side and elevation view of the connector and filter of FIG. 1; 
     FIG. 7 is a side and elevation view of the connector just prior to complete assembly; 
     FIG. 8 is a side and elevation view of the connector as shown in FIG. 4; and 
     FIG. 9 is a plan view of an alternate embodiment of tape filter showing a pair of signal electrodes. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to FIG. 1, an electrical article such as connector assembly 10 is shown to include a connector 12 and a pair of filters 32 and 32, prior to assembly of connector and filters The connector 12 may be taken to be a modular telephone receptacle jack of a well-known type mountable to a printed circuit board (not shown) at a board connection or mounting face 25. Connector 12 receives into a cavity at a mating face 29, a modular telephone plug (not shown) connected to telephone cable to interconnect such cable and the signals carried thereon through the connectors to the circuit board, telephone receiver, facsimile receiver, and/or computer. The signals transmitted through the plug and jack connectors to the circuit receiving signals may carry unwanted frequencies that find their way onto the cable through radiation of fields, induction, leakage from other circuits and the like. It is these unwanted frequency components that can cause error, particularly with respect to the interpretation of digital 1 and 0 information that makes up digital transmission. It is the purpose of the present invention to filter out the unwanted frequencies while allowing the frequencies that constitute the proper signal representations, namely, voltage levels, to pass through the connector and into the circuit and apparatus receiving such signals. 
     Construction of a connector like 12 is relatively well known, and includes a plastic housing 14 having on the face thereof a shielding and grounding structure 16 that includes posts 18 extending from the bottom of the connector as shown in FIGS. 1 and 2 for connection to circuits of the board. Housing 14 includes a series of grooves denominated 20 that extend from the top and through selected rearwardly projecting portions. Grooves 20 contain sets of signal contacts 22 and 24, offset as shown in FIG. 1, with the contacts ending in posts 28,26 coextending below the bottom surface or mounting face 25 to be terminated to conductive traces of the board, along with the grounding post 18 of shield 16. The front ends of contacts 22 and 24 (not shown) are formed to extend into the plug-receiving cavity at mating face 29 to receive pin portions of contacts of the mating plug connector connected to signal cable. Housing 14 includes a resilient mounting fastener 30 also extending from the bottom or mounting face 25 of the connector that plugs into a corresponding aperture of the circuit board served by the connector. The fastener 30 is shown in more detail in FIGS. 6 to 8 to include an interior slot, a barbed edge 31 that will latch and lock the connector housing 12 to the board prior to soldering posts 18, 26, and 28 to the board. 
     The shielding structure 16 includes opposed side portions 15 and at the top thereof a portion 17 as shown in FIGS. 1, 2, 4 and 5 and, as shown in FIGS. 4, 5, and 8 is folded down against the top surface of housing 12. As can also be discerned from the various figures, the housing 12 has an exterior surface comprised of a top, rear, sides, and a bottom. The top and sides represent relatively flat planar surfaces, the rear also containing flat surfaces as well as the reliefs as shown in the various figures. 
     In accordance with the invention, representative filters are included for two of the six signal contacts, the filters being shown carried by two filter elements 32 and 32&#39;; it being understood that all six signal conductors can be filtered in the manner to be described. As can be seen in FIG. 1, the filter element 32 includes an upper electrode 34 and a lower electrode 38. A substrate of dielectric material 36 is provided therebetween in the manner shown in FIG. 3. At the forward end of the element 32 is a finger 35 of upper electrode 34 defining a signal connection section, apertured as at 37 with the aperture aligned to receive the inner post 28 inserted therethrough and soldered thereto as by a solder fillet S as shown in FIG. 3. At the rear is a grounding finger 39 of lower electrode 38 defining a ground connection section that is soldered to ground shielding structure 16 in final assembly. Posts 26,28 defining signal connection sites spaced from each other, and top portion 17 of shield 16 defines a ground connection site remote from all signal connection sites. Finger 35 is shown laterally staggered and otherwise electrically separated from the other filter element 32&#39; to allow clearance and nonengagement with a post 26 extending therepast for termination to electrode 34&#39; of element 32&#39;, noting the finger 35&#39; and aperture 37&#39; associated with post 26. Element 32&#39; also includes a grounding finger 39&#39;. 
     Each of the filter elements is comprised then of an upper electrode 34 and a lower electrode 38 separated by a substrate 36 of dielectric material. Such an element can be formed such as by first laminating respective layers of conductive material to respective surfaces of a sheet of the dielectric material, after which an etching process defines the boundaries of the respective electrodes, in which process a plurality of such tape filters can conveniently be fabricated. Preferably outwardly facing surfaces of the electrodes have an insulative covering after etching, such as by spraying with a polymer paint or by lamination to a polymeric film, except at soldering sites of the electrodes. The individual electrodes 34,34&#39;, one for each of the signal contacts associated with one post 28 and one for each signal contact associated with one post 26 and with common grounding electrodes 38 and 38&#39;, have areas selected in conjunction with the particular dielectric material having a particular dielectric constant and the thickness of the coating 36 to provide a desired capacitance associated with each signal contact and, in essence, connecting each signal contact through the capacitive material to ground through the common ground electrode 38. As is well known, capacitance is a function of area of electrode, dielectric constant of the dielectric material, and the spacing between electrodes with capacitance values decreasing as the space between electrodes is increased and with capacitance increasing with the dielectric value increasing. 
     In accordance with one embodiment of the invention, the electrodes were formed of foils each on the order of about 0.0014 inches thick, with the substrate on the order of 0.002 inches thick, the package thus formed being on the order of 0.005 inches thick. A film of polymeric material such as RHEOPLEX LC 40 acrylic emulsion adhesive sold by Rohm and Haas, Inc., Philadelphia, Pa. having a matrix of acrylic polymer with barium titanate filler homogeneously dispersed therein on the order of about fifty percent by weight, with particle size of about one micron, was employed for the dielectric material. The conductive layers were of half-ounce copper which were joined to the sheet of dielectric material with a three-ply heat and pressure laminating machine. 
     The lamination thus formed was found to have a capacitance varying between 400 and 480 picofarads when the individual electrodes were on the order of 0.200 inches wide and 1 inch in length. The resulting capacitance provided an attenuation beginning at on the order of several dB insertion loss at slightly less than 10 Mhz rising to on the order of 12 to 15 dB at around 100 MHz and peaking for the 400 picofarad capacitance at about 34 dB at around 250 MHz. The 480 picofarad sample had an insertion loss at slightly less than 30 dB at a frequency of around 200 to 300 MHz. The use of an appropriate amount of barium titanate in the polymer further provides a voltage withstanding of 1000 volts or greater, needed for certain FCC requirements. 
     Alternatively a pair of opposing foils of anodized aluminum could be utilized, laminated to a sheet of the barium titanate-filled polymer; or a coating of barium titanate-filled polymer may be screen printed or sprayed onto one sheet of foil as the other foil sheet is then laminated thereonto; and then after application of masking of appropriate geometry, the foil sheets are etched in conventional manner to result in a structure similar to the etched electrode structure described above, after which dielectric coating such as 350 CC epoxy sold by Mavidon Corp., Palm City, Fla., may be applied to one or both electrode outer surfaces. The tape filters may then be cut from the sheet of dielectric material. 
     The filters 32 and 32&#39; were in turn laminated with a thin insulating film shown as layers 134 and 138 in FIG. 3. In the embodiment shown, layer 138 is between filter elements 32 and 32&#39; thereby electrically isolating electrode 38 from electrode 34&#39;, in the fashion shown in FIG. 2 with the various separate electrodes soldered to the various contacts 22 and 24 at respective post portions 26 and 28. The lamination was folded around from the bottom of the connector housing 14, up the back, resting on the flat surfaces thereof, and across the top in the manner shown in FIG. 7, traversing grooves 20 and 18 seen in FIGS. 1 and 2 and being disposed between raised lips 41 of housing 12 for protection against the side edges being snagged and the filters becoming dislodged or otherwise stressing the solder termination joints. The filter elements 32,32&#39; are shaped and dimensioned such that the signal connection sections defined by fingers 35,35&#39; are staggered with respect to each other and are adjacent respective signal connection sites (posts 26,28); ground connection sections defined by fingers 39,39&#39; are staggered with respect to each other and are adjacent the ground connection site defined by top portion 17 of shield 16. 
     With the end of the elements 32 and 32, folded down against the upper surface, the projection 17 was then folded down over the top of the fingers 39 and 39&#39; of the filters in the manner shown in FIG. 8 and in the manner shown in FIG. 5. As can be seen in FIG. 5, a solder fillet S&#39; interconnects finger 39 of electrode 38 to projection 17 and thus to shielding structure 16 and the fillet solder S&#39;&#39; connects the finger 39&#39; to electrode 38&#39; of element 32&#39; to the same grounding structure. In this fashion, two filter elements such as 32 and 32&#39; may be folded as shown and terminated to the grounding structure. It may be desired after soldering, for a plastic covering to be molded over the filter tapes for protection thereof, or alternatively a premolded plastic cover to be secured to the connector over the filter tapes by conventional methods to protect the filter tapes. 
     The invention contemplates additional elements such as 32 that may be individually grounded rather than commonly grounded as shown and terminated by using fingers such as 39 and 39&#39; appropriately. The invention also contemplates that where necessary to achieve a desired capacitance, the area of the electrodes, such as electrodes 34, may be increased for a given signal contact with additional elements provided for the remaining signal electrodes. Also contemplated is the use of additional area achieved by providing electrodes 40 extending over the sides of the housing in the manner shown in phantom in FIG. 8, such additional area providing an increased capacitance for the device. 
     The invention contemplates a use with one signal contact and one ground contact or with two, four, or six contacts. For example, FIG. 9 is an alternate embodiment of tape filter 80 adapted to filter two contacts by means of one tape structure. Tape filter 80 is shown having two signal electrodes 82,84 on a common side of the dielectric substrate, separated by a gap 86. A single common ground electrode 88 is disposed across the opposed surface of the substrate. Each of the signal electrodes 82,84 have respective fingers 90,92 extending to traverse the axis of the corresponding signal terminals of the connector (not shown), with the terminals received through respective apertures 94,96 through the fingers 90,92 and soldered thereto, upon assembly of the tape filter to the connector. Ground electrode 88 is shown to include grounding fingers 98 extending beyond the extent of signal electrodes 82,84 for soldering to a ground shield of the connector (not shown). 
     Various layouts utilizing various portions of the exterior area of the housing may be employed with adequate areas for the desired capacitance as indicated. Having now described the invention to enable a preferred practice thereof, claims are appended intended to define what is inventive.