Abstract:
A modular electrical connector including at least one body portion having an electrical terminal and at least one mating surface. An end portion has a mating surface interconnected to the mating surface of the body portion. The body portion and the end portion define a connector body.

Description:
BACKGROUND 
     Various embodiments of an electrical connector are described herein. In particular, the embodiments described herein relate to an improved electrical connector for surface mount technology (SMT) applications. 
     As the use of electronic devices becomes increasingly prevalent, there is a need to provide an increasing number of electronic components on printed circuit boards (PCBs). It has not been uncommon for an electronic component to have wire leads that were inserted into holes in the PCB. With such “through-hole” technology, the wire leads from the electronic component extended completely through the PCB. This made it very difficult to use both sides of the PCB for different circuits. 
     In many applications, electrical connections on PCBs are being made with SMT. With SMT components, blade terminals are connected to a surface on one side of the PCB, usually by soldering. This leaves the opposite side of the PCB available for constructing a different circuit using the same or different SMT components. It would however, be desirable to provide an improved electrical connector for SMT applications. 
     SUMMARY 
     The present application describes various embodiments of an improved modular electrical connector. One embodiment of the modular electrical connector includes at least one body portion having an electrical terminal and at least one mating surface. An end portion has a mating surface interconnected to the mating surface of the body portion. The body portion and the end portion define a connector body. 
     In another embodiment, the modular electrical connector includes a first body portion having an electrical terminal and opposing mating surfaces. A second body portion has an electrical terminal and opposing mating surfaces. A mating surface of the first body portion is interconnected to a mating surface of the second body portion. An end portion has a mating surface interconnected to one of the mating surface of the first body portion and the mating surface of the second body portion. The first body portion, the second body portion, and the end portion define a connector body. 
     In another embodiment, the modular electrical connector includes a first body portion having an electrical terminal and opposing mating surfaces. One mating surface defines a male connector portion and the other mating surface defines a female connector portion. A second body portion has an electrical terminal and opposing mating surfaces. One mating surface defines a male connector portion and the other mating surface defines a female connector portion. A mating surface of the first body portion is interconnected to a mating surface of the second body portion. An end portion has a mating surface, wherein the mating surface is one of a male connector portion and a female connector portion. The mating surface of the end portion is interconnected to one of a mating surface of the first body portion and a mating surface of the second body portion. The first body portion, the second body portion, and the end portion define a connector body. 
     Other advantages of the electrical connector will become apparent to those skilled in the art from the following detailed description, when read in light of the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first embodiment of a modular electrical connector. 
         FIG. 2A  is a top plan view of a power distribution box for a vehicle that includes the modular electrical connector illustrated in  FIG. 1   
         FIG. 2B  is a perspective view of an in-line connector structured and configured to mate with the modular electrical connector illustrated in  FIG. 1 . 
         FIG. 3  is an enlarged perspective view of a body portion illustrated in  FIG. 1 . 
         FIG. 4  is an exploded view of the modular electrical connector illustrated in  FIG. 1 . 
         FIG. 5  is an exploded perspective view of a second embodiment of the modular electrical connector. 
         FIG. 6  is a perspective view of a third embodiment of the modular electrical connector. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, there is illustrated in  FIG. 1  a first embodiment of a surface mount technology (SMT) modular electrical connector, indicated generally at  10 . The illustrated connector  10  is a header connector that can be used in an electrical box such as may be used in a vehicle, such as the box  12  shown in  FIG. 2A . The electrical box  12  may, for example, be a power distribution box, a junction box, and the like. As shown in  FIG. 2A , the electrical box  12  includes a plurality of electronic components  14 A,  14 B,  14 C,  14 D, and  14 E, which are attached to a PCB  16 . If, for example, the electrical box  12  is a power distribution box in a vehicle, an in-line connector  18 , as shown in  FIG. 2B , may be used to connect the SMT connector  10  to various systems within the vehicle via a wiring harness  20 . 
     Referring to  FIGS. 1 and 4 , the connector  10  includes a body  22  and a plurality of electrical terminals  24  and  26 . The body  22  includes one or more identical body portions  28  having an axis A, an upper or first surface  30 , a lower or second surface  32 , a first mating surface  34 , and second mating surface  36 . An axially extending mounting aperture  38  is formed between the mating surface  34  and the mating surface  36 . 
     As best shown in  FIG. 3 , four terminals  24  are integrally formed with the body portion  28 . Each terminal  24  is substantially L-shaped and has a blade end  40  (extending upwardly from the body portion  28  when viewing  FIG. 3 ) and an SMT end  42  (extending downwardly from the body portion  28  when viewing  FIG. 3 ) having a solder aperture  44 . 
     The SMT end  42  of the terminals  24  may be connected to a PCB  16  by any SMT connection methods that are familiar to those skilled in the art; such as for example the method described in U.S. patent application Ser. No. 11/624,409, the method of connecting an SMT terminal end disclosed therein is incorporated herein by reference. 
     The body portion  28  may be formed from plastic, such as for example, polyamide (PA), polyphthalamide (PPA), or other desired thermoplastic material. The body  22  may be formed of thermally conductive material, such as ceramic, and polymer filed with heat conductive fibers and/or fillers to create equalization block, enhance heat transfer between terminal blade ends  40 , and improve PCB heat dissipation performance. It will be understood that some body portions, such as the body portions  28 , may be made of high temperature capable polymers, and other body portions may be made of relatively lower performance or relatively lower temperature capable polymers. 
     In the illustrated embodiment, the blade ends  40  are 2.8 mm blade terminals. Alternatively, the blade ends  40  may be any other desired type of terminal, such as 0.64 mm, 1.2 mm, 1.5 mm, 4.8 mm, and 6.3 mm blade terminals. 
     The body  22  also includes a first end portion  46  and a second end portion  48 . The first end portion  46  has an axis A, an upper or first surface  50 , a lower or second surface  52 , an end surface  54 , and the second mating surface  36 . An axially extending mounting aperture  56  is formed between the end surface  54  and the mating surface  36 . The second end portion  48  is substantially similar to the end portion  46  and has an axis A, an upper or first surface  50 , a lower or second surface  52 , an end surface  58 , and the first mating surface  34 . An axially extending mounting aperture  60  is formed between the end surface  58  and the mating surface  34 . 
     In the illustrated embodiment, the terminal  26  is integrally formed with the end portions  46  and  48 . Each terminal  26  has a blade end  62  (extending upwardly from the end portion  46 , b when viewing  FIG. 2 ) and an eye-of-the-needle terminal end  64  (extending downwardly from the end portion  46 ,  48  when viewing  FIG. 2 ). Such eye-of-the-needle terminal ends  64  attach the connector body  22  to the PCB  16  and ensure that the body  22  remains attached to the PCB  16  during the soldering of the SMT ends  42  of the terminal  24 . 
     Alternatively, the terminals  24  and  26  may be “stitched in” to the body portions  28  and the end portions  46  and  48 , respectively, in an automated manufacturing operation that is familiar to those skilled in the art. 
     The end portions  46  and  48  may be formed from plastic, such as for example; polyamide (PA), polyphthalamide (PPA), or other desired thermoplastic material. The end portions  46 ,  48  may be formed of thermally conductive material, such as ceramic, and polymer filled with conductive fibers and/or fillers to create equalization block, enhance heat transfer between terminal blade ends  40 , and improve PCB heat dissipation performance. It will be understood that some end portions, such as the end portions  46 ,  48  may be made of high temperature capable polymers, and other body portions may be made of relatively lower performance or relatively lower temperature capable polymers. In the illustrated embodiment, the blade end  62  is a 6.3 mm blade terminal. Alternatively, the blade end  62  may be any other desired type and size of terminal, such as 9.5 mm blade terminal. 
     As best shown in  FIGS. 1 and 4 , the connector  10  may be described as modular, that is the connector  10  may be formed by assembling (i.e., interconnecting) any desired number of body portions  28  to first and second end portions  46  and  48 , respectively. A connecting rod  66  may then be inserted through the mounting apertures  38 ,  56 ,  60 , such that a portion of the rod  66  extends outwardly beyond the end surfaces  54  and  58 . The ends of the rod  66  may then be deformed, as shown at  68  in  FIG. 1 , by any desired method, such as by heat staking or by sonic welding. The illustrated rod  66  has a rectangular cross section to prevent rotation and/or axial bending of the assembled components prior to heat staking or sonic welding. Alternatively, the rod  66  may have any other desired cross sectional shape, such as square, triangular, other geometric shapes, and oval and irregular shapes. 
     In the illustrated embodiment, the mating surfaces  34  and  36  are stepped. It will be understood however, that the mating surfaces  34  and  36  may have any desired shape which facilitates the interconnection of the mating surfaces  34  and  36 . 
     In the embodiment illustrated in  FIG. 1 , the connector  10  includes three body portions  28 . It will be understood however, that the connector  10  may be formed with any desired number of body portions, such as one body portion  28 , two body portions  28 , or four or more body portions  28 . 
     The small size of the body portion  28  and end portions  46 ,  48  relative to known SMT connector strips minimizes the effect of material shrinkage and warping that can occur when molding or forming larger connector strips or components. Accordingly, lower cost polymers may be used. Additionally, the final assembly process of the connector  10  allows for adjustment and alignment of the component body portions  28  and end portions  46 ,  48 , such that required tolerances may be easily achieved. 
     By standardizing the size and geometry of the internal (i.e., the terminals  24 ) and external (i.e., the body portions  28 ) components, a common mold tool may be used, reducing cost. Additionally, automated assembly equipment may be used for final connector  10  assembly. 
     The connector  10  described herein above is modular and scaleable to allow the manufacture of multiple different PCB header connectors, such as the connector  10 , using different combinations of the body portions  28 , end portions  46 ,  48 , and rods  66 , and processes, such as heat staking or sonic welding. 
     It will be understood that the body portions  28  and end portions  46  and  48  may have any desired number and combination of electrical terminals, such as the terminals  24  and  26 . For example, one body portion  28  may have a first combination of electrical terminals  24 , an adjacent body portion  28  may have a second combination of electrical terminals  24 , and the end portions  46  and  48  may have a third combination of electrical terminals  26 , advantageously allowing for modularity and scaleability to allow the manufacture of multiple different PCB header connectors. 
     Reduced overall complexity of the component parts of the connector  10  allows for efficient use of manufacturing equipment. For example, one family mold; i.e., a single molding tool with multiple cavities for all assembly components, may be used to form the body portions  28 , end portions  46 ,  48 , and rods  66 . A single assembly machine may be used to stitch terminals  24  into the body portions  28 , end portions  46 ,  48  (if the terminals  24  are not integrally molded therewith). 
     Referring now to  FIG. 5 , there is illustrated a second embodiment of an SMT electrical connector, indicated generally at  70 . The connector  70  is substantially identical to the connector  10 , except for the method of interconnecting the body portions. 
     The illustrated connector  70  includes a body  72  and a plurality of the electrical terminals  24  and  26 . The body  72  includes one or more identical body portions  74  having an axis A, the upper or first surface  30 , the lower or second surface  32 , a first mating surface  76 , and second mating surface  78 . For the sake of brevity and clarity, the connector  70  is shown having only one body portion  74 , however, any desired number of body portions  74  my be used. 
     In the illustrated embodiment, the mating surfaces  76  and  78  are stepped. The second mating surface  78  includes an outwardly and axially extending male connector portion  80 . The connector portion  80  includes a boss  82  extending outwardly (upwardly as viewed in  FIG. 5 ) of the first surface  30 . In the illustrated embodiment, the boss  82  is semi-spherical; however the boss  82  may be any other desired shape. The first mating surface  76  includes a connecting aperture  84  corresponding in size and shape to the size and shape of the connector portion  80 . 
     It will be understood however, that the mating surfaces  76  and  78 , and the connector portion  80  and the aperture  84 , may have any desired shape which facilitates the interconnection of the mating surfaces  76  and  78 . 
     In the illustrated embodiment, the four terminals  24  are integrally formed with the body portions  74 , as described herein above regarding the connector  10 . The body portion  74  may be formed from plastic, such as described herein above regarding the body portion  28 . 
     The body  72  also includes a first end portion  86  and a second end portion  88 . The first end portion  86  has an axis A, the upper or first surface  30 , the lower or second surface  32 , the end surface  54 , and the second mating surface  78 . The second end portion  88  is substantially similar to the end portion  86  and has an axis A, the upper or first surface  30 , the lower or second surface  32 , the end surface  58 , and a first mating surface  76 . 
     In the illustrated embodiment, the terminal  26  is integrally formed with the end portions  86  and  88 . The end portions  86  and  88  may be formed from plastic, such as described herein above regarding the end portions  46  and  48 . 
     As best shown in  FIG. 5 , the connector  70  may be formed by assembling (i.e., interconnecting) any desired number of body portions  74  to first and second end portions  86  and  88 , respectively, in a snap-fit connection. 
     In the embodiment illustrated in  FIG. 5 , the connector  70  includes one body portion  74 . It will be understood however, that the connector  70  may be formed with any desired number of body portions, such as two or more body portions  74 . 
     Referring now to  FIG. 6 , there is illustrated a third embodiment of an SMT electrical connector, indicated generally at  90 . The illustrated connector  90  includes a body  92  having a plurality of body portions  94 , and a spacer portion  96  between each body portion  94 . The illustrated embodiment of the connector  90  includes first and second end portions  98  and  100 , respectively. The body portions  94 , end portions  98 ,  100 , and spacer portions  96  may be connected by a connecting rod  66 , as described herein above. The body portion  94  includes the terminal  26  having the blade end  62  and the terminal end  64  as described regarding the connectors  10  and  70 . 
     The body portion  94  and the spacer portion  96  may include the mating surfaces  34  and  36  as described in detail regarding the connector  10 . Alternatively, the body portion  94  and the spacer portion  96  may include the snap-fit mating surfaces  76  and  78  as described in detail regarding the connector  70 . The use of the spacer portions  96  allows the pitch spacing between the terminals  26  to be easily changed. 
     The principle and mode of operation of the electrical connector have been described in its various embodiments. However, it should be noted that the electrical connector described herein may be practiced otherwise than as specifically illustrated and described without departing from its scope.