Abstract:
A multi-piece microelectronic connector is disclosed which permits rapid assembly of the connector components during manufacture. The connector is comprised of an insert and a connector body. The insert has a cavity configured to receive at least one electrical component. The insert also has leads for electrically connecting the electrical component with a modular plug. The connector body has a front, a back and a dividing wall separating the front and the back. The front of the connector body has a cavity for receiving a modular plug therein. The back has a cavity for receiving the insert therein. The dividing wall has a set of openings providing communication between the cavity in the front and the cavity in the back. The set of leads of the insert are configured to protrude through the set of openings in the dividing wall and into the cavity in the front of the connector body.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates generally to miniature electrical connectors used in printed circuit board and other microelectronic applications, and more particularly to a microelectronic connector with improved modularity and a method of fabricating the same. 
     2. Description of Related Technology 
     Existing microelectronic electrical connectors (such as those of the RJ 45 or RJ 11 type) frequently incorporate magnetics or other electrical components to provide a variety of functions, such as signal voltage transformation or noise suppression. In one common connector design, the magnetics or component package is fabricated as a separate device that is then subsequently inserted within or mated to another component of the connector. See, for example, U.S. Pat. No. 5,647,767 “Electrical Connector Jack Assembly for Signal Transmission” (“&#39;767 patent”), and U.S. Pat. No. 5,587,884, “Electrical Connector Jack with Encapsulated Signal Conditioning Components” (“&#39;884 patent”). A related design illustrated in U.S. Pat. No. 5,178,563, “Contact Assembly and Method for Making Same” employs the multi-component arrangement of the &#39;767 and &#39;884 patents, yet with no installed electrical component. Common to each of the aforementioned designs is the use of a separate lead insulator or “carrier” that insulates and segregates the electrical leads connecting the modular plug contacts with the electrical component (or output leads of the connector). This general lead carrier arrangement is illustrated in FIG. 1 a.    
     In addition to the functions listed above, as shown in FIG. 1 b,  a lead carrier  110  also acts as a mechanical fulcrum for the leads  120  when installed. Specifically, the distal ends  115  of the leads engage contacts of a modular plug  130  when the plug  130  is inserted into a connector body  100 , thereby tending to bend the leads  120  upward and away from the plug  130 . The modular plug  130  has a latch  131  which securely engages the plug  130  with the connector body  100 . The plug  130  is shown in FIG. 1 b  with the latch  131  on the underside of the plug, also referred to as a “latch-down” configuration. The carrier  110  tends to maintain the leads  120  in engagement with their respective contacts on the modular plug  130 , thereby increasing the reliability of the connector. This is especially true during relative movement of the plug  130  within the connector body  100  or after many insertion/removal duty cycles. 
     While providing the above-identified functionality, the use of a lead carrier  110  has several drawbacks as well. Specifically, the additional labor and materials associated with molding and inspecting the lead carrier  110  add significant cost to the final product. Furthermore, the connector body (“sleeve”)  100  requires additional costly tooling to accommodate the carrier  110 . After carrier insertion, the distal ends of the leads  120  must also be bent into their final position. This adds another process step and precludes the subsequent removal of the leads  120  and carrier  110  from the connector body  100 . Additionally, the carrier  110  provides no bias or resistance to separating the component package  140  (and carrier  110 ) from the connector body  100 , thereby necessitating the use of adhesives or other means for maintaining a solid connection of these components. 
     Once an existing microelectronic connector has been installed in, for example, a printed circuit board, replacement of the component package  140  requires removal and replacement of the entire connector. Further, one set of leads  150  is typically soldered to the circuit board to provide mechanical stability and a secure electrical connection. Thus, removal of the connector and the attached component package  140  is made difficult. 
     Accordingly, it would be most desirable to provide an improved microelectronic connector design that would yield a simpler and more reliable connector, and further facilitate more economical fabrication. Such a connector design would avoid the use of a separate lead carrier and mating adhesives, thereby simplifying the manufacturing process and reducing device cost. The improved connector would also utilize a simplified and compact mounting system to further reduce manufacturing costs. Additionally, the improved connector would provide for simple replacement of components. 
     SUMMARY OF THE INVENTION 
     The invention satisfies the aforementioned needs by providing an improved microelectronic connector and method of fabricating the same. 
     According to one aspect of the invention, a microelectronic connector assembly comprises an insert having a first cavity which is configured to receive at least one electrical component; a set of leads extending from the insert, the set of leads being configured to provide an electrical connection between the electrical component and a modular plug; and a connector body having a front, a back, and a dividing wall separating the front from the back, the front having a second cavity adapted to receive a modular plug therein, the back having a third cavity for receiving the insert, and the dividing wall having a set of openings providing communication between the second cavity and the third cavity, wherein the set of leads are configured to protrude through the set of openings into the second cavity. 
     According to another aspect of the invention, a method of manufacturing a microelectronic connector comprises providing a connector body with a front having a first cavity adapted to receive modular plugs, a back having a second cavity adapted to receive an insert, and a dividing wall separating the front from the back, the dividing wall having openings for allowing leads to pass between the first cavity and the second cavity; and inserting an insert into the second cavity, the insert having a set of leads and a third cavity, the set of leads passing through the openings into the second cavity, the third cavity being adapted to receive at least one electrical component. 
     According to yet another aspect of the invention, a microelectronic connector assembly comprises an insert, the insert comprising means for receiving at least one electrical component and means for electrically connecting the electrical component with a modular plug; and a connector body, the connector body comprising means for receiving a modular plug in a first location; means for receiving the insert in a second location different from the first location; and means for separating the means for receiving a modular plug and the means for receiving the insert, the separating means including means for passing the electrically connecting means between the means for receiving a modular plug and the means for receiving the insert. 
     According to another aspect of the invention, a microelectronic connector assembly comprises an insert having a first cavity configured to receive at least one electrical component; and a connector body having a front, a back, and a dividing wall separating the front from the back, the front having a second cavity adapted to receive a modular plug therein, the back having a third cavity for receiving the insert, and the dividing wall having a set of openings providing communication between the second cavity and the third cavity. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 a  is an exploded perspective view of a prior art electrical component connector utilizing a lead carrier assembly. 
     FIG. 1 b  is a side elevation view of the prior art connector of FIG. 1 a  with modular plug inserted, showing the relative relationship of the leads, plug contacts, and lead carrier. 
     FIG. 2A is a perspective view of the front portion of one embodiment of a connector body according to the invention. 
     FIG. 2B is a perspective view of the back portion of the connector body shown in FIG.  2 A. 
     FIG. 3 is a cross-sectional side view of the connector body of FIGS. 2A and 2B taken along line  3 — 3  of FIG.  2 A. 
     FIG. 4 is a perspective view of an insert according to the present invention. 
     FIG. 5 is a cross-sectional side view of the insert of FIG. 4 taken along line  5 — 5  of FIG.  4 . 
     FIG. 6 is a perspective view of relative arrangement of the insert shown in FIGS. 4 and 5 and the connector body of FIGS. 2A,  2 B and  3 . 
     FIG. 7 is a cross-sectional view of a microelectronic connector according to another embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference is now made to the drawings wherein like numerals refer to like parts throughout. 
     FIGS. 2A,  2 B and  3  illustrate a first embodiment of a connector body  200  of the invention. Referring initially to FIG. 2A, the connector includes a body  200  which may be formed of a unitary construction. The connector body  200  is ideally formed from a nonconductive material, such as nylon, using an injection molding process of the type well known in the art, although other materials and processes may be substituted. The connector body  200  has a top wall  220  and side walls  230  which extend downward from opposite ends of the top wall  220  in planes that are perpendicular to that of the top wall  220 . A separating wall  240  separates the back  250  of the connector body  200  from its front  210 . The separating wall  240  extends downward from the top wall  220  in a plane that is perpendicular to that of the side walls  230 . The front  210  has a cavity  260  for accommodating a modular plug (not shown) therein. The cavity  260  terminates at the separating wall  240 . The back  250  also has a cavity  280  (not shown in FIG. 2A) terminating at the separating wall  240 . 
     The separating wall  240  is provided with a set of vertical openings  270 . The number of openings  270  in the set corresponds to the number of leads to be provided for contacting a modular plug. The openings  270  in the separating wall  240  begin at the line of intersection of the separating wall  240  with the top wall  220  and extend downwardly from the intersection along the separating wall  240 . The openings  270  allow communication between a cavity  280  in the back  250  of the connector body  200  and the cavity  260  in the front  210  of the connector body  200 . 
     As seen in FIG. 2B, the cavity  280  in the back  250  has side surfaces  282  with latching slots  284  defined along the interior surface thereof. The latching slots  284  extend from the back end of the side surfaces  282  of the cavity  280  inward to a latching point  285  (shown in FIG.  3 ). The latching slots  284  run in a direction that is parallel to the line formed by the intersection of the top wall  220  and a side wall  230 , while the latching point  285  protrudes from the side wall  230  and runs perpendicular to the latching slots  284 . 
     The cavity  280  in the back  250  of the connector body  200  is adapted to receive an insert. FIGS. 4 and 5 illustrate one embodiment of an insert  400 . The insert  400  includes an open cavity  410  for accommodating a magnetics or component package (not shown) to provide any of a variety of functions, such as signal voltage transformation or noise suppression. One or more electrical components may be integral with the component package. 
     It should also be noted that with respect to the invention, the term “electrical component” includes, without limitation, (i) discrete components such as resistors, capacitors, and inductors; (2) magneto-electric devices (such as choke coils and transformers); and (3) semiconductive devices. 
     In the embodiment illustrated in FIGS. 4 and 5, the insert  400  is configured substantially as a rectangular box. Referring to FIG. 4, a back face  420  of the insert  400  defines the outer rim of the cavity  410 . A front face  490  (see FIG. 5) is configured as a rectangular wall and opposes the back face  420 . The front face  490  is in a plane that is substantially parallel to that of the back face  420 . The insert  400  also has a top face  460  and an opposing bottom face  470 , each being perpendicular to the side faces  430  and the back face  420  and extending away from the back face  420 . The insert  400  also comprises a first set  440  and a second set  450  of electrical leads extending from the top face  460  and the bottom face  470 , respectively. 
     Two side faces  430  are connected to the front face  490  and the back face  420  and are in planes that are substantially perpendicular to those of the front face  490  and the back face  420 . Each side face  430  is provided with a protrusion  432  located near the intersection of the side face  430  and the back face  420 . The protrusion  432  extends from the side face  430  near the intersection, tapering to merge with the side face  430  away from the intersection, in a configuration so as to slide into the latching slots  284  (shown in FIG. 2B) and to engage the latching point  285  (shown in FIG. 3) of the connector body  200 . The insert  400  can thus be secured within, for example, the cavity  280  (shown in FIGS. 2A,  2 B and  3 ) in the back  250  of the connector body  200  by interlocking the protrusions  432  of the insert  400  with the corresponding latching point  285  of the connector body  200 . 
     The first set of leads  440 , with a first end  442  and a second end  444 , is adapted to contact a modular plug within, for example, the cavity  260  in the front  210  of the connector body shown in FIGS. 2A and 3. A portion  446  of the first set of leads  440  near the first end  442  is completely embedded within the top face  460  of the insert  400  by, for example, molding the insert body  400  around the leads. The first end  442  of the first set of leads  440  protrudes from the back face  420  along a first edge  422  of the opening to the cavity  410 . Alternatively and preferably, as illustrated in FIGS. 4 and 5, the portion  446  may be partially exposed to an upper wall  412  of the cavity  410 . The first set of leads  440  extends upward from the top face  460  of the insert  400 . At a location along the body of the leads  440 , they are bent at a roughly 90-degree angle, forming a first bend  441 , such that the leads  440  are substantially flush with the top face  460  of the insert  400  and extend in a horizontal direction toward the plane of the front face  490  of the insert  400 . At another location along their body between the second end  444  and the first bend  441 , the leads  440  are bent again at an angle of roughly 150 degrees to form a second bend  443 . 
     The second set of leads  450 , with a first end  452  and a second end  454 , is adapted for providing an electrical connection with, for example, a printed circuit board. In accomplishing this, a portion  456  of the second set of leads  450  near the first end  452  is completely embedded within the bottom face  470  of the insert  400  by, for example, molding the insert body  400  around the leads. The first end  452  of the second set of leads  450  extends from the back face  420  along a second edge  424  of the opening to the cavity  410 . Alternatively and preferably, as illustrated in FIG. 5, the portion  456  may be partially exposed to a lower wall  414  of the cavity  410 . The second set of leads  450  extends downward from the bottom face  470  of the insert  400 . The leads  450  may then be bent in any direction necessary for a connection with, for example, a printed circuit board. 
     FIG. 6 illustrates the insertion of the insert  400  into the connector body  200 . The insert  400  slides into the cavity  280  in the back  250  of the connector body  200 . The shape of the cavity  280  is configured to accommodate the shape of the insert  400 . The protrusions  432  on the side faces  430  of the insert  400  slide into the latching slots  284  on the side surfaces  282  of the cavity  280  in the back  250  of the connector body  200 . The first set of leads  440  of the insert  400  slide through the set of openings  270  (shown in FIG. 2A) into the cavity  260  in the front  210  of the connector body  200 . Thus, the leads  440  are placed in a position to contact a modular plug inserted into the cavity  260  in the front  210 . When the insert  400  is completely inserted into the cavity  280 , the protrusions  432  of the insert  400  engage the latching points  285  (shown in FIG. 3) by interlocking the protrusions  432  with the latching points  285 . The insert  400  is thereby securely attached to the connector body  200 . 
     The cavity  410  of the insert  400  can accommodate electrical components (not shown) therein. The electrical components may be inserted within the cavity  410  either before or after insertion of the insert  400  into the connector body  200 . The electrical components contact the first set of leads  440  and the second set of leads  450  of the insert  400 . The point of this contact may either comprise the first ends  442 ,  452  of the leads  440 ,  450  or the portions  446 ,  456  (shown in FIGS. 4 and 5) of the leads  440 ,  450  partially exposed within the upper wall  412  and the lower wall  414  of the cavity  410 . The electrical components may be secured within the cavity  410  with the use of a nonconductive adhesive or a mechanical latch. An adhesive may provide a secure, permanent connection of the electrical component to the first and second sets of leads  440 ,  450 . A mechanical latch system may allow the electrical components to be readily removed and replaced. 
     The embodiment of the insert  400  shown in FIGS. 4-6 provides a cavity  410  opening to the rear of the assembly when the insert  400  is inserted into the connector body  200 . FIG. 7 illustrates another embodiment of the insert  400  according to the invention in which the cavity  410  of the insert  400  opens forward. In this arrangement, the electrical components (not shown) must be inserted prior to the insertion of the insert  400  into the connector body  200  since access to the cavity  410  is not available after insertion. 
     Once the insert  400  is inserted into the connector body  200  (as shown in FIG. 6 or FIG.  7 ), the insert is easily removable. As discussed above, the insert  400  is securely attached in the connector body  200  when the protrusions  432  are interlocked with the latching points  285 . This interlocking engagement is secure but not permanent. To remove the insert, the protrusions  432  can be depressed inwardly by any flat, small tool, thereby disengaging the protrusions  432  from the latching points  285 . The insert  400  can then be removed from the connector body  200  as inward pressure on the protrusions  432  is maintained until the protrusions  432  clear the latching points  285  and the insert  400  is fully removed from the cavity  280  of the connector body  200 . 
     Thus, the invention provides a reliable microelectronic connector which is provided through simple fabrication and assembly. The connector according to the invention allows simple replacement of electrical components and provides increased modularity of the elements of the connector. 
     While the above detailed description has shown, described, and pointed out novel features of the invention as applied to various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the device illustrated may be made by those skilled in the art without departing from the spirit of the invention.