Abstract:
A surface mount connector includes one or two spaced conductive contacts. Each conductive contact(s) include a substantially flat base portion suitable for soldering to a pad or land on a printed circuit board (PCB), At least one vertical finger extends substantially normally from each flat base portion and each terminates in a point or hook formed with a piercing tip at the free end thereof remote from the that base portion. The vertical finger(s) and flat base portion(s) define a space for receiving an insulated conductor arranged in a plane substantially parallel to the plane of the flat base portion(s). The finger(s) are directed inwardly at their free end(s) proximate to the piercing tip(s) and configured to deflect inwardly in a curling action when forced downwardly and crimped to pierce an associated insulated conductor positioned on the flat base portion(s).

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention generally relates to surface mount connectors and, more specifically, to a surface mount connector for securing a zipcord to a printed circuit board and method of making electrical contact with zipcord conductors. 
     2. Description of the Prior Art 
     Manufactures want to be able to use zipcord and attach the same to a printed circuit board (PCB), zipcords being inexpensive cables of two insulated wires bonded together along their length. To make a functional surface mount zipcord connector several technical problems need to be solved. The connector needs to be capable of piercing the insulation and make good connection with both internal wires or conductors while causing damage to a minimum number of wire strands. The connector also needs to provide strain relieve to hold the wire securely. Additionally, the connector needs to be capable of being mounted on a PCB easily and crimped in one action. Preferably, such connectors do not require preparation of the zipcord prior to termination. 
     U.S. Pat. No. 2,680,235 is for an “Electrical Connector” for terminating a conductor and includes opposing ears that form barbs that are suitable for piercing the insulation and making contact with a central conductor. However, this patent teaches a connector for a single conductor, not a zipcord and there is no suggestion that the electrical connector can or should be surface mounted. 
     U.S. Pat. No. 6,461,188 to Reul is for a “Solderable Electrical Connection Element with a Solder Deposit”. The patent teaches attachment of conducting track or metal conductors by means of a soldered joint that can be made using a solder deposit. 
     An “Insulation Displacement Connector (IDC)” is disclosed in U.S. Pat. Nos. 7,833,045 and 7,955,116 to Bishop. These patents are designed to connect one or more insulated wires to a component such as a printed circuit board. However, the receptacle for each of the wires is separated by a surface 22 that would prevent its use with a standard zipcord without first splitting the cord into two individual conductors. These patents disclose a plurality of generally standard IDC connectors arranged in tandem to receive as few or as many individual conductors. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide a surface mount connector for securing a zipcord that does not possess the disadvantages inherent in prior art connectors. 
     It is another object of the present invention to provide a surface mount zipcord connector that is simple in construction and economical to manufacture. 
     It still another object of the present invention to provide a surface mount zipcord connector that can be easily and efficiently surface mounted by a pick-and-place machine. 
     It is yet another object of the present invention to provide a surface mount zipcord connector as in the previous objects that maintains the individual conductors for each of the zipcord wires at predetermined desired spacings from each other suitable for surface mounting on fixed lands or pads on a PCB. 
     It is a further object of the present invention to provide a surface mount zipcord connector of the type under discussion that can be placed on a PCB easily in one action. 
     It is still another object of the present invention to provide a surface mount zipcord connector as in the previous objects that does not require pretreatment for the wires. 
     It is yet a further object of the present invention to provide a surface mount zipcord connector that allows the wires of the zipcord to continue beyond the connector for further termination in parallel on the same circuit board. 
     It is an additional object of the present invention to provide a surface mount zipcord connector as in the previous objects that provides good electrical and mechanical contact with the wires of the zipcord with minimal damage to the wires strands within the conductors. 
     It is also an additional object of the present invention to provide a surface mount zipcord connector as in the previous object that provides good strain relief to hold the wires securely. 
     It is yet an additional object to provide a simple and convenient method of closing a surface mount zipcord connector as in the previous objects to make electrical contact with one or both conductors of the zipcord. 
     In order to achieve the above and other objects a surface mount zipcord connector in accordance with the invention includes a pair of conductors spaced from each other at predetermined distance. Each conductor comprises a substantially flat base portion suitable for soldering to a pad or land on a printed circuit board (PCB). Each conductor is provided with at least one but preferably with plurality of spaced vertical fingers extending substantially normal from the base portion and each terminating in a piercing tip. Non-conductive means such as nonconductive tips is provided for maintaining the spaced base portions of the conductors at a set predetermined distance. The conductors define a space for receiving a zipcord or a pair connected insulated conductors arranged in a plane substantially parallel to the plane of the base portions. The fingers are directed inwardly at the upper ends proximate to the tips at the free ends and configured to deflect inwardly in a curling action when forced downwardly to pierce the associated zipcord wires. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Those skilled in the art will appreciate the improvements and advantages that derive from the present invention upon reading the following detailed description, claims, and drawings, in which: 
         FIG. 1  is a top plan view of a printed circuit board on which there are mounted two surface mount zipcord connectors in accordance with the invention, one prior to receiving a zipcord and the other with a zipcord securely mounted after the fingers of the zipcord have been deformed and have pierced associated wires of the zipcord; 
         FIG. 2 . is a transverse cross section through the surface mount zipcord connector with a zipcord arranged therein prior to deformation of the piercing fingers; 
         FIG. 3  is similar to  FIG. 2  but shown after the piercing fingers have been inwardly deflected to pierce the insulation and conductors in associated zipcord wires; 
         FIG. 4  is a top plan view of a surface mount zipcord connector in accordance with the invention prior to surface mounting; 
         FIG. 5  is a longitudinal cross sectional view of the connector shown in  FIG. 4 , taken along the line  5 - 5 ; 
         FIG. 6  is a transverse cross sectional view of the connector shown in  FIG. 4 , taken along the line  6 - 6 ; 
         FIG. 7  is a top plan view of a pair of lands or pads of the type that can be formed on a printed circuit board for being attached to the surface mount zipcord connector; 
         FIG. 8  is an embodiment of the invention in which a strip of surface mount zipcord connectors are formed adjacent ones of which are connected to each other by means of connecting tabs; 
         FIG. 9  is a side elevational view of the tab-connected connector shown in  FIG. 8 ; 
         FIG. 10  is a transverse section of the tab-attached connectors shown in  FIG. 9  as taken along line  10 - 10 ; 
         FIG. 11  is a fragmented side elevational view of the fingers forming the connector shown in  FIG. 10  as taken along direction A; 
         FIG. 12  is a side elevational view of a reel for dispensing tab-attached connectors of the type shown in  FIGS. 8 and 9 ; 
         FIG. 13  illustrates another method of dispensing the surface mount zipcord connectors by storing the connectors in pockets on a tape of the type commonly used with pick-and-place machines; 
         FIG. 14  is a side elevational view of the tape and pockets shown in  FIG. 13 ; 
         FIG. 15  is a plan view of a modified zipcord connector for contacting one wire of a zipcord or other single insulated wire or conductor housed in a pocket on a tape; 
         FIG. 16  is a cross-sectional view of the connector taken along line  16 - 16  in  FIG. 15 ; 
         FIG. 17  is an end elevational view of a tool for crimping the prongs of the zipcord to make electrical contact with conductors or stands within the zipcord; 
         FIG. 18  is a transverse cross-sectional view of an SMT connector in accordance with the invention shown after the piercing prongs have been crimped and deflected inwardly to mechanically secure the zipcord and make electrical contact with the conductors or strands therein; 
         FIG. 19  is similar to  FIG. 17  but shows a modified tool for crimping and deflecting one single row of prongs for engaging a single wire; 
         FIG. 20  is an enlarged detail of region A in  FIG. 19 ; 
         FIG. 21  is similar to  FIG. 18  but shows a single row of prongs partially crimped and deflected by the tool of  FIG. 19 ; and 
         FIG. 22  is similar to  FIG. 21  showing a successive stage of crimping and deflecting the prongs by further action of the tool of  FIG. 19 . 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENT 
     Referring now specifically to the Figures, in which identical or similar parts are designated by the same reference numerals throughout, and first referring to  FIG. 1 , a printed circuit board (PCB)  10  is illustrated bearing two surface mount zipcord connectors in accordance with the present invention. The first connector  12  is shown in its open condition, prior to receiving a zipcord and a similar second connector  12 ′ is shown with a zipcord  14  received therein for providing good mechanical as well as electrical connection with the conductive strands within the zipcord, as it will be more fully described. 
     The zipcord  14  is generally a relatively inexpensive cable formed of two insulated conductors  14   a ,  14   b  with their insulations bonded together at a thin frangible, rupture or parting line  14   c  to facilitate, when desired, the separation of the two conductors  14   a ,  14   b  from each other by severing or rupturing the zipcord along the relatively weak parting or separation line  14   c.    
     Referring to  FIGS. 2-6 , each zipcord connector  12  is dimensioned and configured to be surface mounted on a pair of lands or solder pads  16 . The solder pads are formed of two generally rectangular lands or pads  16   a ,  16   b  ( FIG. 7 ) that are made of copper and are formed on a PCB in a conventional manner. As shown in  FIGS. 2 and 3 , the connector  12  is surface mounted on the lands or pads  16   a ,  16   b  by means of solder  18  that may be applied in any conventional way such as reflow soldering. 
     Referring to  FIG. 2 , each connector  12  is formed of a pair of legs  20 ,  22  that are spaced from each other a predetermined distance to accommodate the width of the zipcord and to register with the pads or lands  16 . The legs  20 ,  22  include bottom horizontal base portions  20   a ,  22   a , vertical fingers  20   b ,  22   b  and upper piercing points or hooks  20   c ,  22   c , respectively. The legs  20 ,  22  are similarly shaped but oriented to be mirror reflections of each other, as shown. 
     In order to maintain the desired spacing between the legs  20 ,  22  a non-conductive tape  24  is applied to the upper surfaces of the bottom horizontal base portions  20   a ,  22   a , as shown. The tape may be any suitable tape. In the present preferred embodiment, the tape  24  is a polyamide tape such as Kapton® tape. 
     Referring to  FIGS. 2 ,  3  and  4 - 6 , the legs  20 ,  22  are positioned to create a space therebetween sufficient to receive a zipcord  14  in which the individual insulated conductors  14   a ,  14   b  are arranged in a plane that is substantially parallel to the bottom base portions  20   a ,  22   a  and, therefore, substantially parallel to the PCB  10 . The height  42  ( FIG. 6 ) of the connector is selected to position the upper piercing tips or hooks  20   c ,  22   c  above the zipcord  14  when the latter is placed into contact with the tape  24  as shown in  FIGS. 2 and 3 . In this manner, when a suitably configured crimping tool applies a pressure P on each of the legs  20   b ,  22   b , the upper piercing points or hooks  20   c ,  22   c  are bent inwardly and forced to pierce the insulation, in a curling action, and enter the space with the internal wire strands  26  to make electrical contact therewith while the fingers provide secure mechanical contact with the external insulation  14   a ,  14   b.    
     Referring to  FIGS. 4-7 , the spacing  30  between the rectangular pads or lands  16   a ,  16   b  can be 0.045″ and the width  32  of the pad footprint is approximately 0.245″. The length of the pad footprint  34  is approximately 0.33″. To accommodate lengths with the aforementioned dimensions, the length  36  of the zipcord connector  12  approximately equals the dimension  34  as approximately 0.32″ at the extreme ends, while the effective length of the connector  36 ′ of the connector is approximately 0.3″. The width  38  of the connector is approximately equal to the dimension  32  as approximately 0.234″. Spacing or gap  40  between the individual contact fingers is approximately equal to the dimension  38  and equal to approximately 0.055″. The height  42  of the contacts is approximately 0.247″. 
     In order to facilitate the suggested curling action, the upper piercing points or hooks  20   c ,  22   c  may be provided with V-shaped coins, bends or fold lines  20   d  ( FIG. 5 ). 
     Since the zipcord connector  12  is intended to be used as a surface mount (SMT) connector it is preferably made in a form in which a plurality of such connectors may be continuously fed to a pick up station of a pick-and-place machine. In this connection the tape  24  forms a good upper surface for a vacuum nozzle (not shown) of a pick-and-place machine. Also, while the upper piercing points or hooks are inwardly directed, as shown, the minimum spacing  38 ′ between them is 0.144″ in the illustrated embodiment, selected to assure adequate space for a vacuum nozzle to penetrate into the space for contact with the tape  24 . 
     Referring to  FIG. 11 , the upper piercing points or hooks are shown to be provided with a plurality of V-shaped coins  48  that are parallel to each other as shown and spaced from each other a distance  52  that may typically be 0.023″. The actual piercing tips  50  of the points or hooks have a height  54  of approximately 0.038″. 
     In  FIG. 12 , a strip of connectors  58  is shown coiled about a reel  56  suitable for use of a pick-and-place machine. Referring to  FIGS. 8 and 9 , adjacent connectors  12  may be connected to each other by intermediate tabs T that have a width to ensure that the tabs are sufficiently flexible to allow the strip  58  to be wound about a reel. A feeding machine can be used to feed successive connectors  12  to a pick up station by severing the endmost connector from the next successive connector at a severance line  46 . 
     The zipcord connectors may also be fed to a pick up station by means of continuous tape  60  formed with or carrying pockets  62  each for securely receiving one connector as shown in  FIGS. 13 and 14 . The tape  60  may be formed of a carbon polystyrene or other suitable material. Only one edge  64  of the tape  60  is provided a series of spaced holes  66  as shown that are 0.16″ apart and have a diameter of approximately 0.06″. These spaced holes are used to register and accurately maintain the position of individual pockets as they enter the pick-and-place machine in a manner or well known in the art. The individual pockets are initially covered with a suitable removable tape  68  that can be removed prior to pick up and may be a Kapton® tape. The tape can also be any known heat sealed or pressure sensitive tape. The spacing between individual pockets is not critical but in the example shown the spacing  70  is approximately 0.47″. 
     Referring to  FIGS. 15 and 16 , there is shown an alternative version of the SMT connector  12 ,  12 ′ designated by the reference numeral  12 ″. The connector  12 ″ is essentially one half of the connector  12 , cut along a vertical cutting plane normal to the plane defined by the base portions  20   a ,  22   a . The connector  12 ″ can be used in the same way to mechanically and electrically connect to a single insulated wire instead of a double side-by-side wires forming a zipcord. The modified connector  12 ″ is shown within a carrier similar to one shown in  FIGS. 13 and 14  in which a continuous carrier tape  60  is provided with registration holes  66  and pockets  62  that are open at the top in the plane of the carrier tape  60  but covered by a removable tape  68 . As indicated, this removable tape may be heat sealed or pressure sensitive tape that can be suitably removed from the carrier tape to expose the upper window access opening  70  and to allow a vacuum nozzle of a pick-and-place machine to enter into the pocket  62  for engaging the connector  12 ″ and placing it onto a printed circuit board. This single wire modified SMT connector  12 ″ will be more fully discussed in connection with  FIGS. 19-22 . 
     Referring to  FIG. 17 , a tool for crimping the fingers  22  of the connectors  12  is illustrated and designated by the reference numeral  72 . The tool  72  may be made of any suitable hard and durable material, such as stainless steel, and arranged to be supported by a press (not shown) that selectively moves it from an upper position in which it does not engage the connector to a bottom-most position in which it is lowered sufficiently to fully crimp the fingers  22  so that they pierce the insulation and engage or make electrical contact with the internal conductors or strands as shown in  FIG. 3 . The block  74  is formed, along a lower base surface S, with a cavity  76  having a width w 1  that substantially corresponds to the width  38  of an SMT connector  12  as shown in  FIG. 6 . Preferably, the width w 1  is somewhat greater than the width  38  of the connector to allow the connector to be received within the cavity  76  with some clearance. The cavity  76  has two spaced substantially upright surfaces  78   a ,  78   b  that respectively merge into cylindrical surfaces  88   a ,  88   b  as shown in  FIG. 17 . The cylindrical surfaces have a radius R 1 . A rounded surface is provided at the point where the lower base surface S and the vertical walls  78   a ,  78   b  merge, as shown, each resulting round having a radius R 2 . A bearing surface  84 , at a height h 2  above the base surface S, is substantially parallel to the lower surface S extends between the two cylindrical surfaces  80   a ,  80   b  as shown, such that the bearing surface  84  is spaced a distance δ that is equal to the difference between the upper most height h 1  of the cavity  76  the height h 2  of the bearing surface  84 . The height h 1  is selected to ensure that the fingers  22  can be properly crimped and forced inwardly and downwardly to make contact with the inner conductors and still able to receive the SMT connector as well as the zipcord therein. The bearing surface  84  is positioned at a height h 2  to contain the conductors and insulation that might otherwise be forced upwardly and outwardly between the opposing sets of fingers. In the example illustrated, the radius R 1  is equal to 0.042″, the radius R 2  is equal to 0.015″, the height h 1  is equal to 0.102″ while the height h 2  is equal to 0.086″. This produces a δ of 0.016″ or δ is equal to approximately 16% of the overall height h 1  of the cavity  76 . Preferably δ is selected to be within a range of 10-25% of the maximum height of the cavity h 1 . In  FIG. 18 , an enlarged cross-sectional view is shown of an SMT crimp piercing connector  12 ′ after it has been crimped and deformed by the tool  72  while maintaining the insulation as well as most of the conductors in contact with the fingers by limiting their movements and preventing them from being forced upwardly between the fingers. 
     Referring to  FIGS. 19 and 20 , a modified tool  82  is shown for crimping the modified single-row of fingers of the SMT connectors  12 ″ shown in  FIGS. 15 and 16 . Here, similarly, the base lower surface S is provided with a cavity  86  that has different profile than one shown in  FIG. 17  in order to specifically crimp the connectors  12 ″. The detail A in  FIG. 19  is shown in  FIG. 20 . The upright wall  88  ( FIG. 20 ) is provided with a tapered surface  96  having a height  96   a  and width  96   b  to define angle θ greater than 90°. In the example shown,  96   a  is 0.01″,  96   b  is 0.003″ to provide an angle θ of 105°. This angle is not critical and other angles may be used to lead the fingers into the cavity  86  with different degrees of advantage. As with shown in  FIG. 17 , the upright surface  88  in  FIG. 20  merges with a cylindrical surface  90  and terminates in a horizontal bearing surface  92  that is parallel to the base surface S. A lateral surface  94  can be used to contain the materials including the modified connector  12 ″ and the single conductor that is captured within it when being crimped. The specific angle β of the lateral surface  94  in relation to the base surface S is not critical. In the example shown, the maximum height h 1  of the cavity  86  is 0.048″ while the width of the cavity up to the point where the surfaces  92  and  94  meet is equal to 0.06″.  FIGS. 21 and 22  show two successive time points and crimping conditions when crimping the modified connector  12 ″ 
     With the construction shown and described, the zipcord connector  12  provides surface mounting with opposing spaced fingers, each set of which is suitable for piercing of an associated connector of a zipcord to make both good mechanical connection with wire and the individual conductor strength inside the insulation while damaging a minimum number of wire strands. The connector  12  provides reliable strength relief to hold the wire securely. A connector  12  can be easily placed on a PCB with one action with no pre-treatment of the wire. The top down curling action provides good strength relief and makes good connection to the strand despite the inconsistent strand positioning within the wire. This curling is assisted by the V-shaped score lines on the row(s) or fingers. This zipcord connector in accordance with the invention also provides electrical insulation between the individual spaced fingers while maintaining this spacing at substantially constant and predictable dimensions to prevent the fingers from floating apart or coming together to make crimping inconsistent. This has been realized in a practical way by using Kapton® tape on the bottom of the part that effectively makes the spaced individual conductive fingers one integrated piece that maintains the desired spacing precisely between the fingers, as well as maintain the outer walls parallel to each other while electrically insulating the two sets of fingers from each other. 
     The advantages of the zipcord in accordance with the invention allows the rapid and secure termination of a zipcord to a circuit board using surface mount features. It is quicker and more efficient than a process that requires separation of the wires and does not require any preparation of the individual wires prior to termination. The invention also allows the same zipcord wire to continue beyond the connector for further parallel terminations on the same or other PCB&#39;s. 
     The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.