Abstract:
A simplified modular microelectronic connector having an internal component cavity and integral crimped leads, and a method of manufacturing same. One or more electrical components are located within the cavity, with their conductors being routed to the crimp leads integral to the connector body. The conductor terminations are completed via crimping or other bonding techniques. The crimped leads are deformed into the desired position to minimize connector size, and the component is sealed within the cavity using an epoxy or other electrically non-conductive material. The connector body may be further mounted to a multi-connector carrier assembly, which utilizes one or more pins to secure the individual connectors to the carrier so that they may be arranged in both vertically-stacked and horizontal (“side-by-side”) configurations, and each connector may be removed separately and replaced in the event of component failure.

Description:
RELATED APPLICATIONS 
     This patent application claims priority under 35 U.S.C. Section 119(e) to U.S. provisional patent application entitled, “Modular Microelectronic Connector and Method”, Ser. No. 60/082,467, and filed on Apr. 20, 1998. 
    
    
     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 particularly to an improved microelectronic connector and 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 within the connector body itself These components may provide a variety of electrical or signal conditioning functions, such as noise suppression or signal transformation. Often, the magnetics or electrical component is fabricated as part of a package or separate device and then subsequently mounted on a small circuit board; the circuit board assembly is then mounted within a rear connector body element or “trailer.” As can be seen in FIG. 1, the trailer  100  is received by the front connector body  102 , which also receives the modular plug (not shown). As shown in FIG. 1, a separate lead “carrier”  104  is also commonly used to maintain electrical separation between the leads  106  which mate with the modular plug. The lead carrier  104  is typically molded onto the leads (at a location between the trailer and the distal end of the leads) in a separate process step. See, for example, U.S. Pat. No. 5,587,884 assigned to the Whitaker Corporation, which describes a connector design incorporating both a trailer with circuit board and lead carrier. 
     However, the fabrication of such prior art connector designs typically requires a significant number of processing steps and labor, thereby increasing cost, and further necessitating the allocation of a significant volume within the connector to the component package, circuit board, and trailer. The additional volume within the connector required by these components may dictate the use of a larger connector body than would otherwise be necessary. This is a substantial detriment, since space conservation is a prime consideration with any electrical component, including connectors. Furthermore, the additional components and process steps associated with fabrication of the component package, trailer, and carrier, and any electrical terminals associated therewith may also ultimately affect both the cost and reliability of the connector as a whole. 
     Microelectronic connectors may also suffer from internal component failure or damage during use. In this case, the failed connector often must be entirely replaced. However, typical prior art connectors are often not easily removed from their mounting for replacement. Furthermore, when mounted in multiple configurations (such as in side-by-side groupings), the replacement of one. defective connector often necessitates the replacement of all connectors within the configuration. This produces the unnecessary cost of replacing components which have not failed. Modular connector arrangements have been suggested in the prior art; however, such arrangements do not allow variation of the connector grouping configuration (e.g., either vertically or horizontally) using the same connector and mounting hardware. 
     Accordingly, it would be most desirable to provide an improved low cost and replaceable connector which would 1) reduce the internal connector volume required to house the necessary electrical components; 2) allow for a simpler, more cost effective, and more reliable method of connector fabrication; 3) facilitate replacement without the need for desoldering and/or replacement of other components on the circuit board in the event of connector failure; and 4) permit the user to configure multiple connectors in both an over-under and/or side-by-side arrangement. 
     SUMMARY OF THE INVENTION 
     The present invention satisfies the aforementioned needs by providing an improved, simplified microelectronic connector and method of fabricating the same. 
     In a first aspect of the invention, an improved microelectronic connector is disclosed which utilizes magnetics or other electrical components embedded directly within a cavity in the rear portion of the connector body. The component leads are terminated to exposed leads in the connector body using bendable leadwire crimps which then may be soldered or otherwise bonded if desired. The components and terminated leads are sealed within the cavity using a standard epoxy or other insulating compound, thereby obviating the need for a separate component package and leads and allowing for reduced connector body dimensions. 
     In a second aspect of the invention, an improved microelectronic connector having a modular construction and the previously described embedded electrical component(s) is disclosed. The aforementioned connector body includes one or more apertures therein which receive respective pins mounted on a connector carrier so as to hold the connector body to the carrier. A transverse land and groove arrangement is also included within the upper and lower mating surfaces of the connector body. The carrier is then fixed to a circuit board or other structure. In this fashion, one or more connector bodies may be attached to the carrier in vertical and/or horizontal arrangement, and any single connector may be removed or replaced as desired. 
     In a third aspect of the invention, an improved method is disclosed for fabricating a microelectronic connector having embedded internal components. The connector body with cavity is formed using injection molding or other conventional techniques. The electrical components are placed within the cavity and component leads are routed and terminated to the appropriate connector leads using a mechanical crimp. The crimped leads are then bent into place within the cavity, and the cavity is filled with a liquid epoxy or other suitable compound which insulates the component and leads and prevents further movement thereof. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is cross-sectional view of a prior art electrical component connector utilizing a circuit board and trailer arrangement. 
     FIG. 2 is a front perspective view of a first embodiment of the connector of the present invention. 
     FIG. 3 is a rear perspective view of the connector of FIG.  2 . 
     FIG.  3   a  is a detail view of the crimp leads of the connector of FIG.  3 . 
     FIG.  3   b  is a detail view of a second embodiment of the crimp leads of the present invention. 
     FIG. 4 is a cross-sectional view taken along line  4 — 4  of FIG. 3 illustrating the internal arrangement of components within the connector. 
     FIG. 5 is a perspective view of a second embodiment of the connector of the present invention, having the electrical component and cavity located in the top portion of the connector body. 
     FIG. 6 is a perspective view of a multiple modular connector assembly mounted on a first embodiment of the connector carrier of the present invention. 
     FIG. 7 is a detail perspective view of the connector carrier of FIG.  6 . 
     FIG.  7   a  is a detail view of a second embodiment of the connector carrier of the present invention. 
     FIG. 8 is a perspective assembly drawing of a third embodiment of the connector carrier of the present invention, showing two connectors mounted vertically thereon. 
     FIG. 9 is a process flow diagram illustrating one embodiment of a method of manufacturing the microelectronic connector of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference is now made to the drawings wherein like numerals refer to like parts throughout. 
     FIGS. 2 and 3 show a first embodiment of the microelectronic connector  21  of the present invention (front and rear, respectively). A connector body  10  having a modular plug recess  11 , an electrical component cavity  12 , two sets of lead passages  17   a ,  17   b , and a plurality of mounting element apertures  13  disposed therein is formed using any one of a number of conventional methods, ideally injection molding. The outer surfaces of the connector body  10  of the illustrated embodiment are generally rectangular in shape, although other shapes may be used. The body  10  may be comprised of any non-conductive material such as RTP, polyethylene, fluoropolymer, or similar. In this embodiment, the modular plug recess  11  is disposed in the front portion  15  of the connector body  10 , while the electrical component cavity  12  is disposed in the rear portion  14 , although it can be appreciated that other cavity locations may be used for these purposes (see discussion of FIG. 5 below). 
     As shown in FIG. 3, first and second sets of crimp leads  16   a , 16   b  are positioned within the body  10  generally adjacent to the cavity  12  and on opposed edges thereof These crimp leads  16   a , 16   b  are fabricated from any electrically conductive and ductile material such as metal or metal alloys. The first set of crimp leads  16   a  act as extensions of the modular plug contact leads  23  (shown in FIG. 4) which provide an electrical path between the electrical contacts on the modular plug (not shown) and the electrical component(s)  28 . The second set of crimp leads  16   b  are connected to the external connection leads  25  and provide an electrical pathway between the electrical component(s)  28 , the external leads  25 , and any external device connected thereto such as a printed circuit board shown in FIG.  4 . In this embodiment, each of the first crimp leads  16   a  and their respective modular plug contact leads  23  comprise a unitary, continuous assembly, as do the second crimp leads  16   b  and their respective external connection leads  25 . These continuous leads are routed through respective passages  17   a , 17   b  or alternatively grooves (not shown) formed in the connector body  10  leading to the rear cavity  12 . In this manner, a series of continuous leads can simply be inserted or molded into the passages  17   a , 17   b  or into grooves of the connector body during connector fabrication and can subsequently be bent or deformed to the desired shape. It can be appreciated, however, that any number of different arrangements for connecting and routing the crimp leads  16   a ,  16   b  to the contact leads  23  and external leads  25  may be used. 
     As illustrated in FIG. 3, the electrical component  28 , in this case a magnetic choke coil, is disposed within the cavity  12  and the conductors  26  thereof are routed to the connector crimp leads  16   a ,  16   b . It will be understood that with respect to the present invention, the term “electrical component” includes but is not limited to resistors, capacitors, inductors, choke coils, transformers, and semiconductive devices. As shown in FIG.  3   a , these crimp leads may have two (or more) flutes  20  located at their distal ends  22  which form a “V” shaped structure into which the component conductors  26  are received. The flutes  20  are ductile such that when a closing or crimping force is applied to the outer surfaces of the flutes, both flutes  20  deform and crimp the conductor  26  enclosed there between, holding the conductor in place. 
     FIG.  3   b  shows a second embodiment of the crimp lead arrangement of the present invention. In this second embodiment, a separate crimp element  70  is placed over the distal end  22  of the crimp leads and conductors  26  and is subsequently crimped to from a mechanical bond. The crimp elements  70  are generally cylindrical in shape and hollow, and are fabricated from a ductile material such that they are easily deformed under crimping force, yet maintain a strong mechanical bond. The distal ends  22  of the crimp leads  16   a ,  16   b  in this embodiment are also generally cylindrical in shape yet not hollow, and do not include the flutes  20  as in the prior embodiment described above. It will also be recognized that other shapes and configurations may be used for the crimp elements  70 , such as partial cylinders (semicircular cross-section) or staples. 
     In addition to or as an alternative to crimp bonding, the conductors  26  of the electrical component may be soldered or otherwise bonded to the crimp leads  16   a ,  16   b . For example, the crimped conductor may be subsequently fluxed and soldered using any number of soldering techniques well known in the electrical arts. Alternatively, a crimp lead having a “U” shaped distal end may be used, wherein the conductors  26  are laid within the “U” and subsequently fluxed and soldered without crimping. As yet another alternative, the conductors can be heated with laser energy or other means to effectively weld or fuse the conductors to the crimp leads  16   a ,  16   b.    
     After the conductors  26  are crimped and/or bonded to their respective crimp leads  16   a ,  16   b , the crimp leads and conductors are bent or folded downward so as to extend into the cavity  12 . Ideally, the bend is 90 degrees or greater so that the ends of the crimp leads  16   a ,  16   b  are below the plane of the rear face of the connector body. Prior to bending, the relative extension of the crimp leads  16   a ,  16   b  beyond the edges of the cavity  12  allows the comparatively ductile leads to be easily folded into the cavity after the component conductors  26  are bonded thereto. Specifically, the edges  37  of the connector body  10  to which the crimp leads are adjacent act as fulcrums to permit the adjacent region  39  of the leads to bend. Alternatively, the crimp leads  16   a ,  16   b  may be tapered or thinned in the adjacent region  39  near the connector body  10  such that they preferentially bend in this region. 
     The electrical component  28 , crimp leads  16   a ,  16   b , and conductors  26  are ultimately encapsulated within the cavity  12  using an epoxy  30 , although other such insulating compounds may used based on the properties desired. The epoxy is ideally pour-filled into the cavity  12  so as to immerse the electrical component(s) and crimp leads entirely and fill the cavity  12 . The epoxy is then allowed to dry to form a hard, permanent structure. 
     Note that by using the above-described construction, the space necessary to accommodate the component(s)  28  is reduced as compared to the prior art, since no other leads, parts or packages are required. Hence, the overall size of the connector may be smaller or, alternatively, more components can be fit within a given connector size. It is further anticipated that individual smaller cavities or recesses may be used in place of the single large cavity  12  described above, thereby providing electrical separation between individual electrical components  28  and minimizing the amount of epoxy necessary to fill the connector body  10 . 
     Note also that the above-described construction substantially reduces the number of process steps necessary to fabricate the finished connector; specifically, those steps associated with fabricating a separate component package and the connector body leads associated therewith, or a trailer, are obviated in the present invention. 
     FIG. 4 shows a cross-sectional view of the connector of FIGS. 2 and 3 mounted on a printed circuit board, illustrating the relationship and placement of the internal components of the connector and the external modular plug  31 . The use of continuous modular plug contact leads  23  and external connection leads  25  which terminate in the first and second crimp leads  16   a ,  16   b , respectively, is clearly shown. 
     FIG. 5 shows a second embodiment of the microelectronic connector of the present invention. In this embodiment, the cavity  12  is located adjacent to and communicating with the top surface  34  of the connector body  10 , and grooves  32  are formed within the top surface  34  and rear surface  36  of the body  10  to allow for the passage of component leads  25  to the connector crimp leads  16   b.    
     Referring now to FIG. 6, two connectors  21  of the type illustrated in FIGS. 2 through 4 are shown mated to a first embodiment of a connector carrier  40 . The carrier  40  (shown in detail in FIG.  7 ), is comprised of a base element  42  having one or more mounting elements  44  substantially normal thereto. The carrier  40  is ideally formed from an injection molded polymer, although other materials may be used. In the present embodiment, the mounting elements  44  are cylindrically shaped pins, although other arrangements may be employed. The pins  44  of the carrier  42  are spaced so as to fit within the corresponding apertures  13  of each connector body  10 , while the base element  42  fits substantially within a lateral recess  46  of each body  10 . The mating pins may be of any cross-sectional shape as desired such as square to prevent connector body rotation when using a single pin. In a second embodiment, the mating elements may also be of split design with retaining clips  43  as illustrated in FIG.  7   a  to prevent unwanted separation of the connector  21  from the carrier  40 . 
     Alternatively, a third embodiment of the carrier having longer mating pins  44  may be used to permit vertical stacking of the connector bodies  10  as shown in FIG.  8 . The elongated pins  44  protrude through the apertures  13  to a height sufficient to allow mating of the pins  44  with apertures  15  in successive connector bodies. In this embodiment, the pins  44  are made severable at discrete locations corresponding to the installed height of n connectors, where n is an integer greater than or equal to 1. Note that while no theoretical maximum number of connectors which may be vertically stacked exists, most microelectronic applications would use no more than two or three vertical rows of connectors. The pins may be made severable using any number of techniques well known in the mechanical arts, including circumferential scoring in the desired region(s) (shown in FIG.  8 ), or a localized reduction in pin thickness. Alternatively, the pins  44  can be made in snap-together longitudinal segments. 
     Note also that the connector body of FIG. 8 employs a top land  50  which mates with the transverse recess  46  of the connector body stacked above it, thereby providing additional mechanical stability and strength, Such an arrangement may also be used on the side surfaces of the connectors illustrated in FIG. 6 if desired to provide further stability. 
     The carrier(s) of FIGS. 7 through 8 are attached to an external device (such as a printed circuit board, not shown) using any number of attachment means including, without limitation, snap pins and holes, or adhesives. Alternatively, the carrier may be formed directly within or as part of the external device. The selected method of attachment must have sufficient rigidity so as to allow the addition and/or removal of individual connector bodies to the connector carrier  40  without separating the carrier  40  from the external device. 
     It should further be noted that various connector configurations may be used in conjunction with the pin/aperture arrangement described above. See, for example, Applicant&#39;s co-pending patent application entitled “Two-Piece Microelectronic Connector and Method,”, Ser. No. 09/169,842, filed Oct. 9, 1998, incorporated herein by reference in its entirety, which describes one microelectronic connector configuration compatible with the present invention. 
     Method of Manufacturing 
     Referring now to FIG. 9, one embodiment of a method of manufacturing the improved microelectronic connector of the present invention is disclosed. 
     FIG. 9 is a process flow diagram generally illustrating the method or process of manufacturing. As shown in FIG. 9, the process  200  of the present invention begins with a first process step  202  of forming a connector body  10  having a modular plug recess  11 , cavity  12 , and passages  17   a ,  17   b  as previously described. The connector body is formed using injection molding techniques well known in the polymer arts, although it will be recognized that other molding or formation techniques may be employed. Injection molding is chosen in part, however, for its ease of use and substantial economies. 
     In the second process step  204 , the modular plug contact leads  23  and external connection leads  25  are prepared and inserted into their respective passages  17   a ,  17   b  in the connector body. In the embodiment of FIGS.  2 - 4 , the plug contact leads are inserted into their passages  17   a  from the rear of the connector and subsequently bent within the modular plug recess to the desired shape, thereby retaining the leads  23  in position relative to the connector body. The external connection leads  25  are similarly inserted into their respective passages  17   b  and formed to the desired shape (projecting in a direction normal to the bottom surface of the connector body in the embodiment of FIGS.  2 - 4 ). Note that the external connection leads may alternatively be formed into their final shape prior to formation of the connector body, and then positioned within the injection mold and effectively molded into place. 
     Next, an electrical component  28  (such as the choke coil shown in FIG.  10   a , discussed below) is prepared in a third process step  206 . This component preparation may include, for example, the formation of a toroidal core and subsequent winding of the core with electrical conductors  26 . 
     In a fourth process step  208 , the electrical component  28  fabricated in the third process step  206  is placed within the cavity  12 . In the fifth process step  210 , the conductors  26  of the component  28  are routed (either manually or by machine) to the appropriate crimp leads  16   a , 16   b  of the connector. A crimping machine (not shown) or other device is then used in the sixth process step  212  to 1) crimp the flutes  20  of the crimp leads  16   a ,  16   b  around the component conductors  26  so as to form a friction fit; and 2) sever the portions  54  of the component conductors  26  which extend beyond the end of the crimp leads  16   a ,  16   b . If desired, the crimped leads  16   a ,  16   b  may be solder-dipped or otherwise bonded for additional strength and reliability, or optionally, solder or other bonding may be used as the exclusive method of attachment. 
     As shown in FIG. 9, the seventh process step  214  includes bending the crimp leads  16   a ,  16   b  into place substantially into the cavity  12 . As previously noted, the edges of the connector body passages  17   a ,  17   b  or grooves act as fulcrums to permit the leads to be bent in the region  39  immediately adjacent to the connector body so that the profile of the connector as a whole is minimized. 
     Finally, in the eighth process step  216 , the cavity  12  is pour-filled with epoxy  30  or other compound to seal the electrical component(s) in place. Note that while pour-filling is described, other methods of epoxy/compound placement and curing (or insert molding) may be used with equal success. 
     It will be recognized that while the aforementioned process steps are performed in a sequential fashion, the order of performance of certain of these steps may be permuted, or certain steps performed in parallel with other steps. For example, the formation of the connector body  10  and the electrical component  28  can be accomplished in parallel in order to increase production throughput. Also, it may be desirable to bond the conductors  26  of the component  28  to the crimp leads  16   a ,  16   b  prior to inserting the component into the cavity  12  of the connector body  10 . A substantial number of such variations are possible, and considered to be within the scope of the present invention. 
     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 or process illustrated may be made by those skilled in the art without departing from the spirit of the invention.