Abstract:
A power module of an electrical connector is provided which has a dielectric housing and a pair of blade terminals. The housing has a forward face and a support arm projecting forwardly from the face. The support arm has opposing first and second sides. The housing has a cavity. The face has a pair of slots extending therethrough which are in communication with the cavity and which are provided adjacent the sides of the support arm. Each of the blade terminals has a body portion and a blade portion. The body portions are housed in the cavity and the blade portions extend through the slots and are positioned alongside the sides of the support arm. The electrical connector may also have a signal module interconnected to the power module. The electrical connector may also be configured to mate with another electrical connector as part of a connector assembly.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 61/845,419, filed Jul. 12, 2013 which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to field of connectors, more specifically the field of connectors suitable for providing power. 
       DESCRIPTION OF RELATED ART 
       [0003]    Generally, an electrical connector includes some form of insulative or dielectric housing which mounts one or more conductive terminals. The housing is configured for mating with a complementary mating connector or other connecting device which, itself, has one or more conductive terminals. A connector assembly typically includes a pair of mating connectors, such as plug and receptacle connectors sometimes called male and female connectors of which, corresponding terminals of the connectors, themselves, may be male and female terminals. 
         [0004]    Existing computer systems tend to have a power supply positioned in one location and various components that use the provided power in other locations. This allows for desirable thermal management and further allows for the positioning of processors in the preferred location. One issue that results from such a configuration, however, is that the supplied power must be delivered to the various consumption devices. For certain devices this is not an issue. However, for other power consumption devices (such as CPU or other devices that change power states rapidly) the distance creates certain issues. 
         [0005]    One issue that is commonly present is the issue of inductance between the power supply and the power consumption device. As is known, current flowing along a path will generate a magnetic field that will act to resist the flow of current. Many modern power consumption devices switch power usage at relatively high frequencies (e.g., up to and beyond 1 MHz). The rapid switching of power causes the voltage being delivered to sag, which can be problematic to the consumption device, depending on the sensitivity of such a device to variations in the provided power. Thus, for certain applications it has been determined that such voltage sag is unacceptable and therefore capacitors are provided adjacent the power consumption device so as to ensure a constant voltage is supplied. Certain individuals would appreciate being able to reduce or eliminate the use of capacitors 
       BRIEF SUMMARY 
       [0006]    The present disclosure generally relates to combined electrical power and signal connectors that can be integrated into a connector system and that can provide desirable operation under high current density conditions. In general, connectors are suitable for use as modular components within modular assemblies. For example, modular assemblies can take, for example, the form of wire-to-board or wire-to-wire connectors and can, when desired, provide a low-profile connector system. 
         [0007]    A connector assembly may be provided that includes a plug connector and a receptacle connector. The connector assembly includes one or more blade-type power contacts on the plug connector and multiple-pronged power contacts on the receptacle connector. The plug connector includes signal pin contacts mounted within a shrouded area of the connector. The receptacle connector may include a signal module that is slidably mateable with the receptacle connector. A power contact includes a pair of blade portions forming the mating portion of the power contact with an intermediate insulator spaced between each conductive blade portions. Thus, the connector allows power and signals to be coupled together with a single connector assembly. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The present invention is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which: 
           [0009]      FIG. 1  is a perspective view of an electrical blade connector; 
           [0010]      FIG. 2  is an unmated perspective view of the blade connector of  FIG. 1 ; 
           [0011]      FIG. 3  is an exploded view of the blade connector of  FIGS. 1 and 2 ; 
           [0012]      FIG. 4  is a perspective view of a power module of the electrical blade connector; 
           [0013]      FIG. 5  is a perspective view of a power module of the electrical blade connector  FIG. 5  looking from the rear of the module; 
           [0014]      FIG. 6  is an exploded view of a plug module and receptacle module of the electrical blade connector; 
           [0015]      FIG. 7  is an exploded view of an alternative embodiment of a plug module and receptacle module of the electrical blade connector; 
           [0016]      FIG. 8  is a perspective view of the plug power module of  FIG. 7 ; 
           [0017]      FIG. 9  is a partially explode view of the power module of  FIG. 7  looking from the rear of the module; 
           [0018]      FIG. 10  is a partially explode view of the power module of  FIG. 7 ; 
           [0019]      FIG. 11  is a front view of the power module of  FIG. 7 ; and 
           [0020]      FIG. 12  is a perspective view of the receptacle power module of  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The detailed description that follows describes exemplary embodiments and is not intended to be limited to the expressly disclosed combination(s). Therefore, unless otherwise noted, features disclosed herein may be combined together to form additional combinations that were not otherwise shown for purposes of brevity. 
         [0022]      FIGS. 1 and 2  illustrate an embodiment of the present invention and it is to be understood that the disclosed embodiment is merely exemplary, which may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art. 
         [0023]    One or more embodiments of the present disclosure utilizes multiple both signal and power circuits in a connector system that provide proper alignment, mechanical connection and electrical connection, while providing a low profile connection. If desired the configuration can be modified to provide board-to-board, wire-to-board and wire-to-wire connection. 
         [0024]      FIGS. 1-3  illustrate an embodiment of a board-to-board connector assembly  10  including a first connector  20  and a second mating connector  80  with each connector  20 ,  80  including a plurality of modules. The connector system  10  is configured to include a first connector  20  having a plurality of individual modules including both signal  14  and power types  24  and a second connector  80  having a plurality of cooperating mating modules including signal  82  and power types  84 . Typically, individual modules  12 ,  24  are aligned in a linear array with an interlocking structure to secure the modules  12 ,  24  together in a side by side arrangement. This interlocking arrangement can include and is not limited to a dovetail type interlock (not shown). 
         [0025]    A typical signal module  14  generally is comprised of a series of over-molded wafers  16  having a number of signal circuits held within a shroud or holding assembly  18 . The wafers  16  are retained in the holding assembly  18  generally by a snap fit and an optional stiffener, which in turn is secured to an adjacent module of either signal  14  or power type  24 . 
         [0026]    As best shown in  FIG. 4-6  a power module  24  includes a housing  26  and a power contact  27 , the power contact having a series of individual power or blade terminals  28 ,  28 ′ received therein. In the embodiment shown, each power blade terminal  28 ,  28 ′ includes a body portion  30  and a blade portion  36  that is sized according to the current carrying capabilities of the circuit requirements, for instance, circuits requiring a higher current will include power blade terminals or contacts  28 ,  28 ′ having a substantially large blade portion  36  providing a greater area surface area allowing for the transmission of greater current. In this embodiment, as shown in  FIG. 4  the module  24  includes adjacent pairs of blade terminals  28 ,  28 ′ supported on each respective support arm  42  and each pair of terminals  28 ,  28 ′ having front edge surfaces that are aligned with each other. Additionally, the front edge surface of the first pair of terminals is spaced apart from the front edge of the second pair of terminals along a mating direction. 
         [0027]    As illustrated in  FIGS. 6-8  the power module  24  includes a housing  26  that receives the power contact  27  therein, the housing have a main body portion  40  and a support arm  42  having a first side  44  and a second side  46  extending in a first direction D corresponding to the mating face  8  of the connector assembly  10 . The support arm  42  is positioned in a vertical or upward direction and spaced in a lateral direction along the connector  20  width. 
         [0028]    In  FIGS. 7-8 , the embodiment shown includes a power module  24  having a power contact  27  and a single pair of blade terminals  28 ,  28 ′ arranged in a back to back relationship, with the blade terminals  28 ,  28 ′ positioned on either side of the support arm  42  alternatively, a module  24  or connector  20  is contemplated that may include a plurality of terminal power contacts  27  also arranged in a back to back relationship and spaced laterally along the length of the connector  20  in a spaced apart orientation. In this case, each module  24  or connector  20  will include an equal number of vertically formed support arms  32  corresponding to the total number of power contacts  27 . 
         [0029]    As best shown in  FIG. 5-8 , each power terminal  28 ,  28 ′ includes a main body portion  30  and a blade portion  36  extending from the body portion  30 . Terminal mounting pins  34  are formed from another end or edge of the body portion  30 . As best shown in  FIG. 7 , a series of tails project from an adjacent edge of the body portion  30 , in this arrangement a right angle is formed between the blade portion  36  and the terminal tails  34  forming a right angle type configuration. In an alternative arrangement, the terminal tails  34  may extend from an apposite end of the body portion  30  from which the blade portions  36  are formed, this case is considered a vertical type configuration (not shown). 
         [0030]      FIGS. 7 and 9  show a locking tab  38  that is formed on a top edge of the body portion  30  for engaging a wall of the housing  26  upon assembly. The locking tab  50  has a tip portion  52  that digs into or skives into the housing  26  upon insertion and is angled in the direction of insertion such that it will resist removal when attempted to be withdrawn from the housing  26 . A locating tab  54  having an edge  56  is formed from a side surface of the body portion and engages a shoulder  58  in the housing  26  to properly position the terminal  28 ,  28 ′ within the housing  26 . 
         [0031]    As best shown in  FIGS. 7-10  the module  24  is assembled with a pair of power blade contacts  28 ,  28 ′ arranged in a back-to-back relationship with each respective main body portion  30 ,  30 ′ retained in an insulative housing  26 . In this case, each blade portion  36  has an interior surface  37  and an exterior surface  39 , with the interior surfaces  37  of the pair of blade terminals  28 ,  28 , facing each other and the exterior surfaces  39  of the pair of blade terminals  28 ,  28 ′ facing away from each other. Upon insertion of each terminal  28  the blade portion  36  of each terminal  28  is inserted into the cavity  60  from the rear of the module housing  26  with the blade portion  36  protruding through an opening  62  and extending to the mating end of the module  24  with the locating tab  54  aligned with the shoulder  58  formed in the housing  26  to position each terminal  28 ,  28 ′ in the cavity  60 . Each body portion  30 ,  30 ′ of the power contact  28 ,  28 ′ is fitted into the insulative module housing  26  with the locking tab  50  digging into or skiving in the side wall of the housing  26  and securing each terminal  28 ,  28 ′ in the housing  26 , alternatively the power contacts  28 ,  28 ′ may also be molded within the insulative housing  26 . 
         [0032]    Each power module  24  has an interlocking structure (not shown) formed on each side of the housing  26  for being secured to an appropriate adjacent power module  24  or signal module  14 . The interlocking structure typically utilizes a dove tail structure with appropriate male and female portions of the dovetail (not shown) on respective sides of each module  14 ,  24 . As can be appreciated, other structures such as a “T” shape or any other suitable interlocking shape may be substituted. 
         [0033]    In the embodiment shown in  FIGS. 7-10  the power module  24  of the embodiment has a power contact  27  that is split apart and formed with an insulator placed between two individual power terminals  28 ,  28 ′. The module  24  includes a housing  26  with support arm  42  extending from the main body portion  30  of the module housing  26  and towards the mating face of the connector  20  in a direction D. A variation in the support arm is shown in  FIGS. 7-8  and includes a channel  70  disposed on each of the side walls or faces  44 ,  46  of the support arm  42  and extending along the support arm  42 . Each channel  70  is defined having a bottom surface  72  and opposing side walls  74 . Each respective blade portion  36  of the corresponding terminal  28  is disposed in the channel  70  with only the outside or exterior surface  39  of the blade portion  36  being exposed. That is, the interior side surface  37  of the blade portion  36  abut the bottom surface  72  of the channel  70  and each of the side surfaces or edges of the blade portions  36  being adjacent a respective side wall  74  in the channel  70 . Similarly, these power terminals can be either press fitted or molded into the insulative module or brick. 
         [0034]    In certain instances, it is desirable to have different current carrying loads for individual circuits in certain power applications. For instance, one application may require high current and thus require a power terminal with a large blade portion. Of course, with increased current loads the power terminals will exhibit a temperature increase. The surface area also aids in the dissipation of this heat, consequently each blade portion of certain power terminals can be formed with a different surface area and in the embodiment shown, the lengths of the individual power contact blade portions have different lengths. In another embodiment, the blade portions lengths can be the same for each power contact but the lengths of adjacent power contacts are different. By the use of different lengths and the insulative barrier, the thermal characteristics and electrical characteristics can be tuned accordingly. 
         [0035]    A similar arrangement is shown for the receptacle module  84 . As illustrated in  FIGS. 3 and 7  a pair of receptacle terminals  86  is positioned and secured in an insulative housing  96  for mating with the power contacts  28  of the plug module  24 . Each receptacle terminal  96  has a plurality of spring fingers or contacts  98  with a contacting portion  99  that slideably engage the blade portions  36  of the power contacts  28  of the plug module  24 . In an alternative embodiment, shown in  FIG. 6  an insulative spacer  87  is positioned between the individual receptacle terminals  86  of the receptacle module  84  and similarly providing the ability to modify or tune the electrical characteristics of the receptacle module  84  and the connector assembly  10 . 
         [0036]    The receptacle also includes a passageway  85  that extends through the housing  96  allowing for airflow through the receptacle module  84  as well. In this instance as best shown in  FIG. 12 , the passageway  85  is formed between the receptacle terminals  86  so that upon mating of the plug  24  and receptacle  84  a continuous passageway is created through both the plug  24  and receptacle  84  across the mating interface of the blade terminal  28  and the receptacle terminal  86  to allow direct cooling of the connector system  10 . 
         [0037]    As shown in  FIGS. 11-12  the housing  26  of the power module  24  includes a passageway  25  formed thorough the housing  26  and adjacent each side of the support arm  42 . Upon assembly of the terminals  28 ,  28 ′ the passageway  25  provides a non-restricted area allowing air to flow past the each blade terminal  28 ,  28 ′ to aid in the cooling of the power terminals. The receptacle also includes a passageway  85  that extends through the housing  96  allowing for airflow through the receptacle module  84  as well. In this instance as best shown in  FIG. 12 , the passageway  85  is formed between the receptacle terminals  86  so that upon mating of the plug  24  and receptacle  84  a continuous passageway is created through both the plug  24  and receptacle  84  across the mating interface of the blade terminal  28  and the receptacle terminal  86  to allow direct cooling of the connector system  10   
         [0038]    As can be appreciated, the placement of two blades close to each other has a beneficial impact on the electrical performance of the connector. As noted above, a current flowing along a path will generate a magnetic field that resists the flow of current. If current is flowing in the opposite direction in close proximity then the two magnetic fields can cancel out and the loop inductance and resultant impedance will be reduced. The depicted embodiments thus allow for a connector that provides for desirable electrical performance while still providing good electrical isolation between positive and negative terminals. In addition, in certain embodiments the blades can be kept in close proximity substantially the entire length of the blades, thus providing a desirable improvement in impedance such that the system can reduce voltage lag. Consequentially, in a system the number of local capacitors that would normally be used to protect against voltage sag can be reduced. 
         [0039]    As shown in  FIG. 2  the end configurations of each connector assembly  20 ,  80  include a separate module or end cap  4 ,  6  that is used to provide an alignment structure to guide the connector system  10  together to prevent stubbing between respective mating modules  24 ,  84  and individual electrical terminal contacts  28 ,  86  therein. The guiding element typically is constructed of a post  5  and receiving hole  3  both of which having tapered ends to provide a lead in upon connector mating. Various keying features and may also be included to insure that mis-matching of the connectors does not occur. This arrangement allows for any number of signal and power configurations in a low profile form factor. 
         [0040]    It should be noted that in general, while plug connectors and receptacle receptors have been described as having certain features, the depiction of whether a connector is a plug or receptacle type in the figures is done merely for illustrative purposes. Therefore, it is envisioned that a particular connector could be configured to be a plug or a receptacle type or a combination of plug and receptacle, as desired. For example, a connector could include a power contact that is a plug type or a receptacle type and also include a signal contact that is a plug type or a receptacle type. Therefore, unless otherwise noted, the determination of whether a contact is a receptacle or plug is not intended to be limiting. 
         [0041]    The disclosure provided herein describes features in terms of preferred and exemplary embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure.