Abstract:
A connector-transport assembly for holding and transporting a electronic component includes a socket connector having a receptacle sized to receive the component therein and a transport carrier member. The socket receptacle includes two engagement arms formed therewith which are deflectable between first and second operative positions. In the first operative position, the engagement arms extend into the receptacle for contacting opposing exterior surfaces of the component, and in the second position the engagement arms are deflected away from the receptacle so as to not engage exterior surfaces of the component. The engagement arms have cam portions disposed thereon, and the carrier member includes actuating members disposed thereon in opposition to the socket connector engagement arm cam portions so that movement of either the socket connector or the carrier member will move the engagement arms between their first and second operative positions to release or engage the electronic component.

Description:
REFERENCES TO RELATED APPLICATIONS  
       [0001]    This application claims priority from prior U.S. provisional patent application No. 60/383,567, filed May 28, 2003. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    This invention relates to generally electrical connectors, and more particularly, to a connector packaging assembly and method for the mounting of an electrical component on a connector and transportation of the connector and mounted component.  
           [0003]    Connectors are used for a number of applications, In one such application that occurs commonly in the computer area, a computer chip or similar electronic component is placed into a socket connector and then transported to an assembly location where the socket and chip are installed upon a circuit board. The socket connector may have a receptacle area for receiving the chip therein and also may incorporate resilient beam members for securing the chip, or component to the connector. When the component is placed into the socket, it may contact with the connector beam members, causing them to deflect and allowing the component to be seated into the connector receptacle area. After the component is fully seated, the beam members return to their undeflected states, thereby securing the component to the connector. The connector beam members in such a connector are used to align the chip and hol dit in place in the socket connector.  
           [0004]    One problem with these type mechanisms is that moving contact between the component and the connector during the mounting operation may cause the component to abrade the connector housing material, creating unwanted debris which may interfere with electrical contact between the component and the connector, or which may interfere with later manufacturing processes. It has been found difficult to formulate a connector housing material which will both satisfy the rigid dimensional requirements imposed by connector miniaturization and resist the abrasion encountered during mounting of electrical components. Another, ongoing problem is damage to connector terminals during shipping and handling.  
           [0005]    Typically, the chip or component is placed into the socket connector either manually or robotically. In either instance, the beam members must be deflected outwardly so that the chip may enter and seat within the socket and then they return back into contact with the exterior surfaces of the chip to hold it in place. It is desirable to do this process in an automated manner with a mechanism that actuates the beam members into and out of engagement with the chip edges, and which is incorporated in a structure that also provides a protective transport assembly for the chip and its socket connector.  
           [0006]    The present invention is directed to such an assembly which overcomes the aforementioned disadvantages.  
         SUMMARY OF THE INVENTION  
         [0007]    Accordingly, it is a general object of the present invention to provide a socket connector for receiving a chip therein which has a chip-securing means integrated into its structure and which is operate by automated means.  
           [0008]    Another object of the present invention is to provide a connector-carrier assembly for receiving an electronic component within a connector and for holding the connector in place upon a transport carrier, the transport carrier having actuating means formed therewith for actuating one or more component engagement members formed with the connector, such that movement of the connector upon the transport carrier, actuates the component engagement members to engage or disengage the component.  
           [0009]    A further object of the present invention is to provide a connector-transport assembly for holding and transporting a electronic component, the assembly including a socket connector having a receptacle sized to receive a component therein, the receptacle including at least two engagement arms that are formed therewith and which are deflectable between first and second operative positions, wherein in the first operative positions, the engagement arms extend into the receptacle for contacting opposing exterior surfaces of the component and in the second position, the engagement arms are deflected away from the receptacle so as to not engage exterior surfaces of the component, the engagement arms having cam portions disposed thereon, and a carrier member that supports the socket connector in a transport orientation thereon, the carrier member having actuating members that are disposed thereon in opposition to the socket connector engagement arm cams so that movement of either the socket connector or the carrier member will move the engagement arms between their first and second operative positions.  
           [0010]    Yet another object of the present and as exemplified by another embodiment thereof is to provide a socket-style connector having a receptacle for receiving an electronic component therein, the receptacle having a plurality of terminal-receiving passages, each of which receives a conductive terminal therein, the terminals being held in place within their cavities by a elastomeric substance such as a silicone rubber, the bottom surface of the socket connector defining a surface for dispensing the elastomeric substance during assembly, the dispensing surface being separated from the rest of the connector by way of a channel that extends around the dispensing surface and separates it from sidewalls of the connector, the dispensing surface having a hard edge where it meets the channel, the edge forming a barrier to liquid elastomers disposed onto the dispensing surface.  
           [0011]    These objects are performed by means of the structure of the present invention. In one aspect of the present invention, a conventional socket connector that has a plurality of engagement arms formed therewith has is modified to include openings adjacent the engagement arms. The engagement arms have cam surfaces provided on them that extend through the openings of the socket connector. In another aspect, the socket connector is modified to include a number of positioning surfaces in the receptacle portion thereof, against which the electronic component abuts.  
           [0012]    In still another aspect of the present invention, a liquid dam is provided along the bottom surface of the connector by forming a hard, unbroken edge that is spaced apart from the sides of the socket connector. The bottom surface of the connector may be considered as a dispensing surface, upon which a liquid sealant is dispensed during assembly of the connector. This continuous edge contains liquid sealants, such as silicone that may be dispensed onto the bottom surface of the connector for sealing the conductive contacts of the socket connector in place in contact-receiving passages of the connector. Surface tension keeps the liquid from moving past the edge of the connector into other parts of the connector.  
           [0013]    In yet another aspect of the present invention, a carrier member is provided to support the socket connector and actuating members are formed in the surfaces thereof which oppose the cam surfaces formed on the socket connector engagement arms. When either the socket connector or the carrier member are moved relative to each other, the cam surfaces of the engagement arms contact the actuating members of the carrier member and they are preferably drawn into an open position where they are deflected away from the socket connector receptacle, thereby opening the socket connector receptacle for insertion of an electronic component therein. Relaxation of the movement results in the cam surfaces being separated from their associated actuating members and the engagement arms will typically deflect back into the receptacle, thereby gripping the edges of any component resident in the socket connector receptacle. The engagement arms hold the component in place on the carrier member, and the connector-carrier member assembly may be used to transport the component without damage.  
           [0014]    The socket may be constructed with a reaction surface that an assembler may press to move the socket connector upon the carrier member. In an alternative embodiment, a hinge member may be formed as part of the carrier member that serves as the reaction surface against which an assembler pushes. Pushing on either reaction surface moves the socket connector on the carrier member and causes the engagement arms to engage the actuating members of the carrier members to thereby cam the engagement arms outwardly to open up the socket receptacle for insertion of an electronic component into its receptacle These and other objects, features and advantages of the present invention will be clearly understood through a consideration of the following detailed description. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    In the course of this detailed description, the reference will be frequently made to the attached drawings in which:  
         [0016]    [0016]FIG. 1 is a perspective view of one embodiment of a connector and a packaging carrier constructed in accordance with the principles of the present invention;  
         [0017]    [0017]FIG. 1A is a perspective view of a known socket connector;  
         [0018]    [0018]FIG. 2 is a perspective view showing the connector mounted to the packaging carrier of FIG. 1;  
         [0019]    [0019]FIG. 3 is a perspective view of the connector shown in FIG. 1 showing the connector mounting face (bottom) of the connector;  
         [0020]    [0020]FIG. 4 is a top view of the connector mounted to the packaging carrier as seen in FIG. 2 , showing the connector beam members in an undeflected state;  
         [0021]    [0021]FIG. 5 is a cross-sectional view of the connector of FIG. 1 showing the configuration of the terminals mounted in their terminal-receiving cavities;  
         [0022]    [0022]FIG. 6 is a perspective view of an electronic component configured for mounting in the connector of FIG. 1;  
         [0023]    [0023]FIG. 7 is a cross-sectional view showing the retention stub and engagement surface of the second beam member;  
         [0024]    [0024]FIG. 8 is a cross-sectional view showing the retention stub and engagement surface of the first beam member;  
         [0025]    [0025]FIG. 9 is a cross-sectional view showing the retention stub and engagement surface of the third beam member;  
         [0026]    [0026]FIG. 10 is the top view of FIG. 4 showing the connector beam members in a deflected state;  
         [0027]    [0027]FIG. 11A is a perspective view of the packaging assembly of FIG. 2 showing the directions and points of application of forces applied to the assembly to deflect the connector beam members;  
         [0028]    [0028]FIG. 11B is a perspective view of the packaging assembly of FIG. 2 showing the electronic component fully seated in the connector;  
         [0029]    [0029]FIG. 12 is a perspective view showing removal of the connector from the packaging plate after the latch members have been disengaged: and,  
         [0030]    [0030]FIG. 13 is a top plan view of an alternate embodiment of socket connector and carrier member assembly constructed in accordance with the principles of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0031]    Referring first to FIGS. 1 and 2, a connector packaging assembly  18  is seen to include a packaging plate, or carrier  66 , and an electrical connector  20 , that takes the form of a socket connector. The connector  20  has a generally rectangular dielectric housing  22  (although other configurations may be used) and a plurality of conductive terminals  24  mounted in the housing  22 . The housing  22  comprises a base portion  25  with a plurality of walls projecting upwardly from base portion  25 . The base portion  25  includes a component mounting surface  26 , a connector mounting surface  28  and an array of terminal receiving cavities  30  formed in the base portion  25  which extend between the component mounting surface  26  and connector mounting surface  28 . A first end wall  32 , a second end wall  34  and a pair of opposed side walls  36 ,  38  project from base portion  25 , generally circumscribing component mounting surface  26  to define a receptacle  40  for receiving an electrical component therein. As shown in FIG. 3, a pair of recesses  44  are formed between first end wall  32  and base portion  25 . An additional recess  46  is formed between side wall  36  and base portion  25 .  
         [0032]    [0032]FIG. 1A illustrates a conventional socket connector  20 ′ that is used to hold an electronic component such as a chip. The socket  20 ′ has a housing  22 ′ with a base  25 ′ and an interior receptacle  40 ′ formed by the cooperation of a plurality of raised walls  32 ,  34 ,  36 ,  38 . A series of cavities  30 ′ are formed in the housing  22 ′ and each such cavity receives a conductive terminal therein. In order to hold the electronic component in the receptacle  40 ′, the connector  20 ′ is provided with a plurality of engagement arms  48 ′,  50 ′,  52 ′ that are disposed along two distinct (and adjacent) interior walls  300 ′ of the receptacle  40 ′. These engagement arms take to form of cantilevered beam members which are fixed at one end thereof and which are free at the other end  302 ′ thereto so that the overall engagement arms are deflectable structures. The engagement arms may be provided with enlarged end portion  304 ′ that extend toward the receptacle  40 ′ and which will abuttingly engage an opposing surface of the component when it is placed in the receptacle  40 ′.  
         [0033]    Returning to FIG. 1 which shows a connector  40  that has been modified to incorporate the principles of the present invention, a plurality of openings  200 ,  204  have been made in the base  25  of the housing  22 , and specifically in the base portion  25  of the receptacle. The first openings  200  are disposed adjacent to a series of standoffs  205  that are shown formed as part of wall  34 , but which are also preferably disposed on adjacent wall  38 . These openings permit inspection of the seating of the component or chip within the receptacle by automated and visual means. The second openings  204  are disposed in the base portion  25  adjacent to the engagement arms  48 ,  50 ,  52  and portions of the engagement arms may extend into the openings  204  as shown with the bottom of engagement arm  52 . The purpose of these openings shall be come more apparent in the explanation which follows.  
         [0034]    In FIG. 1, the engagement arms of the socket connector  20  are illustrated as cantilevered beam members  48 ,  50  and  52 . First and second beam members  48 ,  50  are shown projecting from first end wall  32  along openings  204  intermediate base portion  25  and first end wall  32 . Also, a third beam member  52  projects from an adjacent side wall  36  along a corresponding opening  204  intermediate base portion  25  and side wall  36 . (FIG. 3.) In the described embodiment, the engagement arm beam members  48 ,  50  and  52  each have a cantilevered structure. Th engagement arm beam members  48 ,  50  and  52  may alternatively be supported at two ends with a retention stub, as described, below positioned intermediate the supported ends.  
         [0035]    As seen in FIGS. 4 and 7- 9 , the engagement arm beam members  48 ,  50  and  52  have enlarged ends, or contact stubs  54 ,  130  and  132 , respectively, projecting from free ends of the engagement arms. These enlarged ends  48 ,  50  and  52  have first sloped sides  56 ,  124  and  126 , respectively, sloping toward component mounting surface  26  and second sides  58 ,  128 ,  130  opposite the first sides, with each second side defining a clearance shoulder that clears the actuating members  88 ,  90 ,  92  formed as part of the carrier member. These shoulders, in effect, define notches that contain internal cam surfaces  60 ,  110 ,  112 , which oppose the actuating members  88 ,  90 ,  92  of the carrier member  66  when the socket connector is in place on the carrier member  66 . As seen best in FIG. 3, a pair of guide posts  62  extend downwardly from the connector mounting surface  28  for insertion into a corresponding pair of elongated guide post cavities  94  formed in the carrier member  66 , in a manner to be described later.  
         [0036]    Referring now to FIGS. 2 and 5, an electrically conductive terminal  24  is mounted in each of the terminal-receiving cavity  210 . The terminals  24  may have any configuration suitable for insertion and securement into the terminal receiving cavities and the terminals may be secured within the cavities using any suitable method. In the present embodiment, the terminals  24  are of an LGA-type, meaning that they are configured so that contact portions  152  of the terminals  24  extend above the component mounting surface  26  and that base portions  150  extend below the connector mounting surface  28  of the connector  20  to contact respective contact pads of an electronic device, such as a circuit board  215 . The terminals  24  are positioned within receiving cavities  30  and encapsulated therein by application of a suitable medium that has insulative properties and adhesive properties to hold and retain the terminals  24  in place within their corresponding cavities  210 .  
         [0037]    A conventional such medium that is used in these type applications is a liquid silicone rubber, which is poured onto the connector  20  and which flows into the portions of the cavities  210  that are between the terminals  24  and the surrounding connector housing and then is permitted to cure to hold the terminals  24  in place in the connector  20 . In order to facilitate the application of this liquid medium and to prevent it from going astray during the application process, as illustrated best in FIG. 3, the connector base portion  25  and its surrounding walls are preferably integrally formed as a single piece. A moat, or recess,  217  is provided along the perimeter of the bottom mounting surface  28  which extends completely around the base portion  25  of the connector and which serves to space the base portion  25  apart from the various sidewalls  32 , 34 ,  36 ,  38 . In so doing, the base portion  25  is provided with a hard perimeter edge  219  (“hard” meaning a right angle or its equivalent and excluding rounded and sloped surfaces) that forms a virtual dam which substantially prevents the migration of the silicone (or other liquid) into the moat by way of surface tension and the like. The liquid silicone is usually poured onto the bottom surface and it flows along the surface until it comes into contact with the hard edge where its surface tension prevents the liquid from falling over the edge into the moat.  
         [0038]    Referring to FIGS. 1 and 5, a cavity  180  is formed in packaging plate  66  which extends below plate connector mounting surface  76 . When connector  20  is mounted on packaging plate  66 , terminal base portions  150  reside within cavity  180 . Cavity  180  has a depth extending below connector mounting surface  76  sufficient to ensure clearance between terminal base portions  150  and the cavity bottom such that terminals base portions  150  will not come into contact with the cavity bottom when connector housing  22  abuts plate connector mounting surface  76 .  
         [0039]    Referring to FIG. 1, it cam be seen that the packaging carrier  66  has a first (rear) end  68 , a second (front) end  70 , a pair of opposed ends  72 ,  74  and a connector carrying surface  76 . A latch member  78  is located along each of opposed sides  72 ,  74  for securing the connector  20  to the carrier plate  66  in a manner to be described in more detail later. Each latch member  78  has a body  80  and an actuating tab  82  projecting from the body  80 . The latch member body  80  includes lead-in portions  84  and a retention ledge  86 .  
         [0040]    Cam blocks or actuating members  88 ,  90 ,  92  are provided as part of the carrier plate  66  and project upwardly therefrom from pre-defined locations on the connector support surface  76  thereof. Cam blocks  88 ,  90 ,  92  are configured to engage corresponding engagement surfaces  60 ,  110 ,  112  that are formed on the engagement arm beam members  48 ,  50 ,  52 , respectively, in a manner to be described later. The two actuating members  88  and  90  are shown as upright posts or the like, while the other actuating member  92  is shown in the form of a longitudinal rail with an actuating head  192  formed at one end thereof. These actuating members fit within the notches defined in the large ends of the engagement arms as explained above. A pair of elongated guide post cavities  94  are formed in the carrier plate support surface and are configured to receive corresponding guide posts  62  that are formed with and extend down from the connector housing  22  in a clearance fit therein. The elongated configuration of the cavities  94  permits movement of guide posts  62  therein along the reciprocal directions indicated by the arrow “A”.  
         [0041]    The carrier plate  66  may further include one or more walls  100 ,  101  extending from the 4 plate connector support surface  76 . The shapes of the carrier plate walls  100 ,  101  substantially correspond to the shapes of outer portions of respective connector side walls  36 ,  38  such that packaging plate walls  100 ,  101  aid in guiding the movement of the socket connector  20  in the direction “A” along the plate connector support surface  76 , in the manner described below.  
         [0042]    The method of securing connector  20  to the carrier plate  66  will now be described. As shown in FIG. 1, the socket connector  20  is first spaced apart from the support face  76  and is oriented with respect to therewith such that connector housing second end wall  34  is opposed to the support plate first end  68 . With the connector  20  in this orientation, the guide posts  62  are positioned opposite, and within guide post cavities  94 .  
         [0043]    From this position, the connector  20  is then urged toward the carrier plate support surface  76 . As connector  20  approaches the carrier plate  66 , the connector side walls  36 ,  38  abut the lead-in portions  84  of the latch members  78 , forcing the latch member bodies  80  to resiliently deflect away from the connector  20 . Also, as the connector  20  approaches the carrier plate  66 , the guide posts  62  are received within guide post cavities  94  in packaging plate  66 .  
         [0044]    Connector side walls  36 ,  38  maintain latch member bodies  80  in a deflected state until the connector  20  abuts the carrier plate support surface  76 . When the connector  20  reaches a point where it abuts plate connector mounting surface  76 , the latch member bodies  80  automatically return to their undeflected state wherein the latch member retention ledges  86  slide over the connector side walls  36 ,  38  such that they are positioned between the plate support surface  76  and the latch member retention ledges  86 , thereby securing connector  20  to packaging plate.  
         [0045]    The connector storage assembly is designed such that, when connector  20  abuts packaging plate  66 , the connector  20  is permitted a limited amount of travel along the carrier plate connector mounting surface  76  in the directions indicted by arrow “A”. When the connector  20  abuts plate connector mounting surface  76 , the connector resides between latch member bodies  80  and the carrier plate walls  100 ,  101 , which cooperatively define a longitudinal channel in which the connector  20  can be moved . The latch bodies  80 , carrier plate walls  100 ,  101  and the movement of guide posts  62  within guide post cavities  94  act to substantially restrict movement of connector  20  to the directions indicated by arrow “A”. Also, as shown in FIGS. 1 and 7- 9 , when connector  20  abuts plate connector mounting surface  76 , third beam member engagement surface  112  is positioned opposite packaging plate engagement block  92  and first and second beam member engagement surfaces  60  and  110  are positioned opposite packaging plate engagement blocks  88  and  90 .  
         [0046]    The method of securing electrical component  42  to connector  20  will now be described. Electrical component  42  may comprise, for example, an integrated circuit device. Referring to FIG. 6, electrical component  42  includes a retention flange  160  for engagement by retention shoulders  58 ,  128 ,  130  of beam members  48 ,  50  and  52 .  
         [0047]    After connector  20  is secured to packaging plate  66 , packaging plate  66  may be used to aid in mounting electrical component  42  to connector  20 . First, electrical component  42  is laid within receptacle  40  as shown in FIG. 11 A. Sloped surfaces  56 ,  124 ,  126  of retention stubs  54 ,  120 ,  122  aid in positioning electrical component  42  within receptacle  40  prior to fully seating the electrical component within the receptacle. Pressure is then applied to packaging plate first end  68  and connector housing first end wall  32  in the directions indicated by arrows “D” and “E”. This pressure forces connector  20  to move relative to packaging plate  66  in the direction indicated by arrow “E”. Movement of connector  20  along plate connector mounting surface  76  is guided by the latch bodies  80 , packaging plate walls  100 , guide posts  62  and guide post cavities  94  as described above.  
         [0048]    Referring to FIGS. 10 and 1 A, as connector  20  moves along plate connector mounting surface  76  in direction “E”, the actuating members or cam blocks  88 ,  90  engage the first and second engagement arm surfaces  60 ,  110  causing the first and second beam members to resiliently deflect in the direction indicated by arrows “G”. Simultaneously, the actuating member  92 , especially its engagement head  192  engages the third engagement arm surface  112  in a camming action, causing it to resiliently deflect in the direction indicated by arrow “H”. Deflection of the engagement arms moves them out of contact with the inner perimeter of the receptacle and so “opens” the receptacle to permit an electrical component  42  to drop into, and fully seat into, receptacle  40 . This enables contact pads on electrical component  42  to come into contact with corresponding contact portions  152  of terminals  24  mounted in connector  20 .  
         [0049]    When electrical component  42  is fully seated in receptacle  40 , the pressure applied on packaging plate first end  68  and connector housing first end wall  32  is released. When this pressure is released, the outwardly deflected engagement arms  48 ,  50  and  52  return to their undeflected state. As they return to their undeflected state, the forces exerted by the beam member engagement surfaces on packaging plate engagement blocks  88 ,  90 ,  92  cause connector  20  to move in direction “D”. As the engagement arms  48 ,  50  and  52  reach their undeflected states, they contact the sides  160  of the component  42 .  
         [0050]    Referring to FIGS. 2 and 12, to release the socket connector  20  from abutment with packaging plate  66 , latch member actuation tabs  82  are pressed in the direction indicated by arrows “J”, causing latch bodies  80  to deflect away from connector side walls  36 ,  38  until side walls  36 ,  38  are no longer positioned between latch member retention ledges  86  and plate connector mounting face  76 . Connector  20  with electrical component  42  still mounted thereto may then be grasped and lifted from plate connector mounting face  76 , as seen in FIG. 12.  
         [0051]    [0051]FIG. 13 illustrates another embodiment  400  of the invention that includes a carrier member  401  and a corresponding socket connector  402  with a receptacle formed therein for receiving an electronic component (not shown) therein. The socket connector  402  has two sets (shown as pairs) of engagement arms  404 ,  405  that are disposed on two adjacent sides, preferably on sidewalls, of the socket receptacle  403 . These engagement arms  404 ,  405  are spaced apart from each other and have openings  406  associated with them which are formed in the base of the socket receptacle so that cam portions of the engagement arms  404 ,  405  may depend downwardly into contact with opposing actuating members  420 ,  421  in the manner shown and described above.  
         [0052]    Whereas the prior embodiments utilized a reaction surface  1040  (FIG. 2) formed as part of the socket connector for an assembler to push against and cause the socket connector to move toward the endwall of the carrier member and to cause actuating movement to occur between the socket connector and the carrier member, this embodiment  400  utilizes a reaction surface  430  that is formed as part of a hinged member as part of the carrier member  401 . This reaction surface  430  is used by an assembler to push the socket connector  402  toward the endwall  4010  and cause the engagement arms to contact the actuating members and cam outwardly. The hinged nature is accomplished by connecting the carrier base to the reaction surface  430  by extends of material and such structure may be easily accomplished by way of molding. The reaction wall  430  preferably includes contact points  434  on ends thereof that impinge upon and contact the opposing surface of the socket connector. Their contact location are preferably as illustrated in FIG. 13, in areas which are outside of, or past the area of deflection for the engagement arms  404 .  
         [0053]    It should be understood that the preceding is merely a detailed description of one embodiment of this invention and that numerous changes to the disclosed embodiment can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention. Rather, the scope of the invention is to be determined only by the appended claims and their equivalents.