Patent Publication Number: US-2016233631-A1

Title: Electrical connector

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 14/791,696, filed Jul. 6, 2015, which claims benefit of the filing date under 35 U.S.C. §119(a)-(d) of Taiwan Patent Application No. 103214719, filed Aug. 18, 2014, the entire contents which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an electrical connector. 
     2. Description of the Related Art 
     As technology advances, the sizes of electrical connectors are getting smaller and smaller, and the number of terminals increases with the upgrade of the transmission specifications. Take one of the new electrical connector specifications (USB C type connector) as an example: the overall size of a USB C type electrical connector is smaller than the USB 2.0 electrical connector, and the USB C type electrical connector has two rows of terminals, in which the number of terminals in each row is 12. 
     In other words, a USB C type connector includes a larger amount of terminals needed to be disposed in a smaller space (the insulative base) as compared with the USB 2.0 electrical connector. In consideration of holes provided as corresponding to the positions of the terminals in the insulative base of an electrical connector, therefore, if the number of terminals increases, the structural strength of the insulative base will reduce. Furthermore, since the terminals are narrowed in width, the structural strength of the terminals becomes weaker. When this kind of electrical connector is being assembled, the differences among the strengths exerted on the terminals by different operators may lead to a bend or a curve in the terminals and a false installation of the terminals on the insulative base. In addition, since the terminal width is very small and the number of terminals is quite large, the operators have difficulties determining with eyes whether the terminals are properly assembled. Therefore, such kind of electrical connector has higher defect rate. 
     SUMMARY OF THE INVENTION 
     The present invention provides an electrical connector with novel structure and preferred assembly yield. 
     The electrical connector of the present invention comprises: a casing, an insulative base, a plurality of first terminals, a plurality of second terminals, an external conductive sheet, an upper internal conductive sheet, and a lower internal conductive sheet. The insulative base is disposed within the casing and includes a top complex, a center complex, and a bottom complex in sequential connection. The plurality of first terminals and the plurality of second terminals penetrate through the top complex and the bottom complex respectively. The external conductive sheet penetrates through the center complex to isolate plurality of first terminals and the plurality of second terminals. The upper internal conductive sheet is fixed to the insulative base and disposed at a side of the top complex in such a manner that a partial portion of the plurality of first terminals is sheltered by the upper internal conductive sheet. The lower internal conductive sheet is fixed to the insulative base and disposed at a side of the bottom complex in such a manner that a partial portion of some of the plurality of second terminals is sheltered by the lower internal conductive sheet. 
     According to one embodiment of the present invention, the insulative base includes at least one first engagement hole and at least one second engagement hole. The upper internal conductive sheet includes at least one first positioning protrude which is inserted into the first engagement hole. The lower internal conductive sheet includes at least one second positioning protrude which is inserted into the second engagement hole. 
     According to one embodiment of the present invention, the first engagement hole and the second engagement hole are disposed within the center complex. 
     According to one embodiment of the present invention, the center complex includes a tongue, whose two opposite surfaces have a plurality of ditches for accommodating a partial portion of some of the plurality of some of first terminals and a partial portion of the plurality of second terminals. 
     According to one embodiment of the present invention, the internal conductive sheet includes a first section and a second section connected to the first section. There is a turn between the first section and the second section. The first section covers a partial portion of the top complex, and the second portion covers a partial portion of some of the plurality of first terminals. 
     According to one embodiment of the present invention, the first section of the internal conductive sheet includes a plurality of arms, which slightly tilts toward the casing. 
     According to one embodiment of the present invention, the second section of the internal conductive sheet includes a plurality of resistant contacts, which are used to contact a corresponding electrical connector to increase the plug strength between the two. 
     According to one embodiment of the present invention, the external conductive sheet includes an ECS body and a plurality of apertures penetrating the ECS body, wherein a partial portion of the center complex extends into the apertures. 
     According to one embodiment of the present invention, the external conductive sheet includes at least one conductive tail perpendicular to the ECS body. At least one conductive tail and a partial portion of the second terminals that is disposed at a position far away from an opening of the casing are arranged in the same column. 
     According to one embodiment of the present invention, a partial portion of the external conductive sheet is exposed to the leading edge and side edge of the center complex. 
     According to one embodiment of the present invention, the electrical connector of the present invention further includes a block including a plurality of notches which are arranged in at least two rows, and the portion of the second terminals that are disposed at a position far away from the opening of the casing penetrates through at least one partial portion of the notches. 
     According to the above-mentioned structures, the electrical connector of the present invention provides the external conductive sheet between the first terminals and the second terminals to prevent the signal which is sent from the first terminals and the signal which is sent from the second terminals from being interfered with one another. Moreover, the present invention is which disposes the top complex and the bottom complex with the upper internal conductive sheet and the lower internal conductive sheet respectively, and disposes the casing to cover the above-mentioned components to provide the electrical connector with better anti-electromagnetic interference effects. Besides, the assembly of the electrical connector of the present invention begins with inserting the first terminals, the external conductive sheet, and the second terminals into the top complex, the center complex, and the bottom complex respectively via a production method such as Insert-Molding process, and thereafter performs a step of assembling the top complex, the center complex, and the bottom complex together. Next, the conductive tail and the partial portion of the second terminals that is disposed at a position far away from the opening of the casing are covered with the block, and finally the first positioning protrude of the upper internal conductive sheet and the second positioning protrude of lower internal conductive sheet are inserted into the first engagement hole and the second engagement hole of the center complex in such a manner that after the upper internal conductive sheet and the lower internal conductive sheet are disposed at a side of the top complex and the center complex, the upper internal conductive sheet and the lower internal conductive sheet together with the top complex and the center complex are inserted into the casing. The configuration structure of the present invention and the above-mentioned assembly methods can effectively enhance the overall assembly yield. 
     The present invention is further explained by the preferred embodiments and the appended drawings below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of an electrical connector according to one embodiment of the present invention. 
         FIG. 2  to  FIG. 4  are schematic diagrams of the electrical connector shown in  FIG. 1  viewed from different angles. 
         FIG. 5  is an exploded perspective view of the electrical connector shown in  FIG. 1 . 
         FIG. 6  is a schematic diagram of the electrical connector shown in  FIG. 5  viewed from different angles. 
         FIG. 7  is a schematic diagram of a top complex and a plurality of first terminals of the electrical connector shown in  FIG. 1 . 
         FIG. 8  is a schematic diagram of a bottom complex and a plurality of second terminals of the electrical connector shown in  FIG. 1 . 
         FIG. 9  is a schematic diagram of a center complex and a external conductive sheet of the electrical connector shown in  FIG. 1 . 
         FIG. 10  is a schematic diagram of the external conductive sheet of the electrical connector shown in  FIG. 1 . 
         FIG. 11  is a schematic diagram of the center complex of the electrical connector shown in  FIG. 1 . 
         FIG. 12  is a three dimensional view of the electrical connector without the casing. 
         FIG. 13  is a schematic diagram of the electrical connector shown in  FIG. 12  viewed from another angle. 
         FIG. 14  is a sectional schematic view along line A-A shown in  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENT(S) 
       FIG. 1  is a schematic diagram of an electrical connector  100  according to one embodiment of the present invention.  FIG. 2  to  FIG. 4  are schematic diagrams of the electrical connector  100  shown in  FIG. 1  viewed from different angles. More specifically,  FIG. 1  is a front view of the electrical connector  100  according to this embodiment, and  FIG. 2 ,  FIG. 3  are respectively the left side view and the right side view of the electrical connector  100  according to this embodiment.  FIG. 4  is a back side view of the electrical connector  100  according to this embodiment. In this embodiment, the electrical connector  100  is a female USB C type connector, but the present invention does not limit the type of the electrical connector  100 . 
     The detailed components of the electrical connector  100  according to this embodiment are shown in  FIG. 5  and  FIG. 6 .  FIG. 5  is an exploded perspective view of the electrical connector  100  shown in  FIG. 1 .  FIG. 6  is a schematic diagram of the electrical connector  100  shown in  FIG. 5  viewed from different angles. The electrical connector  100  of this embodiment comprises: a casing  110 , an insulative base  120  disposed within the casing  110 , a plurality of first terminals  130 , a plurality of second terminals  140 , an external conductive sheet  150 , an upper internal conductive sheet  160 , a lower internal conductive sheet  170 , and a block  180 . 
       FIG. 7  is a schematic diagram illustrating a top complex  122  and a plurality of first terminals  130  of the electrical connector  100  shown in  FIG. 1 .  FIG. 8  is a schematic diagram illustrating a bottom complex  126  and a plurality of second terminals  140  of the electrical connector  100  shown in  FIG. 1 .  FIG. 10  is a schematic diagram illustrating the external conductive sheet  150  of the electrical connector  100  shown in  FIG. 1 .  FIG. 11  is a schematic diagram illustrating a center complex  124  of the electrical connector  100  shown in  FIG. 1 .  FIG. 9  is a schematic diagram illustrating a center complex  124  and the external conductive sheet  150  of the electrical connector  100  shown in  FIG. 1 . Please refer to  FIG. 5 to 11 , wherein the insulative base  120  includes the top complex  122 , the center complex  124 , and the bottom complex  126  in sequential connection. In this embodiment, the center complex  124  and the bottom complex  126  are made of insulating materials, such as resins or high-polymer. However, the materials of the center complex  124  and the bottom complex  126  are not limited to these as long as they possess insulating properties. 
     A partial portion of these plurality of first terminals  130  and a partial portion of these plurality of second terminals  140  penetrate through the top complex  122  and the bottom complex  126  respectively. More specifically, the middle portion of the first terminals  130  and the middle portion of the second terminals  140  penetrate through the top complex  122  and the bottom complex  126 , and the opposite ends of the first terminals  130  and the opposite ends of the second terminals  140  are exposed outside the top complex  122  and the bottom complex  126 . An end of the first terminals  130  and an end of the second terminals  140  that are disposed at a position near an opening  112  of the casing  110  are for connecting a corresponding electrical connector (not shown in the drawings). An end of the first terminals  130  and an end of second terminals  140  that are disposed at a position far away from the opening  112  of the casing  110  are for connecting with a circuit board (not shown in the drawings). The external conductive sheet  150  penetrates through the center complex  124  to isolate the first terminals  130  and the second terminals  140  so as to prevent the signal which is sent from the first terminals  130  and the signal which is sent from the second terminals  140  from interfering with each other. 
     In this embodiment, the assembly of the electrical connector begins with disposing the first terminals  130 , the external conductive sheet  150 , and the second terminals  140  within the top complex  122 , the center complex  124 , and the bottom complex  126  respectively via Insert-Molding process, followed by fixing relative positions among the top complex  122 , the center complex  124 , and the bottom complex  126 . However, the method of assembling the first terminals  130 , the external conductive sheet  150 , the second terminals  140 , the top complex  122 , the center complex  124 , and the bottom complex  126  is not limited to this. In other embodiments, the first terminals  130 , the external conductive sheet  150 , and the second terminals  140  can be fixed to the top complex  122 , the center complex  124 , and the bottom complex  126  by being inserted into the top complex  122 , the center complex  124 , and the bottom complex  126 . Moreover, the relative positions among the top complex  122 , the center complex  124 , and the bottom complex  126  can be fixed by integrally-molded process or by other methods such as sticking the complexes together. 
     In this embodiment, the electrical connector  100  is a female USB C type connector. The number of the first terminals  130  and the number of the second terminals  140  are both  12 . The center complex  124  includes a tongue  124   a , whose two opposite surfaces have a plurality of ditches  124   b . In this embodiment, each of the two opposite surfaces of the tongue  124   a  has twelve ditches  124   b , and it is noted although  FIG. 5 ,  FIG. 6 ,  FIG. 9 , and  FIG. 11  only show the upper surface of the tongue  124   a  having ditches  124   b  due to the limited viewing angle, the lower surface of the tongue  124   a  also has ditches  124   b . A portion of the twelve first terminals  130  and a portion of the twelve second terminals  140  that are in a position near the opening  112  of the casing  110  are disposed to insert into the ditches  124   b  of the upper and lower surface of the tongue  124   a  to fix the relative position between the plurality of the first terminals  130  and the plurality of the second terminals  140 . 
     Seen from the viewing angle of  FIG. 6 , the partial portions of the twelve first terminals  130  that are disposed at a position far away from the opening  112  of the casing  110  are arranged in the same row, and the partial portions of the twelve second terminals  140  that are disposed at a position far away from the opening  112  of the casing  110  are arranged in two rows, in which each row has six second terminals  140 . Certainly, in other embodiments, the number of the first terminals  130 , the number of the second terminals  140 , and the arrangement method of the partial portions of the first terminals  130  and the second terminals  140  that are disposed at a position far away from the opening  112  of the casing  110  are not limited to the above-mentioned description. In other embodiments of different kinds of electrical connector  100  (not shown in the drawings), the electrical connectors  100  can be arranged with only the first terminals  130 , in which the partial portions of the first terminals  130  that are disposed at a position far away from the opening  112  of the casing  110  are disposed in different rows. Alternatively, the electrical connectors  100  can include both the first terminals  130  and the second terminals, wherein the partial portions of the second terminals  140  that are disposed at a position far away from the opening  112  of the casing  110  can be arranged in the same row. 
     Besides, in this embodiment, the external conductive sheet  150  includes an ECS body  152  and a plurality of apertures  154  penetrating the ECS body  152  so as to stably insert and fix the external conductive sheet  150  into the center complex  124 , as shown in  FIG. 10 . In the insert-molding process, a partial portion of the center complex  124  reaches into the apertures  154  to increase the adhesion between the apertures  154  and the center complex  124 . 
     Furthermore, the external conductive sheet  150  includes at least one conductive tail  156  perpendicular to the ECS body  152 . In this embodiment, the external conductive sheet  150  includes two conductive tails  156 . As can be seen in  FIG. 6  and  FIG. 8 , the partial portions of the second terminals  140  that are disposed at a position far away from an opening  112  of the casing  110  are arranged in two rows. The row near the outside has six second terminals  140 , in which the distance between the any one of the outermost second terminals  140  and it neighboring second terminals  140  is twice longer than the distance between the middle two second terminals  140 . In this row, the space between any one of the outermost second terminals  140  and its neighboring second outermost second terminals  140  is for accommodating the two conductive tails  156  of the external conductive sheet  150  in such a manner that the two conductive tails and the six second terminals are in the same row. Obviously, in other embodiment, the conductive tails  156  and the six second terminals  140  can be arranged in different rows. 
     Besides, as can be seen in  FIG. 9 , a partial portion of the external conductive sheet  150  is exposed at the leading edge and side edge of the center complex  124 . In detail, each outer side of the center complex  124  has a recession  124   c , in which a partial portion of the external conductive sheet  150  is exposed at the recession  124   c . Moreover, partial portions of the external conductive sheet  150  are exposed at the two outer sides of the leading edge of the center complex  124 . When the electrical connector  100  of this embodiment connects with a corresponding electrical connector, the two partial portions of the external conductive sheet  150  that are exposed at the two recessions  124   c  of the two outer edge of the center complex  124  and the two partial portions of the external conductive sheet  150  that are exposed at the two sides of the leading edge of the center complex  124  can electrically connect with the corresponding electrical connector. In this embodiment, the external conductive sheet  150  is not exposed outside the whole leading edge of the center complex  124  so as to maintain the structural strength of the center complex  124 . However, in other embodiments, if other ways exist for increasing the structural strength of the center complex  124 , the external conductive sheet  150  can be exposed outside the leading edge of the center complex  124 . Certainly, the partial portion of the center complex  124  at which the external conductive sheet  150  is exposed is not limited to this. 
     Please refer back to  FIG. 5  and  FIG. 6 . The block  180  includes a plurality of notches  182  to fix the relative positions among the partial portions of the second terminals  140  that are disposed at a position far away from the opening  112  of the casing  110 . Since the portions of the second terminals  140  disposed at a position far away from the opening  112  of the casing  110  are arranged in two rows, the plurality of notches  182  of the block  180  corresponding to the two rows of the second terminals  140  are arranged in two rows in such manner that the second terminals  140  penetrate through a place far away from the opening  112  of the casing  110 . Certainly, in other embodiments, the number of rows of the notches  182  can vary according to the arrangement method of the second terminals  140 , or the arrangement method of the first terminals  130 . 
       FIG. 12  is a three dimensional view of the electrical connector  100  of  FIG. 1  without the casing  110 .  FIG. 13  is a schematic diagram of the electrical connector  100  shown in  FIG. 12  viewed from another angle.  FIG. 14  is a sectional schematic view along line A-A shown in  FIG. 13 .  FIG. 12  to  FIG. 14  are schematic diagrams of assembling the elements of the electrical connector  100  of this embodiment without the casing  110 . Please refer to  FIG. 5 ,  FIG. 12  to  FIG. 14  at the same time. The upper internal conductive sheet  160  is disposed at a side of the top complex  120 , sheltering a partial portion of some of the plurality of first terminals  130 . The lower internal conductive sheet  170  is disposed at a side of the bottom complex  126 , sheltering a partial portion of some of the plurality of second terminals  140 . In addition to the casing  110  made of metal material that provides anti-electromagnetic effect, the electrical connector  100  of this embodiment achieves anti-electromagnetic interference effect also through the setting of the upper internal conductive sheet  160  and the lower internal conductive sheet  170  so as to enhance the anti-electromagnetic interference effect. 
     The upper internal conductive sheet  160  and the lower internal conductive sheet  170  are fixed to the insulative base  120  by assembly methods. In detail, the center complex  124  of the insulative base  120  includes at least one first engagement hole  124   d  and at least one second engagement hole  124   e . The upper internal conductive sheet  160  and the lower internal conductive sheet  170  respectively include at least one first positioning protrude  166  and at least one second positioning protrude  172 . The first positioning protrude  166  and the second positioning protrude  172  are inserted into the first engagement hole  124   d  and the second engagement hole  124   e  respectively in such a manner that the upper internal conductive sheet  160  and the lower internal conductive sheet  170  are fixed to the insulative base  120 . Certainly, in other embodiments, the first engagement hole  124   d  and the second engagement hole  124   e  can be disposed at in the top complex  122  or the bottom complex  126 . 
     In addition, as shown in  FIG. 5 ,  FIG. 13  and  FIG. 14 , the internal conductive sheet  160  includes a first section  162  and a second section  168  connected to the first section  162 . There exists a turn between the first section  162  and the second section  168 . The first section  162  covers a partial portion of the top complex  122 , and the second portion  168  covers a partial portion of the plurality of first terminals  130 . The first section  162  of the internal conductive sheet  160  includes a plurality of arms  164 , which slightly tilts toward the casing  110  (shown in the top of  FIG. 14 ). When the casing  110  is mounted onto the above-mentioned components, the plurality of arms  164  of the internal conductive sheet  160  are electrically connected with the casing  110 . The second section  168  of the internal conductive sheet  160  includes a plurality of resistant contacts  169 . When a corresponding electrical connector connects with the electrical connector  100  of this embodiment, the corresponding electrical connector contacts the resistant contacts  169  to increase the resistance between the electrical connector and the corresponding electrical connector. 
     In this embodiment, it is noted that the lower internal conductive sheet  170  includes a plurality of arms and a plurality of resistant contacts as well, which is not shown in the schematic diagrams due to the viewing angle. The shape and function of the arms and the resistant contacts of the lower internal conductive sheet  170  are similar to that of the arms  164  and the resistant contacts  164  of the internal conductive sheet  160 , and therefore the details about the arms and the resistant contacts of the lower internal conductive sheet  170  will not be presented here. 
     In summary, the electrical connector  100  of the present invention provides the external conductive sheet  150  between the first terminals  130  and the second terminals  140  to prevent the signal which is sent from the first terminals  130  and the signal which is sent from the second terminals  140  from being interfered with one another. The top complex  122  and the bottom complex  126  are disposed with the upper internal conductive sheet  160  and the lower internal conductive sheet  170  respectively, and disposes the casing  110  to cover the above-mentioned components to provide the electrical connector  100  with better anti-electromagnetic interference effect. Besides, the assembly of the electrical connector  100  of the present invention begins with inserting the first terminals  130 , the external conductive sheet  150 , and the second terminals  140  into the top complex  122 , the center complex  124 , and the bottom complex  126  respectively via a production method such as Insert-Molding process, and thereafter performs a step of assembling the top complex  122 , the center complex  124 , and the bottom complex  126  together. Next, the conductive tail  156  and the partial portion of the second terminals  140  that is positioned far away from the opening  112  of the casing  110  are covered with the block  180 , and finally the first positioning protrude  166  of the upper internal conductive sheet  160  and the second positioning protrude  172  of the lower internal conductive sheet  170  are inserted into the first engagement hole  124   d  and the second engagement hole  124   e  of the center complex  124  in such a manner that after the upper internal conductive sheet  160  and the lower internal conductive sheet  170  are disposed at a side of the top complex  122  and the center complex  124 , the upper internal conductive sheet  160  and the lower internal conductive sheet  170  together with the top complex  122  and the center complex  124  are inserted into the casing  110 . The configuration structure of the present invention and the above-mentioned assembly methods can effectively enhance the overall assembly yield. 
     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.