Patent Publication Number: US-7708563-B2

Title: Electrical connector with slotted shield

Description:
BACKGROUND OF THE INVENTION 
   The subject matter herein relates generally to electrical connectors, and more particularly, to electrical connectors having an electromagnetic (“EM”) shield. 
   Some known electrical connectors, include a shield disposed within a housing. A portion of the shield may protrude from one cud of the housing. For example, a rim extending entirely around a periphery of one end of the shield may partially protrude from the housing. A pair of openings in the shield that are surrounded by the rim may be provided for a signal contact and a ground contact. For example, the signal contact (nay be inserted through, one of the openings and may pass through the shield and the housing to a mating end of the connector. A second opening may receive a ground contact that is electrically connected to an electrical ground. The ground contact may then connect the shield to the electrical ground. 
   The shield may be secured in the housing by bending, or flaring, the rim away from the pair of openings and towards the housing. The rim is bent towards the housing and engages the housing to prevent separation of the shield from the housing. For example, the housing and shield may each have shapes with substantially cylindrical inner chambers between opposing ends. The shield may be inserted into one end of the housing with the rim protruding from an opposing end of the housing. The rim may be flared towards the housing at this opposing end to prevent the shield from being pulled through the housing. 
   The rim, however, also can present problems in the manufacture and tooling processes involved in manufacturing the shield. In one example, the rim may prevent flash or waste material from being removed from the shield. For example, if the shield is fabricated through a die casting process, the conductive material used to create the shield may be heated so the material is liquid or molten and then pressure injected into a mold. A pin or bit may be inserted into the liquid material in the mold to create the opening for the ground contact. As the liquid material cools and solidifies, the pin is removed froth the mold and the conductive material. As the pin is removed, the pin may pull waste material such as flash and partially solidified conductive material from the opening for the ground contact onto the shield and within the rim. This waste material may then solidify as metallic silvers. Alternatively, the waste silvers may be created by drilling or punching the opening for the ground contact after the shield has been formed. The rim prevents all of these slivers from being removed from the shield because the rim entirely encircles the end of the shield. These waste slivers may dislodge from the shield or rim and contact electronic equipment that is near the connector assembly,. For example, the waste slivers may dislodge from the shield and contact another electrical connector, a conductive trace, and the like, on the circuit board to which the connector is mounted. The slivers may cause electric shorts or cause other damage to the electronic equipment. Thus, a need exists for an electrical connector with a shield that does not retain flash or other waste generated during the manufacture of the shield. 
   BRIEF DESCRIPTION OF THE INVENTION 
   in One embodiment, an electrical connector housing includes a housing and a shield. The housing has an interior chamber that includes an inner surface extending between a housing mating end and a housing back end. The housing mating end is configured to mate with a mating electrical connector. The inner surface has loading and transition portions, with the loading portion located proximate to the housing mating end and the transition portion located proximate to the housing back end. The shield is shaped to fit in the interior chamber and extends between a shield mating end and a shield back end. The shield back end includes a ground contact opening that is configured to receive a ground contact to electrically connect the shield to an electrical ground. The shield includes a rim protruding from the shield back end that extends around a portion of an outer periphery of the shield back end. The rim includes a plurality of rim ends separated by a gap. The rim engages the transition portion to prevent the shield being removed through the housing mating end and the gap exposes a portion of the transition portion. 
   In another embodiment, another electrical connector assembly includes a housing, a shield, a dielectric holder and a signal contact. The housing includes an interior chamber that extends along a longitudinal axis between a housing mating end and a housing back end. The housing mating end is configured to mate with a mating electrical connector. The shield is shaped to fit in the interior chamber and extends along the longitudinal axis between a shield mating end and a shield back end. The shield back end includes a ground contact opening that is configured to receive a ground contact to electrically connect the shield to an electrical ground. The shield includes a rim protruding from the shield back end that extends around a portion of an outer periphery of the shield back end. The rim includes a plurality of rim ends separated by a gap located proximate to the ground contact opening. The dielectric holder is held within the shield and extends along the longitudinal axis. The signal contact is held within the dielectric holder and substantially extends along the longitudinal axis. Each of the housing, shield, dielectric holder and signal contact are coaxial with one another about the longitudinal axis. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of an electrical connector assembly according to one embodiment. 
       FIG. 2  is a cross sectional view of the connector assembly shown in  FIG. 1  taken along line  2 - 2  in  FIG. 1 . 
       FIG. 3  is an elevational view of shield and housing back ends shown in  FIG. 2  of the connector assembly. 
       FIG. 4  is an elevational view of a shield back end shown in  FIG. 2  with a signal contact also shown in  FIG. 2  and a ground contact shown in  FIG. 3  removed from the drawing. 
       FIG. 5  is another elevational view of the shield back end shown in  FIG. 2  with the signal contact also shown in  FIG. 2  and the ground contact shown in  FIG. 3  removed. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  is a perspective view of an electrical connector assembly  100  according to one embodiment. The connector assembly  100  includes a housing  102  and a shield  104 , with the shield  104  being partially held within the housing  102 . A dielectric  200  (shown in  FIG. 2 ) and a signal contact  202  (shown in  FIG. 2 ) are held within the shield  104 . In one embodiment, the connector assembly  100  is an RF connector. For example, the signal contact  202  may be an electrical contact capable of carrying a data or power signal. 
   The shield  104  may shield the connector assembly  100  from electromagnetic interference. The shield  104  comprises, is formed of, or has an outside surface that is coated with a conductive material. For example, the shield  104  may be formed of zinc, copper or an alloy containing copper. Other conductive metals, however, can be used in alternative embodiments. For example, the shield  104  may be formed of a die cast metal. In one embodiment the shield  104  has a conductive coating. For example, the shield  104  may be plated with a conductive material such as nickel. The shield  104  may be formed using a variety of processes, including a screw machining process or a die casting process, for example. 
   The housing  102  is formed from a nonconductive material. For example, the housing  102  maybe formed from a plastic material such as polyester polybutylene terephthalate (“PBT”). In alternative embodiments, the housing  102  may be formed from, or have an outside surface that is coated with, a conductive material. For example, the housing  102  may be formed from a metal or metal alloy, and may be a die east metal. The housing  102  has a housing mating end  112  and the shield  104  has a shield mating end  114 . The housing and shield mating ends  112 ,  114  are shaped to mate with a mating connector (not shown). In the illustrated embodiment, the housing and shield mating ends  112 ,  114  are shaped to mate with a female mating connector. In another embodiment, the housing and shield mating ends  112 ,  114  are shaped to receive a mating end (not shown) of the mating connector. The housing mating end  112  may include threads  108  to enable a secure engagement with the mating connector. The shield mating end  114  may be received within the mating connector when the connector assembly  100  and the mating connector mate. The housing  102  also includes a housing mounting end  110  that is mounted onto a panel (not shown) or circuit board (not shown) of a device (not shown). For example, the housing mounting end  110  may be mounted on a circuit board and the signal contact  202  (shown in  FIG. 2 ) in the connector assembly  100  may be terminated to a conductive trace (not shown) in the circuit board. While the housing mounting end  110  and the housing mating end  112  are substantially perpendicular to one another in the illustrated embodiment, the housing mounting and mating ends  110 ,  112  may be at a different angle with respect to one another. For example, the housing mounting and mating ends  110 ,  112  may be parallel to one another. The connector assembly  100  may provide a conductive pathway between the mating connector and the circuit board when the connector assembly  100  is mated with the mating connector and mounted on the circuit board, for example. 
     FIG. 2  is a cross sectional view of the connector assembly  100  taken along line  2 - 2  in  FIG. 1 . The housing  102  extends between the housing mating end  112  (shown in  FIG. 1 ) and a housing back end  206 . A housing mounting end  110  is substantially perpendicular to the housing mating and back ends  112 ,  206  in the illustrated embodiment. In another embodiment, the housing mounting end  110  is not perpendicular to the housing mating and back ends  112 ,  206 . A mounting pin  214  extends downwards from the housing mounting end  110 . The mounting pin  214  may be mounted onto a circuit board (not shown) or panel (not shown) to mount the connector assembly  100  to the circuit board or panel, for example. The shield  104  extends between the shield mating end  114  and a shield back, end  204 . In the illustrated embodiment, the shield mating and back ends  114 ,  204  are parallel to one another. In another embodiment, the shield mating and back ends  114 ,  204  are substantially perpendicular to one another. In another embodiment, the shield mating and back ends  114 ,  204  are not parallel or perpendicular to one another. The term “back” is not intended to be limiting and merely identifies the relationship between the shield mating and back ends  114 ,  204  and between the housing mating and back ends  112 ,  206 . 
   The housing  102  includes an interior chamber defined by an inner housing surface  218 . In one embodiment the inner housing surface  218  has a cylindrical shape that is staged in diameter to form a loading portion  220 , a back portion  222  and a transition portion  224 . The loading portion  220  may correspond to the housing mating end  112  (shown in  FIG. 1 ). In one embodiment, a shoulder  232  separates the loading and back portions  220 ,  222 . The inner housing surface  218  has an inside diameter  226  within the loading portion  220  and an inside diameter  228  within the back portion  222 . The transition portion  224  comprises a beveled edge in the illustrated embodiment. The transition portion  224  has an inside diameter that gradually changes from an inside diameter  230  at the housing back end  206  to the inside diameter  228  at the interface between the back portion  222  and the transition portion,  224 . In the illustrated embodiment, the inside diameter  226  of the loading portion  220  is larger than the inside diameter  228  of the back portion  222 . In one embodiment, the inside diameter  230  of the transition portion  224  at the housing back end  206  is larger than either of the inside diameters  226 ,  228  of the loading and back portions  220 ,  222 . 
   The housing  102  may include one or more extended housing portions  212  that extend away from the housing back end  206 . One or more of the extended housing portions  212  may hold the signal contact  202  between the shield back end  204  and the housing mounting end  110 . For example, one of the extended housing portions  212  may hold and protect the portion of the signal contact  202  between the shield back end  204  and the housing mounting end  110 . As shown in  FIG. 3 , one or more of the extended housing portions  212  may hold a ground contact  300  between the shield back end  204  and the housing mounting end  110  in a manner similar to that of the signal contact  202 . The ground contact  300  may establish a conductive pathway between the shield  104  and an electrical ground of the circuit board (not shown), panel (not shown), device (not shown), and the like, to which the connector assembly  100  is mounted. 
   The shield  104  is held in the housing  102  and includes an outer shield surface  234 . In one embodiment, the outer shield surface  234  has a cylindrical shape that is staged in diameter to form a mating portion  236 , a front intermediate portion  238 , a rear intermediate portion  240 , and a rim portion  242 . The mating portion  236  may correspond to the shield mating end  114 . In one embodiment, a shoulder  244  separates the front and rear intermediate portions  238 ,  240 . The outer shield surface  234  of the front intermediate portion  238  may have an outside diameter that is approximately the same as the inside diameter  226  of the inner housing surface  218  in the loading portion  220 . The outer shield surface  234  of the rear intermediate portion  240  may have an outside diameter that is approximately the same as the inside diameter  228  of the inner housing surface  218  in the back portion  222 . The outer shield surface  234  of the rim portion  242  may have an outside diameter that is shaped to engage the inside diameter  230  of the inner housing surface  218  in the transition portion  224 . The shield  104  may include an inner ledge  252  in the mating portion  236 . 
   The shield  104  may be inserted, or loaded, into the interior chamber of the housing  102  through the housing mating end  112 . In one embodiment, the shoulder  244  of the shield  104  engages the shoulder  232  of the housing  102  to prevent the shield  104  from being inserted into the housing  102  past the shoulder  232 . The shield back end  204  includes a rim  210  that protrudes from the shield back end  204 . In one embodiment, the rim  210  includes the rim portion  242  of the outer shield surface  234 . In the illustrated embodiment, the rim  210  is flared towards the housing back end  206  so that the rim  210  engages the housing back end  206 . For example, the rim  210  may extend radially outward from a longitudinal axis  246  of the connector assembly  100 . The outer shield surface  234  of the rim portion  242  may have an outside diameter that is approximately the same as the outside diameter of the outer shield surface  234  of the rear intermediate portion  240  when the shield  104  is loaded into the housing  102 . The rim  210  may be flared towards the inner housing surface  218  of the transition portion  224  so that the rim  210  engages the transition portion  224 . The outside diameter of the rim portion  242  thus accordingly increases to approximate the inside diameter  230  of the transition portion  224  when the rim  210  is flared. The rim  210  engages the housing back end  206  so as to impede removal of the shield  104  from the housing  102  through the housing mating end  112 . 
   The dielectric  200  extends through an interior chamber  248  of the shield  104 . The interior chamber  248  may extend through the shield  104  from the shield mating portion  236  of the outer shield surface  234  to the shield back end  204 . In one embodiment, the dielectric  200  includes a nose portion  254 . In the illustrated embodiment, the nose portion  254  protrudes from a location that is proximate to the inner ledge  252  of the shield  104  in the mating portion  236  of the shield  104 . In another embodiment, the dielectric  200  does not protrude past the inner ledge  252 . For example, the dielectric  200  may not include the nose portion  254  or the nose portion  254  may not extend past the inner ledge  252 . The dielectric  200  may protrude through a dielectric holder opening  208  in the shield back end  204 . The dielectric  200  may be a ring of a dielectric or insulating material with an open center that receives the signal contact  202 . The signal contact  202  may extend through the dielectric  200  and protrude through a signal contact opening  216  in the dielectric  200 . The signal contact  202  may include a bend  250  proximate to and outside of the dielectric  200 . In the illustrated embodiment, the bend  250  is approximately 90 degrees. In one embodiment, the housing  102 , shield  104 , dielectric  200  and signal contact  202  are substantially coaxial with one another about the longitudinal axis  246  of the connector assembly  100 . 
     FIG. 3  is an elevational view of the shield and housing back ends  204 ,  206  of the connector assembly  100 . In the illustrated embodiment, the extended housing portion  212  extends from the housing back end  206  while leaving a portion of the housing back end  206  exposed. In another embodiment, the extended housing portion  212  is omitted from the connector assembly  100 . The shield back end  204  includes the dielectric holder opening  208  and a ground contact opening  302  surrounded by an outside periphery  316  of the shield back end  204 . The ground contact opening  302  is a cavity or opening in the shield back end  204  into which the ground contact  300  is inserted. The ground contact  300  may be terminated to the shield back end  204  through the ground contact opening  302 . For example, the ground contact  300  may be affixed into the ground contact opening  302 . The longitudinal axis  246  (shown in  FIG. 2 ) may extend through a center point  410  of the shield back end  204 . 
   The rim  210  of the shield back end  204  is a slotted rim. The rim  210  extends radially away from the center point  410  and has a rim width  326  in a direction that extends radially away from the center point  410 . In one embodiment, rim  210  may extend around a portion, and less than all, of the transition portion  224  of the housing  102 . For example, the rim  210  may include a plurality of rim ends  312 ,  314  separated from one another by a gap  308 . In the illustrated embodiment, the rim  210  includes atop rim portion  304  and a bottom rim portion  306  separated from one another by a pair of gaps  308 ,  310 . The top rim portion  304  may extend between top rim portion ends  312 ,  318 . The bottom rim portion  306  may extend between bottom rim portion ends  314 .  320 . The gaps  308 ,  310  may expose arcuate portions  322 ,  324  of the transition portion  224 . In embodiments where the transition portion  224  is not circular, the arcuate portions  322 ,  324  may have non-arcuate portions and may include the portions of the transition portion  224  between the rim ends  312 ,  314  and between the rim ends  318 ,  320 . The portions  322 ,  324  of the transition portion  224  that are exposed may have an exposed portion width  328 . The exposed portion width  328  may include the width of the transition portion  224  that is not covered by the rim  210 . For example, the exposed portion width  328  may include the width of a portion of the transition portion  224  that is visible from the viewpoint illustrated in  FIG. 3 . In the illustrated embodiment, the exposed portion width  328  is greater than the rim width  326  in directions that extend radially away from the center point  410 . In another embodiment, the exposed portion width  328  is less than or approximately equal to the rim width  326  in directions that extend radially away from the center point  410 . 
   In the illustrated embodiment, the top and bottom rim portions  304 ,  306  are arcuate portions of the rim  210  that oppose one another. The gaps  308 ,  310  also oppose one another in the illustrated embodiment. In another embodiment, the rim  210  does not have a circular shape and the top and bottom rim portions  304 ,  306  do not have arcuate shapes. For example, the rim  210  may have a square or rectangular shape and the top and bottom rim portions  304 ,  306  may be portions of the square or rectangular shape. Other shapes of the rim  210  and top and bottom rim portions  304 ,  306  are possible as well. In one embodiment, the top and bottom rim portions  304 ,  306  are approximately the same size and the gaps  308 ,  310  are approximately the same size. 
   While only two gaps  308 ,  310  and the top and bottom rim portions  304 ,  306  are shown in the illustrated embodiment, a different number of gaps  308 ,  310  and top and bottom rim portions  304 ,  306  may be provided. For example, in one embodiment, only one of the gaps  308 ,  310  is provided. In such an embodiment, the rim  210  may extend around a portion of the periphery of the shield back end  204  with the gap  310  omitted and the gap  308  separating top rim portion end  312  and bottom rim portion end  314 . In another embodiment, more than two gaps  308 ,  310  and more than the two top and bottom rim portions  304 ,  306  maybe provided. In one embodiment, the top and bottom rim portions  304 ,  306  do not oppose one another and the gaps  308 ,  310  do not oppose one another. In another embodiment, the top and bottom rim portions  304 ,  306  are not provided at the top and bottom of the shield back end  204  and the gaps  308 ,  310  are not provided at the sides of the shield back end  204 . 
   The gaps  308 ,  310  may be created by removing portions of the rim  210  before or after the shield  104  (shown in  FIG. 1 ) is inserted into the housing  102  (shown in  FIG. 1 ). In another embodiment, the gaps  308 ,  310  may be provided by machining the gaps  308 ,  310  from the rim  210  when the shield  104  is machined from a stock of conductive material. In another embodiment, the gaps  308 ,  310  may be provided by not tilling in corresponding portions of a mold in a die casting process used to create the shield  104 . 
   In one embodiment, the gap  308  is located proximate to the ground contact opening  302 . For example, the ground contact opening  302  may be closer to the gap  308  than one or more of the dielectric holder opening  208 , the dielectric  200 , the signal contact opening  216  and the signal contact  202 . The gap  308  may be provided near the ground contact opening  302  to provide a path for flash or other waste material of the shield  104  (shown in  FIG. 1 ) to be removed from the shield back end  204 . The waste silvers may be removed from the shield back end  204  by providing the gap  308  near the ground contact opening  302 . Rather than be held near the shield hack end  204  by the rim  210 , the waste slivers may fell away from the shield back end  204  through the gap  308 . For example, the shield  104  may be positioned during the manufacture of the shield  104  so that gravity pulls the waste slivers down through the gap  308  or the gap  310 . In another example, air or another fluid may be used to flush the waste slivers away from the shield back end  204  and through one or more of the gaps  308 ,  310 . 
   In one embodiment providing the gap  308  in a location that is proximate to the ground contact opening  302  provides a clearance for flaring the top and bottom rim portions  304 ,  306 . For example, if the rim  210  did not include the gap  308  near the ground contact opening  302 , only a very thin flaring tool could be inserted between the ground contact opening  302  and the rim  210  in order to flare the rim  210  towards the housing  102  (shown in  FIG. 1 ). However, with the gap  308  near the ground contact opening  302  in one or more embodiments, a more robust flaring tool can be used to flare the top and bottom rim portions  304 ,  306  towards the housing  102 , as shown in  FIG. 2 . 
   In one embodiment, the sectioning of the rim  210  into portions may reduce the force required to flare the rim  210  towards the housing  102 , as shown in  FIG. 2 . For example, providing the gaps  308 ,  310  in the rim  210 , thereby creating the top and bottom rim portions  304 ,  306 , may reduce the force required to bend the top and bottom rim portions  304 ,  306  towards the housing  102 . 
     FIG. 4  is an elevational view of the shield back end  204  with the signal contact  202  (shown in  FIG. 2 ) and the ground contact  300  (shown in  FIG. 3 ) removed. In the illustrated embodiment, each of the gap  308 , the gap  310 , the ground contact opening  302  and the dielectric holder opening  208  is centered on a center axis  412 . In the illustrated embodiment, the center axis  412  is substantially perpendicular to the longitudinal axis  246  (shown in  FIG. 2 ). The center axis  412  may extend through the center point  410  of the shield back end  204 . In one embodiment, the center point  410  is located at the center of the shield back end  204 . 
   In one embodiment, the top rim portion end  312  and the bottom rim portion end  314  are separated by a separation distance that is larger than the ground contact opening  302 . The top rim portion end  318  and the bottom rim portion end  320  also may be separated by a separation distance that is larger than the ground contact opening  302 . For example, each of the gaps  308 ,  310  may be at least as wide as the ground contact opening  302 . In one embodiment, a gap arcuate width  400  of the gap  308  may be greater than an opening arcuate width  402  of the ground contact opening  302 . The gap arcuate width  400  includes the minimum arcuate distance along an outside periphery  316  of the shield back end  204  that a gap angle  404  subtends. For example, the gap arcuate width  400  may be an arc along the outside periphery  316  of the shield back end  204  that is represented by the gap arcuate width  400  and that is the minimum distance between the top rim portion end  312  and the bottom rim portion end  314  along the outside periphery  316 . In the illustrated embodiment, the gap angle  404  is defined by two gap lines  416  that extend radially from the center point  410  to the rim ends  312 ,  314  at the points where the rim ends  312 ,  314  are closest to one another. The opening arcuate width  402  includes the minimum arcuate distance along the outside periphery  316  that an opening angle  406  subtends. For example, the opening angle  406  may subtend an arc along the outside periphery  316  that is represented by the opening arcuate width  402  and that is the minimum angle that spans across and includes the ground contact opening  302 . For example, the opening angle  406  may be sufficiently large to tangentially contact the ground contact opening  302 . As shown in the illustrated embodiment, the opening angle  406  is formed by two radial lines  414  that are each tangent to the ground contact opening  302 . Both the gap and opening angles  404 ,  406  may be measured from the center point  410  of the shield back end  204 . 
     FIG. 5  is another elevational view of the shield back end  204  with the signal contact  202  (shown in  FIG. 2 ) and the ground contact  300  (shown in  FIG. 3 ) removed. In the illustrated embodiment, each of the gap  308 , the ground contact opening  302  and the dielectric holder opening  208  is centered on the center axis  412 . The center axis  412  extends through the center point  410 . A transverse axis  500  of the shield back end  204  also extends through the center point  410 . In one embodiment, the transverse axis  500  is perpendicular to the center axis  412 . In another embodiment, the transverse and center axes  500 ,  412  are acute or obtuse to one another. 
   In one embodiment, the top and bottom rim portions  304 ,  306  are separated by a linear separation distance  502  that is at least as great as a diameter  504  of the ground contact opening  302 . The diameter  504  may be the inside diameter of the ground contact opening  302  at the shield back end  204  and measured across the inside of the ground contact opening  302 . The linear separation distance  502  may be the minimum distance between the top rim portion end  312  and the bottom rim portion end  314  in a direction that is substantially parallel to the transverse axis  500 . The linear separation distance  502  may be the minimum distance between the top rim portion end  318  and the bottom rim portion end  320  in a direction that is substantially parallel to the transverse axis  500 . 
   Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used, merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.