Patent Publication Number: US-7713069-B2

Title: Electrical connector and assembly

Description:
BACKGROUND OF THE INVENTION 
   The subject matter herein relates generally to electrical connectors and more particularly, to electrical connectors configured to engage mating contacts that are inserted in a direction that is substantially orthogonal to a mating face of the connector. 
   With some known electronic devices, such as portable computers, peripheral devices may be connected to the electronic device using a plug that is configured to mate with the electronic device. For example, the plug may be inserted into a side slot or cavity that is grooved or keyed to mate with the plug. The mating contacts within the slot are configured to engage mating contacts on the plug when the plug is in a fully engaged position within the slot. However, in order to ensure that the slot contacts and the plug contacts properly engage, the slot contacts and the plug contacts are positioned in a predetermined arrangement. For example, the slot contacts and the plug slots may be arranged in rows and/or columns. However, when the slot contacts or the plug contacts are in a predetermined arrangement, the slot contacts may only be used with plugs that have a predetermined arrangement of plug contacts and vice-versa. 
   Furthermore, in some known electrical connectors, the plug contacts are contact pads that project outwardly from a wall of the plug body. When the plug is inserted into the cavity the contact pads face a direction that is orthogonal to the insertion direction of the plug. As such, sides of the contact pads may stub or incorrectly hit the slot contacts or other parts within the slot thereby damaging or limiting the lifetime of the contact pads. 
   Thus, there is also a need for electrical connectors having plug contacts that may engage different arrangements of slot contacts. In addition, there is a need for electrical connectors that effectively mate the contact pads to the plug contacts while reducing the damage and/or wear of the contact pads as compared to the known electrical connectors. 
   BRIEF DESCRIPTION OF THE INVENTION 
   In one embodiment, an electrical connector configured to interconnect first and second electrical components is provided. The connector includes a connector housing having a mating face that extends substantially in an axial direction and includes a slot opening. The connector also includes a connector contact that extends through the connector housing and the slot opening and is electrically coupled to the first electrical component. The connector contact has a base portion located a depth within the connector housing and a curved portion formed along and protruding through the slot opening and beyond the mating face. The connector contact is configured to pivot about the base portion when a mating contact of the second electrical component is moved alongside the mating face in the axial direction and engages the curved portion. The curved portion is movable within and along the slot opening in the axial direction. 
   Optionally, the connector contact may include a beam connecting the base portion and the curved portion. The beam may extend in a direction that is substantially perpendicular to the mating face. Also, the connector housing may include a pair of opposing inner walls where the base portion of the connector contact is held by and between the inner walls. Further, the connector may include a plurality of slot openings extending along the mating face and a plurality of connector contacts. Each connector contact may extend through the connector housing and one of the slot openings. 
   In another embodiment, an electrical assembly is provided that includes an electronic device having a connector housing that includes a surface and a first electrical component held within the connector housing. The assembly also includes a second electrical component that has a mating contact, and a connector. The connector includes a connector housing that has a mating face extending substantially in an axial direction. The mating face includes a slot opening. The connector also includes a connector contact that extends through the connector housing and the slot opening and is electrically coupled to the first electrical component. The connector contact has a base portion located a depth within the connector housing and a curved portion formed along and protruding through the slot opening and beyond the mating face. The connector contact is configured to pivot about the base portion when a mating contact of the second electrical component is moved alongside the mating face in the axial direction and engages the curved portion. The curved portion is movable within and along the slot opening in the axial direction. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a schematic illustration of an electronic assembly utilizing a pair of electrical connectors formed in accordance with one embodiment. 
       FIG. 2  is a perspective view of an electronic module that may be used with the assembly shown in  FIG. 1 . 
       FIG. 3  is a front perspective view of one electrical connector that may be used with the assembly shown in  FIG. 1 . 
       FIG. 4  is a side view of a connector contact taken along the line  4 - 4  shown in  FIG. 3 . 
       FIG. 5  is a front view of the connector contact taken along the line  5 - 5  shown in  FIG. 3 . 
       FIG. 6  is a side view of the connector shown in  FIG. 3  before the connector engages the module shown in  FIG. 2 . 
       FIG. 7  is a side view of the connector shown in  FIG. 3  when the connector is engaged the module shown in  FIG. 2 . 
       FIG. 8  is a side view of a pair of electrical connectors formed in accordance with another embodiment. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  is a schematic illustration of an electronic assembly  100  that includes electrical systems or devices  102  and  104  connected by an electronic module  106 . The module  106  transmits power and/or electrical signals between the devices  102  and  104 . Also, the module  106  may mechanically support the device  104  while the assembly  100  is in operation. In one embodiment, the device  102  is a primary device that may operate solely without the device  104  connected thereto, and the device  104  is a secondary device that adds functionality to the device  102 . For example, the device  102  may be a communications device. More specifically the device  102  may be a desktop or portable computer, a peripheral device for computers, a personal digital assistant (PDA), ATM machine, or a control panel for a security system. The devices  102  and  104  may include additional features or buttons  110  that may be operated by an individual for controlling the operation of or interacting with the other device. Furthermore, the devices  102  and  104  are not required to be directly linked or connected by the module  106 . For example, the device  102  may be a computing system located in a remote location with respect to the module  106  and the device  104 . The device  102  may be communicatively coupled (e.g., through cables and/or wireless networks) to an electrical connector that engages with the module  106 . 
   As illustrated in  FIG. 1 , the module  106  may have a pair of module mating faces  112  and  114  that are inserted into a cavity or coupled to a surface of the corresponding electronic devices  102  and  104 , respectively. In  FIG. 1 , the module  106  holds the devices  102  and  104  directly adjacent to one another. However, alternative embodiments may hold the devices  102  and  104  a predetermined distance apart. As will be discussed in greater detail below, the mating faces  112  and  114  form an electrical connection with electrical connectors  118  and  116 , respectively, for transmitting power and/or electrical signals therebetween. More specifically each mating face  112  and  114  may include mating contacts  122  and  124  (shown in  FIG. 2 ) that electrically connect with connector contacts  148  (shown in  FIG. 3 ) of the corresponding electrical connector  116  and  118 . 
     FIG. 2  is a perspective view of the module  106  having the mating faces  112  and  114 . The module  106  includes a frame  117  having the mating faces  112  and  114  thereon. In the illustrated embodiment, the mating faces  112  and  114  share a common surface  120 . However, in alternative embodiments, the frame  117  may form separate surfaces for the mating faces  112  and  114 . Furthermore, although  FIG. 2  shows the frame  117  being substantially rectangular and the mating faces  112  and  114  being aligned with one another and extending in opposite directions, the frame  117  may have other shapes and the mating faces  112  and  114  may have other positions and/or other orientations (i.e., the surfaces of the mating faces  112  and  114  are not required to face a common direction but may, for example, be orthogonal to each other). 
   As shown, each mating face  112  and  114  includes a plurality of mating contacts  122  and  124 , respectively. The mating contacts  122  (or, separately the mating contacts  124 ) may be aligned in a staggered relationship with respect to each other in order to accommodate for or obtain a desired electrical performance of the assembly  100  ( FIG. 1 ). Each mating contact  122  is in electrical communication with a corresponding mating contact  124 . By way of example, the mating contact  122 A is in electrical communication with the mating contact  124 A via a conductor (not shown) that extends between the mating contact  122 A and the corresponding mating contact  124 A. Alternatively, the mating contacts may be electrically coupled via traces on a circuit board. Each pair of mating contacts  122  and  124  (and the conductor extending therebetween) may be configured for a separate purpose. For example, mating contacts  122 B and  124 B and mating contacts  122 C and  124 C may be signal lines for transmitting data therebetween. The mating contacts  122 D and  124 D may be a ground. The mating contacts  122 G and  124 G and  122 H and  124 H may be power lines for transmitting power therebetween. In one embodiment, the power lines are capable of transmitting a hazardous voltage (e.g., 48V) therebetween and/or the signal lines are capable of transmitting high speed electrical signals. 
   Also shown, the mating contacts  122  may have a symmetrical relationship with the mating contacts  124  relative to a central axis extending therebetween. Alternatively, the mating contacts  122  and  124  do not have symmetrical relationships. Furthermore, other embodiments may not have a one-to-one relationship with respect to mating contacts  122  and mating contacts  124 . For example, the module  106  may have additional circuitry within the frame  117  that performs operations on the signals received. 
   In the illustrated embodiment, the module  106  may be removably coupled to the devices  102  and  104  ( FIG. 1 ). As used herein, the term “removably coupled” means that the module  106  may be readily separated from the devices  102  and/or  104  without destroying the module  106  and the devices  102  and  104 . For example, the module  106  may have threaded holes for receiving threaded fasteners, latches, or other methods where a technician may easily remove the module  106  from the devices  102  and  104 . In addition, the mating faces  112  and  114  may form an interference fit with the devices  102  and  104 . In alternative embodiments, the module  106  is not removably coupled to the devices  102  and  104 . 
   In one embodiment the mating contacts  122  and  124  are formed into a contact pads that project a distance D 1  (shown in  FIG. 6 ) from the surface  120 . However, in alternative embodiments, the mating contacts  122  and  124  may be flush with the surface  120  or be slightly embedded within an aperture or cavity of the module  106 . Also, the mating contacts  122  and  124  may have an arm that projects from the surface  120  at a non-orthogonal angle. 
     FIG. 3  is a front perspective view of the connector  118 . Although the following is with reference to the connector  118 , the description may be similarly applied to the connector  116  ( FIG. 1 ). As shown, the connector  118  includes a connector housing  128  and a plurality of connector contacts  148 . The connector housing  128  may have a substantially rectangular shape formed by or partially formed by a dielectric material. The connector housing  128  may have a plurality of sides  130 - 134  including a mating face  130 , a front side  131 , and back side  132 . The mating face  130  extends along a plane formed by axes  191  and  192 . The axis  191  extends axially along the mating face  130  between the front side  131  and the back side  132 , and the axis  192  extends laterally between the side  134  and the side  133 . 
   The connector  118  may be coupled to an electrical component  140 , which is illustrated as a circuit board  141  in  FIG. 3 . The mating face  130  forms a plurality of slot openings  142  that lead into a common chamber  144  housed by the connector housing  128 . Alternatively, each slot opening  142  may lead into a chamber that is separated from the other chambers by walls. The front side  131  includes a plurality of notches  146  along a bottom edge of the front side  131 . As shown, each of the connector contacts  148  is directly attached to the circuit board  141  at one end by, for example, soldering the ends to the circuit board  141 . In other embodiments, the ends may form pins that are configured to form an interference fit with thru-holes of the circuit board  141 . The connector contacts  148  extend from the circuit board  141  through the connector housing  128  and protrude through the slot openings  142 . In one embodiment the connector contacts  148  are aligned with respect to each other along a width of the connector housing  128  (i.e., along the axis  192 ). Alternatively, the connector contacts  148  are not aligned and have a staggered relationship along the width of the connector housing  148 . 
   As will be discussed in greater detail below, when the mating contacts  124  ( FIG. 2 ) are moved in an axial direction along the plane formed by axes  191  and  192 , each mating contact  124  may engage a corresponding connector contact  148 . If the mating contacts  124  continue to move along the axial direction after engaging the connector contacts  148 , the connector contacts  148  are pushed away from the front side  131  toward the back side  132  in the axial direction. The connector contacts  148  are resilient in that the connector contacts  148  resile or resist movement away from the unengaged position thereby maintaining an electrical connection with the corresponding mating contact  124 . If and when the mating contact  124  is removed, the connector contact  148  may return to substantially the same position. 
     FIGS. 4 and 5  illustrate the connector contact  148  in a relaxed or unengaged condition. Specifically,  FIG. 4  is a cross-sectional side view of the connector contact  148 A taken along the line  4 - 4  in  FIG. 3 , and  FIG. 4  is a front view of the connector contact  148 A taken along the line  5 - 5  shown in  FIG. 3 . Although the connector contact  148 A is described here in detail, the description may be similarly applied to the other connector contacts  148 . The connector contact  148 A is shaped and formed to resiliently flex in the axial direction (indicated by the arrow A in  FIG. 4 ) and extends between a tail end  150  ( FIG. 4 ) and a distal end  152 . As shown, the connector contact  148 A includes an elbow portion  154  that extends from the tail end  150 , curves and extends alongside a surface of the circuit board  141 , and forms a gap G between the elbow portion  154  and the surface of the circuit board  141 . The elbow portion  154  then curves upward and forms into a base portion  156  that extends away from the circuit board  141 . As shown in  FIG. 5 , the base portion  156  includes ridges  160  that project outward from edges of the base portion  156  and are held between inner wall portions  162  and  164  of the connector housing  128 . (The connector housing  128  is shown by phantom outline in  FIG. 4 .) The ridges  160  may grip and/or be compressed between the wall portions  162  and  164 . The base portion  156  extends away from the circuit board  141  and forms a beam  158 . In the illustrated embodiment, the beam  158  is substantially linear and extends a length L in a direction that is substantially perpendicular to the axial direction A and the surface of the circuit board  141 . As shown in  FIG. 4 , a width of the beam  158  narrows or tapers as the beam  158  extends upward and continues to narrow until the connector contact  148 A protrudes through the slot opening  142 . As such, in the exemplary embodiment, the connector contact  148 A is free to flex from a depth D 2  ( FIG. 4 ) into the connector housing  128  at point E where the base portion  156  forms into the beam  158 . As will be discussed in greater detail below, the length L of beam  158  allows movement of a curved portion  170  in the axial direction. 
   In the illustrated embodiment the length L of the beam  158  provides for more than half of the depth D 2 . In one embodiment, the length L of the beam  158  provides a substantial majority of the depth D 2 . Also, the beam  158  may provide for a substantial portion of a height H of the connector housing  128 . 
   The curved portion  170  is formed from the beam  158  approximately at a point B near the slot opening  142 . The curved portion  170  extends beyond the mating face  130  to the distal end  152 . The curved portion  170  is configured to engage with the mating contact  122  or  124  and, in one embodiment, may engage with a mating contact having a first axial position on one module and engage with another mating contact having a second axial position on a different module. More specifically as shown in  FIG. 4 , the curved portion  170  may have a mating section  172  that extends from point B to an apex point C and a forward-facing section  174  that extends between point C and the distal end  152 . The mating section  172  has a slope S 1  and the forward-facing section has a slope S 2 . In the illustrated embodiment, the magnitude of S 1  is less than the magnitude of S 2  (i.e., S 1  is gentler or shallower than S-). Specifically, in comparison to a common vertical distance Y ( FIG. 5 ) that extends between point B/the distal end  152  and point C, the mating section  172  extends a distance X 1  in the axial direction, and the forward-facing section  174  extends a distance X 2  in the axial direction. The distance X 1  is greater than the distance X 2 . 
   In one embodiment the magnitude of the slope S 1  through the mating section  172  is continuously changing (i.e., the mating section  172  does not include a portion that is substantially linear). Likewise, in one embodiment, the magnitude of the slope S 2  through the forward-facing section  174  is continuously changing. 
   The distal end  152  may extend in a direction that is substantially perpendicular to the axial direction A. In the illustrated embodiment, the curved portion  170  returns through the slot opening  142  and forms the distal end  152 . As shown in  FIG. 5 , the distal end  152  may include projections  166  that grip slot edges  168  formed by the slot opening  142 . The edges  168  project inwardly from the inner wall portions  164  and  162 . When the connector contact  148 A is in the unengaged condition, the projections  166  may grip the edges  168  preventing the curved portion  170  from flexing out of the slot opening  142 . Alternatively the distal end  152  does not include projections  166  and/or does not return through the slot opening  142 . 
     FIGS. 6 and 7  are side views of the connector  118  disposed within a cavity  200  of the device  102  ( FIG. 1 ) when the mating face  112  of the module  106  ( FIG. 2 ) is inserted into the cavity  200 . (For illustrative purposes, only the connector contacts  148 A and  148 B and only the corresponding mating contacts  124 A and  124 B are shown.) More specifically  FIG. 6  illustrates the relaxed condition of the connector contacts  148 A and  148 B (the connector contact  148 B is behind connector contact  148 A in  FIG. 6 ) and  FIG. 7  illustrates the flexed or compressed condition of the connector contacts  148 A and  148 B. 
   The cavity  200  may be keyed or grooved so that when the mating face  112  is advanced through the cavity  200  in the axial direction A, the mating face  112  is directed into a certain position so that the mating contacts  124 A and  124 B may engage the connector contacts  148 A and  148 B. As shown in  FIGS. 6 and 7 , the mating contacts  124 A and  124 B project downward in a direction that is perpendicular to the axial direction A. In the exemplary embodiment the mating contacts  124 A and  124 B have different axial locations on the mating face  112  such that the mating contact  124 A engages the connector contact  148 A before the mating contact  124 B engages the mating contact  148 B. When the mating contacts  124 A and  124 B engage the curved portions  170  of the connector contacts  148 A and  148 B, the beams  158  pivot about the respective base portion  156  ( FIG. 4 ) causing the respective curved portions  170  to move within and along the respective slot opening  142 . In the fully engaged or locked position shown in  FIG. 7 , the connector contacts  148 A and  148 B may have different flexed or compressed conditions (i.e., the connector contact  148 A is more flexed than the connector contact  148 B). Specifically in the fully engaged position, the beam  158  ( FIG. 4 ) of the connector contact  148 A is flexed to a greater angle with respect to the beam  158  in the unengaged condition than the beam  158  of the connector contact  148 B is flexed. As such, the curved portion  170  of the connector contact  148  has moved a greater axial distance than the curved portion  170  of the connector contact  148 B has moved. 
   In addition to the beams  158  being able to move the respective curved portions  170  an axial distance, the shape of the curved portions  170  may be configured to maintain an electrical connection with the respective mating contact  124  as discussed above. Specifically the curved portions  170  may include mating sections  172  that have a slope configured to maintain an electrical connection after engaging the mating contact  124  as the mating contact  124  is moved in the axial direction. 
   In an alternative embodiment more than one of the electrical connectors  118  may be positioned within the cavity  200 . For example, one connector  118  may be placed above another electrical connector  118 . The electrical connectors  118  may oppose each other such that the corresponding mating faces  130  face each other within the cavity  200 . In such embodiments, the mating face  112  may have mating contacts on both a side facing upward and a side facing downward and engage with both electrical connectors  118 . 
     FIG. 8  is a side view of a pair of electrical connectors  316  and  318  formed in accordance with another embodiment. The electrical connectors  316  and  318  may have bodies that are integrally formed with the device housing  302  of an electronic device  304 . The connectors  316  and  318  include connector contacts  348  and  350 , respectively, that may have similar features as described above with respect to the connector contacts  148  ( FIGS. 4 and 5 ). The connector contacts  348  and  350  may be separately coupled to different electrical components (e.g., circuit boards) or may couple to the same electrical component. The electrical connectors  316  and  318  may be staged with respect to each other such that the connector contacts  348  are lower than the connector contacts  350 . As shown, the device  304  is configured to mate with a module  306 , which has staged mating contacts  322  and  324 . The module  306  may include one or more guiding pins  330  that are configured to be inserted into and engage an aperture  332  formed by the device housing  302 . When the module  306  is fully engaged with the device  304 , the guiding pins  330  are inserted into the apertures  332  and the mating contacts  322  and  324  are engaged with the connector contacts  348  and  350 , respectively. 
   In alternative embodiments to the assembly  100  described in  FIG. 1 , the electrical connectors  116  and  118  are coupled to or part of the module  106  and the mating contacts  122  and  124  are part of the devices  102  and  104 , respectively. 
   It is to be understood that the above description is intended to be illustrative, and not restrictive. As such, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. Furthermore, although the above description referred to using the electrical connectors  116  and  118  to mechanically and electrically interconnect a peripheral device to a master device, embodiments described above may be used in a variety of electronic devices and systems that require electrically and/or mechanically coupling two or more systems or devices. 
   In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. 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.