Patent Publication Number: US-9431751-B2

Title: Connector having a pin guide for use with a printed circuit board

Description:
FIELD OF THE INVENTION 
     This invention relates generally to a retention guide for use with an electrical connector. In particular, the invention relates to a guide which facilitates the insertion of terminals on a printed circuit board 
     BACKGROUND OF THE INVENTION 
     It is common practice to make an electrical connection to a printed circuit board by means of an electrical header assembly which comprises a dielectric housing and a plurality of conductor terminals or pins. The conductor terminals are inserted into longitudinal cavities of the housing. The tail ends are then bent perpendicularly, in many instances over anvil portions of the housing, which locks the conductors in place and provides transversely projecting tails for electrical connection to the printed circuit board when the header assembly is attached. The printed circuit board has a precise pattern of holes which receives the projecting tails which are then soldered or otherwise secured to the printed circuit board to provide a good electrical interface. See, for instance, U.S. Pat. No. 3,864,000. 
     Another such header is shown in U.S. Pat. No. 4,491,376 which discloses a header assembly having a thermoplastic housing and two rows of metallic conductor pins is attached to a printed circuit board. The conductor pins have tails which are bent over anvil portions of the housing and project through slots in a locator plate at the conductor end of the housing. The locator plate slots have detents for retaining the bent tails in a pattern to facilitate assembly and soldering of the tails in a matching pattern of holes in the printed circuit board. Stress on the solder connections due to differential thermal expansion is reduced by flexure of the conductor pins in enlarged rearward cavity portions and slippage of the bent tails in the detents. 
     As described above, known connectors provide for locator plates and means for bending contacts. This is advantageous when the conductor pins of the terminals are to be soldered to the printed circuit board. However, if the conductor pins have compliant contact portions which make electrical connection to the printed circuit boards, the insertion of the pins into the openings of the printed circuit board requires force to be applied to the compliant portions. The locator plates currently used are not capable of cooperating with the compliant portions to provide such a force. 
     It would be beneficial to provide a pin retention guide for use with headers which provides sufficient force required to facilitate mating of the compliant pins to the circuit board, thereby eliminating the problems noted above. In addition, it would be beneficial to provide a retention guide which is separate from the header but which can easily be inserted onto the pins and mated to the header. 
     SUMMARY OF THE INVENTION 
     An embodiment is directed to a connector having a pin guide which includes a housing, terminals and the pin guide. The housing has terminal receiving recesses. The terminals include securing sections and substrate mating ends. The securing sections are positioned to maintain the terminals in the terminal receiving recesses. The substrate mating ends extend from the housing. The pin guide is removably attached to the housing, the pin guide having terminal receiving cavities for receiving the substrate mating ends of the terminals therein. 
     An embodiment is also directed to a connector having a pin guide which includes a housing, terminals and the pin guide. The housing has terminal receiving recesses. The terminals include securing sections and substrate mating ends. The securing sections are positioned to maintain the terminals in the terminal receiving recess. The substrate mating ends extend from the housing. The pin guide is removably attached to the housing. The pin guide has terminal receiving cavities for receiving the substrate mating ends of the terminals therein. Positioning recesses are provided proximate each cavity and have shoulders which cooperate with respective terminals. The positioning recesses are proximate a substrate mounting surface of the pin guide. 
     The substrate mating ends of the terminals may have lateral projections which are positioned in the positioning recesses of the pin guide to properly position the substrate mating ends. The lateral projections cooperate with the shoulders to transfer forces from the terminals to the pin guide when the terminals are mated with a mating substrate. 
     The method of assembly and installing a connector with a pin guide includes: inserting terminals into housing; bending a portion of the terminals which extend outward from the housing; and positioning the pin guide over the bent ends of the terminals, whereby the bent ends are retained in cavities of the pin guide. 
     The method may also include positioning projections of substrate mating ends of the terminals in positioning recesses of the pin guide, such that the substrate mating ends of the terminals are retained in position. Additional steps may include; inserting substrate mating portions of the substrate mating ends into openings of a mating substrate; and engaging shoulders of the positioning recesses with the projections of the terminals, whereby forces applied to the terminals during insertion are transferred to the housing. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a connector with an embodiment of a pin guide provide thereon. 
         FIG. 2  is a perspective view of the connector of  FIG. 1  with the pin guide exploded therefrom. 
         FIG. 3  is top perspective view of the pin guide with terminals inserted therein; the connector is not shown for purposes of illustration. 
         FIG. 4  is bottom perspective view of the pin guide with terminals inserted therein; the connector is not shown for purposes of illustration. 
         FIG. 5  is a cross-sectional view taken substantially along the line  5 - 5  of  FIG. 3  and looking in the direction of the arrows. 
         FIG. 6  is a cross-sectional view taken substantially along the line  6 - 6  of  FIG. 3  and looking in the direction of the arrows. 
         FIG. 7  is a perspective cross-sectional view showing lateral projections of the terminals positioned in recesses of the pin guide. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the invention expressly should not be limited to such preferred embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto. 
     Referring now to  FIGS. 1 and 2 , a connector  2  includes an electrical header assembly  10  having a dielectric housing  12 , made of thermoplastic material or other suitable material, and a plurality of conductor pins or terminals  14   a ,  14   b . Conductor terminals  14   a ,  14   b  may be made from any suitable conductive materials which have the appropriate properties required to allow the terminals  14   a ,  14   b  to be mated and unmated over various cycles. 
     The housing  12  has two rows of longitudinal terminal receiving recesses which extend through the housing from a mating connector receiving end  18  to a conductor end  20 . In the illustrative embodiment shown, the mating end  18  of the housing  12  has a socket portion  22  for mating with an appropriate plug-in connector. However, various numbers of rows and other configurations of the terminal receiving recess and the mating end  18  can be used without departing from the scope of the invention. 
     The housing  12  shown in  FIGS. 1 and 2  is shown for illustrative purposes only. Many different housings can be used without departing from the scope of the invention. 
     The recesses are dimensioned to receive mating portions  30  of the conductor terminals  14   a ,  14   b  therein. In the illustrative embodiment shown, the mating ends  30  of the terminals  14   a ,  14   b  are preferably round and have tapered or pointed ends. Each terminal  14   a ,  14   b  has a connector securing section  32  provided proximate the mating portion  30 . The connector securing sections  32  have projections or barbs  34  which extend therefrom. 
     Substrate mating ends or tail ends  38  extend from connector securing sections  32  and from the housing  12 . The substrate mating ends or tail ends  38  are bent, as will be more fully described. The tail ends  38  have substrate mating portions  42 , may have, but are not limited to, compliant section or barbs, which are dimensioned to cooperate with openings  44 , such as, but not limited to, through holes of a mating substrate  46 . The tail ends  38  of the terminals  14   a ,  14   b  have lateral projections  36  which extend therefrom. The lateral projections  36  are position between the securing sections  32  and the substrate mating portions  42 . 
     Referring to  FIGS. 1 through 7  an illustrative embodiment of a pin guide  50  of the connector  2  is shown. The pin guide  50  is configured to cooperate with terminals  14   a ,  14   b , as will be more fully described. The pin guide  50  is made of thermoplastic material or other suitable material, which has the appropriate strength and non-conductive characteristics required. 
     As best shown in  FIGS. 3 and 4 , the pin guide  50  has a header or housing mating surface  52  and an oppositely facing rear surface  54 . A substrate mating surface  56  extends between the header mating surface  52  and the rear surface  54 . In the embodiment shown, the substrate mating surface  56  is essentially perpendicular to the header mating surface  52 , but other configurations can be used without departing from the scope of the invention. A top surface  58  extends between the header mating surface  52  and the rear surface  54  and is opposed to the substrate mating surface  56 . 
     As best shown in  FIG. 5 , cavities or slots  60  extend from the header mating surface  52  toward the rear surface  54  and from substrate mating surface  56  toward the top surface  58 . As best shown in  FIGS. 6 and 7 , walls  62  are provided between the cavities  60  to provide separation between the cavities  60  and to provide structural integrity to the pin guide  50 . The walls  62  also cooperate with the terminals  14   a ,  14   b  to properly position the terminals  14   a ,  14   b  in respective cavities  60 . 
     Referring again to  FIG. 5 , a supporting and positioning partition  64  is provided in each cavity  60 . The partitions  64  are located proximate the top surface  58  and extend between respective walls  62 . The partitions  64  provide positive support and positioning members which cooperate with respective terminals  14   a ,  14   b , as will be more fully described. 
     Positioning recesses  65 , as best shown in  FIGS. 6 and 7 , are provided proximate each cavity  60 . The recesses  65  are located proximate the substrate mounting surface  56  and extend between respective cavities  60 . The recesses  65  have supporting and positioning shoulders  66 . The shoulders  66  are provided on the walls  62  and cooperate with respective terminals  14   a ,  14   b  to provide positive support and positioning, as will be more fully described. 
     As best shown in  FIG. 4 , extending from the substrate mating surface  56  in a direction away from the top surface  58  are mounting and alignment projections or posts  68 . In the embodiment shown, two alignment posts  68  are provided; however, other configurations can be used without departing from the scope of the invention. 
     As best shown in  FIG. 3 , a locking projection  70  extends from the header mating surface  52  in a direction away from the rear surface  54 . The locking projection  70  is configured and positioned to cooperate with a locking surface provided on the conductor end  20  of the housing  12  of the header  10 . 
     As previously stated, in the illustrative embodiment shown, the housing  12  has two rows of recesses. As best shown in  FIG. 2 , each cavity in the upper row is aligned with a cavity in the lower row. 
     The conductor terminals  14   a ,  14   b  are straight when inserted into the recesses. Alternatively, the housing  12  may be overmolded over the terminals  14   a ,  14   b . In the embodiment shown, the conductor terminals  14   a ,  14   b  in the lower row are assembled first. As the terminals  14   a ,  14   b  are inserted into the recesses, the projections  34  of the securing sections  32  engage the walls of the recesses to properly position and maintain the terminals  14   a ,  14   b  in the recesses. The tail ends  38  of these conductor terminals are then bent perpendicular or essentially perpendicular to the longitudinal axis of the recesses. 
     The conductor terminals  14   a ,  14   b  in the upper row are then assembled in like manner. As the terminals  14   a ,  14   b  are inserted into the recesses, the projections  34  of the securing sections  32  engage the walls of the recesses to properly position and maintain the terminals  14   a ,  14   b  in the recesses. The tail ends  38  of these conductor terminals  14   a ,  14   b  are then bent perpendicular or essentially perpendicular to the longitudinal axis of the recesses. 
     As best shown in  FIGS. 1 and 2 , the tail ends of the terminals in the upper row are in line, but spaced from the tail ends of the terminals in the lower row. The tail ends  38  of the terminals  14   a ,  14   b  in the upper row are spaced from the conductor end  20  of the housing  12  a greater distance that the tail ends  38  of the terminals  14   a ,  14   b  in the lower row, such that the substrate mating portions  42  of the tail ends  38  of the terminals  14   a  in the upper row are staggered from the substrate mating portions  42  of the tail ends  38  of the terminals  14   b  in the lower row. 
     While the embodiment shown and described has the tail ends  38  bent in a perpendicular direction, other embodiments may be used without departing from the scope of the invention. In addition, the terminals  14   a ,  14   b  in the upper row and lower row may be inserted and bent at the same time. 
     With the terminals  14   a ,  14   b  properly inserted into the recesses and bent according to the appropriate specifications, the pin guide  50  is inserted onto the terminals  14   a ,  14   b.    
     Referring to  FIGS. 1 through 4 , the pin guide  50  has a plurality of longitudinal slots or cavities  60 . The cavities  60  are dimensioned to be slightly thicker than the tail ends  38  of the terminals  14   a ,  14   b . When the pin guide  50  is inserted onto the terminals  14   a ,  14   b , each cavity  60  of the pin guide  50  is aligned vertically with a recess and its respective terminal  14   a ,  14   b  in the upper row of the housing  12  and a recess and its respective terminal  14   a ,  14   b  in the lower row. 
     Insertion of the pin guide  50  onto terminals  14   a ,  14   b  continues until the terminals  14   a , which extend from the upper row, engage or are positioned proximate to the positioning partition  64  and the rear surface  54 , as best shown in  FIG. 5 . In this position lateral projections  36  of the terminals  14   a ,  14   b  extending from both the upper row and the lower row are positioned in respective recesses  65  and engage respective shoulders  66 , as best shown in  FIGS. 6 and 7 . 
     With the pin guide  50  fully inserted onto the terminals  14   a ,  14   b , the pin guide is properly positioned relative to the housing  12 . In this position, the locking projection  70  of the pin guide  50  engages the locking surface of the housing  12  to removably attach and maintain the pin guide  50  in position relative to the housing  12 . In the illustrative embodiment shown, only one locking projection  70  is shown. However, additional locking projections can be provided without departing from the scope of the invention. 
     In the fully inserted position, the bends of the terminals  14   a  and  14   b  are housed in the pin guide  50 . Terminals  14   a  are positioned proximate to or abutting partition  64  and rear surface  54 . Positioned in each cavity  60  is one respective terminal  14   a  and one respective terminal  14   b . Lateral projections  36  are positioned in respective recesses  64  and cooperate with respective shoulders  66 . 
     With the pin guide  50  properly positioned relative to the terminals  14   a ,  14   b  and the housing  12 , the header  10  and pin guide  50  are moved into position on a printed circuit board or substrate  46 . The housing  12  may have lateral flanges for attaching the housing  12  to the printed circuit board  46  by suitable securing means. The printed circuit board  46  typically has upper and lower conductors which are electrically connected to the terminals  14   a ,  14   b  by the substrate mating portions  42  of the tail ends  38  which project from the substrate mating surface  56  of the pin guide  50 . For this purpose, the substrate  46  has a predetermined pattern of holes  44  which receive the substrate mating portions  42  when the header  10  mated to the substrate  46 . 
     As the connector  2  is moved into engagement with the substrate  46 , the substrate mating portions  42  of the terminals  14   a ,  14   b  are moved into the through holes  44 . The cooperation and positioning of the lateral projections  36  in the recesses  65  ensures that the substrate mating portions  42  are properly positioned relative to the through holes  44  of the substrate  46 . As substrate mating portions  42  of the terminals  14   a ,  14   b  are moved into the through holes  44 , the substrate mating portions  42  engage the walls of the through holes  44  to provide a reliable electrical connection between the plated through holes  44  and the terminals  14   a ,  14   b.    
     As the substrate mating portions  42  are configured to either deform or exert pressure on the wall of the through holes  44 , the amount of force required to insert the terminals  14   a ,  14   b  in the through holes  44  can be significant. It is, therefore, advantageous to provide a mechanism which protects the terminals  14   a ,  14   b  from damage and deformation as the substrate mating portions  42  are inserted into the through holes  44 . The pin guide  50  provides such a mechanism. 
     As the substrate mating portions  42  are inserted in the through holes  44 , the lateral projections  36  of the terminals  14   a ,  14   b  engage the shoulders  66  of the pin guide  50 . In so doing, forces applied to the substrate mating portions  42  will be transferred to the housing of the pin guide  50  through the engagement of the lateral projections  36  with the shoulders  66 . Consequently, forces/stresses associated with mating the terminals  14   a ,  14   b  to the substrate  46  are transferred to the housing of the pin guide  50  rather than through the relatively weak bends of the terminals  14   a ,  14   b.    
     Additionally, the terminals  14   a ,  14   b  may cooperate with the supporting and positioning partition  64  to provide additional support to the terminals  14   a ,  14   b , as insertion of the substrate mating portions  42  in the through holes  44  occurs. 
     The method of assembly and installing a connector includes: inserting terminals into housing; bending a portion of the terminals which extend outward from the housing; and positioning a pin guide over the bent ends of the terminals, whereby the bent ends are retained in cavities of the pin guide. The method may also include positioning projections of substrate mating ends of the terminals in recesses of the pin guide, such that the substrate mating ends of the terminals are retained in position. Additional steps may include; inserting substrate mating portions of the substrate mating ends into openings of a mating substrate; and engaging shoulders of the recesses with the projections of the terminals, whereby forces applied to the terminals during insertion are transferred to the housing. 
     The pin guide  50  accurately locates the tail ends  38  of the conductor terminals  14   a ,  14   b  which facilitates insertion of the tail ends  38  into through holes  44  in the circuit board  46  during assembly. In addition, as lateral projections  36  of the terminals  14   a ,  14   b  are maintained in position by recesses  65  and shoulder  66  of the pin guide  50 , closer tolerances can be held between the tail ends  38  and the through hole patterns. 
     The use of the pin guide  50 , which is a separate piece from the header, allows for ease of insertion of the terminals in the header and bending of the terminals thereafter. The pin guide also cooperates with the terminals to insure that a sufficient force can be applied to the header and the pin guide to facilitate mating of the compliant terminals to the circuit board. As the mating forces are transferred to the pin guide, the terminals are not damaged or deformed during mating, thereby providing a secure and reliable connection between the header and the printed circuit board. The use of the pin guide also protects the terminals during transportation of the header. 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention of the invention as defined in the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other specific forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims, and not limited to the foregoing description or embodiments.