Patent Publication Number: US-8529300-B2

Title: Electrical connector assembly

Description:
BACKGROUND OF THE INVENTION 
     The subject matter herein relates generally to electrical connectors having contact modules. 
     Known electrical systems that utilize right angle electrical connectors typically include a plurality of contact modules or wafers that are held together in a common housing. The contact modules have conductors that extend between a mating interface and a mounting interface that are oriented perpendicular to one another. The mounting interface has a plurality of pins that are configured to be mounted to the circuit board. Such electrical connectors are not without disadvantages. For instance, due to manufacturing tolerances, contact preload at the mating interface or other factors, the contact modules may be improperly positioned or oriented for mounting to the circuit board. For example, the contact modules may be skewed or angled with respect to one another and/or the housing holding the contact modules, causing the pins to be misaligned with the corresponding vias in the circuit board. Mounting the electrical connectors to the circuit board in such case could damage the pins. 
     To address such misalignment problems, some known systems use stiffeners or clips to couple the contact modules together. The stiffeners are typically metal plates that extend along the outside of the contact modules and engage portions of the contact modules to hold the contact modules at predetermined positions with respect to one another. The stiffeners add to the overall size of the electrical connectors. The stiffeners also affect the electrical performance of the electrical connectors by acting as an antenna. 
     A need remains for an improved device for organizing and holding contact modules of electrical connectors. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one embodiment, an electrical connector assembly is provided having a front housing that has a mating interface. Contact modules are loaded into the front housing and extend rearward from the front housing. Each contact module has a plurality of conductors that are held by a dielectric contact module body. The conductors have mating portions that extend from the contact module body and mounting portions that extend from the contact module body. The contact modules have channels formed therein. An organizer bar is received in the channels of the contact modules. The organizer bar is manufactured from a dielectric material. The organizer bar holds the positions of the contact modules relative to one another. 
     Optionally, the organizer bar may engage all of the contact modules held by the front housing. The channels may be open sided and the organizer bar may be snapped into the channels through the open sides thereof. The organizer bar may be circular in cross-section. Optionally, the organizer bar may include an outer surface that is stepped and includes a plurality of shoulders. The channels may include shoulders, where the shoulders of the organizer bar engage corresponding shoulders of the channels to maintain the relative positions of the contacts modules with respect to the organizer bar. 
     Optionally, each contact module body may include a top, bottom, front, rear and opposite sides. The mating portions may extend from the front and the mounting portions may extend from the bottom. The contact modules may be held in the front housing such that the sides of adjacent contact modules face one another. The channels may be located at the intersection of the tops and rears of the contact module body. The channels may be located at the intersections of the tops and the rears of the contact module bodies. The organizer bar may be received in the channels such that an outer surface of the organizer bar is positioned below the top and forward of the rear. The contact module body may include an outer perimeter defined by the front, top, rear and bottom, where the organizer bar is contained entirely within the outer perimeter of the contact module body. The channels may be located at the intersection of the tops and the rears of the contact module bodies, with each channel being bounded by an upper wall and a rear wall. An opening may extend between the upper wall and the rear wall and the organizer bar may be received in the channels through the openings between the upper walls and the rear walls. The openings may be narrower than a diameter of the organizer bar such that the organizer bar is retained within the channels by the upper walls and the rear walls. 
     Optionally, the organizer bar may be manufactured from a material having a dielectric constant approximately equal to a dielectric constant of the contact module body. The channels may be defined by interior surfaces of the contact module bodies that are stepped and include one or more flanges extending outward from the interior surfaces into the channels. The organizer bar may include grooves extending circumferentially around the organizer bar, where the flanges are received in corresponding grooves. The contact modules may be overmolded lead frames with the channels being formed during the molding of the contact module body in an area of the contact module body devoid of the conductors. 
     In another embodiment, an electrical connector assembly is provided having a front housing that has a mating interface. Contact modules are loaded into the front housing and extend rearward from the front housing. Each contact module has a plurality of conductors held by a dielectric contact module body. The contact module body has a top, a bottom, a front, a rear and opposite sides. The contact module body has a channel that extends therethrough between the sides. The channel is located at the intersection of the top and the rear of the contact module body. The conductors have mating portions that extend from the front of contact module body and mounting portions that extend from the bottom of the contact module body. An organizer bar is received in the channels of the contact modules. The organizer bar holds the positions of the contact modules relative to one another. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a coplanar connector system formed in accordance with an exemplary embodiment illustrating two connector assemblies that may be directly connected to one another. 
         FIG. 2  is an exploded rear perspective view of the header assembly showing one of the contact modules poised for loading into the front housing 
         FIG. 3  is a side view of the receptacle assembly showing the organizer bar installed in the contact modules 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a perspective view of an electrical connector system  100  formed in accordance with an exemplary embodiment illustrating two connector assemblies  102 ,  104  that may be directly connected to one another. The connector assemblies  102 ,  104  are each directly connected to first and second circuit boards  106 ,  108 , respectively. 
     The connector assemblies  102 ,  104  are utilized to electrically connect the first and second circuit boards  106 ,  108  to one another. The connector system  100  electrically connects the first and second circuit boards  106 ,  108  without the use of header connectors mounted to a midplane circuit board. Alternatively, the connector system  100  may use header connectors mounted to a midplane circuit board with connector assemblies configured to mate to the header assemblies. Only one separable mating interface is provided between the first and second circuit boards  106 ,  108 , namely the separable mating interface between the first and second connector assemblies  102 ,  104 . Other configurations are possible in alternative embodiments, including a connector system that utilizes connector assemblies that mate to midplane connectors on a midplane circuit board. 
     The first and second circuit boards  106 ,  108  are co-planar or parallel to one another. Other configurations of the circuit boards  106 ,  108  are possible in alternative embodiments. A mating axis  110  extends through both the first and second connector assemblies  102 ,  104  and the first and second connector assemblies  102 ,  104  are mated with one another in a direction parallel to and along the mating axis  110 . In an exemplary embodiment, both the first and second circuit boards  106 ,  108  extend generally parallel to the mating axis  110 . In the illustrated embodiment, the connector system  100  electrically connects the first and second circuit boards  106 ,  108  without the use of a circuit board oriented perpendicular to the mating axis  110  arranged between the first and second connector assemblies  102 ,  104 . 
     In the illustrated embodiment, the first connector assembly  102  constitutes a receptacle assembly, and may be referred to hereinafter as receptacle assembly  102 . The second connector assembly  104  constitutes a header assembly, and may be referred to hereinafter as header assembly  104 . The receptacle assembly  102  is configured for mating with the header assembly  104 . 
     It is realized that in alternative embodiments the receptacle assembly  102  and header assembly  104  may be interchanged such that the receptacle assembly  102  may be mounted to the second circuit board  108  and header assembly  104  may be mounted to the first circuit board  106 . It is also realized that different types of electrical connectors may be utilized to electrically connect the first and second circuit boards  106 ,  108  without the use of a midplane circuit board with corresponding header connectors mounted thereto. The different types of electrical connectors may have different shapes, form factors, mating interfaces, contact arrangements, contact types and the like in alternative embodiments. The receptacle assembly  102  and header assembly  104  are merely illustrative of an exemplary embodiment of the connector system  100 . 
     The receptacle assembly  102  includes a front housing  112  having a mating interface  114  at a front  116  of the front housing  112 . A plurality of contact modules  118  are held by the front housing  112 . The contact modules  118  are loaded through and extend rearward from a rear  120  of the front housing  112 . The contact modules  118  are electrically connected to the first circuit board  106 . The mating interface  114  is oriented perpendicular with respect to the first circuit board  106  and the mating axis  110 . 
     The header assembly  104  includes a front housing  122  having a mating interface  124  at a front  126  of the front housing  122 . A plurality of contact modules  128  are held by the front housing  122 . The contact modules  128  are loaded through and extend rearward from a rear  130  of the front housing  122 . The contact modules  128  are electrically connected to the second circuit board  108 . The mating interface  124  is oriented perpendicular with respect to the second circuit board  108  and the mating axis  110 . 
     The front housing  122  includes a chamber  132  that receives at least a portion of the receptacle assembly  102 . An array of contacts  200  are arranged within the chamber  132  for mating with corresponding mating contacts (not shown) of the receptacle assembly  102 . The mating contacts  200  extend from corresponding contact modules  128  into the chamber  132  when the contact modules  128  are coupled to the front housing  122 . The mating contacts  200  are electrically connected to the second circuit board  108  by the contact modules  128 . In an alternative embodiment, the front housing  112  of the receptacle assembly  102  includes a chamber that receives at least a portion of the header assembly  104  therein. 
     The receptacle assembly  102  includes an organizer bar  140  coupled to the contact modules  118 . In the illustrated embodiment, the organizer bar  140  engages all of the contact modules  118 , however the organizer bar  140  may engage less than all of the contact modules  118  and/or more than one organizer  140  may be used to engage all of the contact modules  118  in alternative embodiments. The organizer bar  140  holds the relative positions of the contact modules  118  with respect to one another and/or with respect to the front housing  112 . The organizer bar  140  holds the contact modules  118  at a predetermined pitch and/or spacing. The organizer bar  140  holds the contact modules  118  parallel to one another. The organizer bar  140  holds the conductors of the contact modules  118  at predetermined positions, such as at the mounting interface of the receptacle assembly  102 , for mounting to the circuit board  106 . 
     The header assembly  104  includes an organizer bar  142  coupled to the contact modules  128 . In the illustrated embodiment, the organizer bar  142  engages all of the contact modules  128 , however the organizer bar  142  may engage less than all of the contact modules  128  and/or more than one organizer  142  may be used to engage all of the contact modules  128  in alternative embodiments. The organizer bar  142  holds the relative positions of the contact modules  128  with respect to one another and/or with respect to the front housing  122 . The organizer bar  142  holds the contact modules  128  at a predetermined pitch and/or spacing. The organizer bar  142  holds the contact modules  128  parallel to one another. The organizer bar  142  holds the conductors of the contact modules  128  at predetermined positions, such as at the mounting interface of the header assembly  104 , for mounting to the circuit board  108 . Optionally, the organizer bar  142  may be substantially similar to, or identical to, the organizer bar  140 . The organizer bars  140 ,  142  may be coupled to the corresponding contact modules  118 ,  128 , respectively, in similar manners. 
       FIG. 2  is an exploded, rear perspective view of the header assembly  104 , showing one of the contact modules  128  poised for loading into the front housing  122 . The contact modules  128  include the contacts  200  and both the contact modules  128  and the contacts  200  are loaded through the rear  130  of the front housing  122 . Optionally, the contacts  200 , at the mating interface, may be blade-type contacts having a generally rectangular cross-section, however other contact types are possible in alternative embodiments. The contacts  200  are configured to be electrically connected to the circuit board  108  (shown in  FIG. 1 ). The contacts  200  include a subset of signal contacts  202  and a subset of ground contacts  204 . In an exemplary embodiment, the ground contacts  204  are longer than the signal contacts  202  such that the ground contacts  204  engage the contacts of the receptacle assembly  102  (shown in  FIG. 1 ) prior to the signal contacts  202  engaging the contacts of the receptacle assembly  102 . A sequential mating interface is defined by such arrangement. Optionally, the header assembly  104  may include other types of contacts, such as power contacts (not shown). The power contacts may have a length that is different from the ground contacts  204  and/or the signal contacts  202 . Additionally, the header assembly  104  may have signal contacts  202  of different lengths. 
     The contact modules  128  define a mounting face  224  of the header assembly  104 . The mounting face  224  is configured to be mounted to the circuit board  108  (shown in  FIG. 1 ). The mating interface  124  is oriented perpendicular with respect to the mounting face  224 , however non-perpendicular configurations are possible in alternative embodiments. 
     The housing  122  includes a body  230  extending between the front  126  at the mating interface  124  and the rear  130 . The contact modules  128  are coupled to the rear  130  of the housing  122  and extend rearward from the rear  130 . Optionally, at least a portion of the contact modules  128  may be loaded into the rear  130  and secured thereto. 
     The body  230  includes a top  232  and a bottom  234 . The body  230  includes opposed sides  236 ,  238  that extend between the top  232  and the bottom  234 . The chamber  132  is defined between the top  232  and the bottom  234 . 
     In the illustrated embodiment, the contact module  128  includes a contact module body  240  having opposed sides  242 ,  244 . The contact module body  240  holds the contacts  200 . The contacts  200  include mating portions  246  that extend forward from the contact module body  240  and contact tails  248  that extend downward from the contact module body  240 . Transition portions of the contacts  200  between the mating portions  246  and the contact tails  248  are encased by the contact module body  240 . Optionally, the contact module body  240  may be overmolded over the contacts  200  with the mating portions  246  and the contact tails  248  extending from the contact module body  240 . Optionally, the contacts  200  may be formed from a lead frame and the contact module body  240  may be overmolded around the lead frame. Alternatively, individual signal contacts, such as stamped and formed contacts, may be separately positioned within the contact module body  240 . 
     The contact module body  240  includes a front  250 , a bottom  252  that is perpendicular to the front  250 , a rear  254  opposite the front  250  and a top  256  opposite the bottom  252 . The front  250  defines a mating edge of the contact module  128  that is loaded into and mated to the front housing  122 . The bottom  252  defines a mounting edge that is configured to be mounted to the circuit board  108 . The contacts  200  generally extend between the mating edge and the mounting edge along a conductor plane. The mating portions  246  extend from the front  250 . The contact tails  248  extend from the bottom  252 . The contacts  200  may be arranged in pairs with two signal contacts representing a differential pair, and the pairs being separated by ground contacts. 
     The contact tails  248  may be eye-of-the-needle type contacts that fit into vias in the circuit board  108 . Other types of contacts may be used for through hole mounting or surface mounting to the circuit board  108 . Different types of contacts may be used to terminate the contact module  128  to cables rather than to the circuit board  108 , in alternative embodiments. 
     In the illustrated embodiment, at least some of the contacts  200  represent ground contacts  204  that are part of the lead frame and held within the contact module body  240 . The ground contacts  204  may be connected to corresponding ground mating contacts of the receptacle assembly  102 . Alternatively, rather than ground contacts  204  held by the contact module body  240 , a separate shield (not shown) may be coupled to the contact module body  240 , where the shield has the ground contacts  204  extending therefrom and interspersed between the mating portions  246  of the signal contacts  202  of the contact module  128 . 
     The contact module body  240  includes a channel  260  extending therethrough. The channel  260  receives the organizer bar  142 . The channel  260  extends between the sides  242 ,  244  along a channel axis  262 . In an exemplary embodiment, the channel axis  262  is generally parallel to the mating interface  124  of the front housing  122 . The channel  260  is generally cylindrical in shape, however other shapes are possible in alternative embodiments. 
     In an exemplary embodiment, the channel  260  is provided at the intersection between the rear  254  and the top  256 . The channel  260  is open at the corner defined between the rear  254  and the top  256 . The channel  260  is open-sided such that the organizer bar  142  may be snapped into the channel  260  through the open side of the channel  260 . 
     The channel  260  is defined by an interior surface  264  of the contact module body  240 . The channel  260  is stepped and includes at least one shoulder  266 . In the illustrated embodiment, the channel  260  includes a plurality of flanges  268  that extend from the interior surface  264  into the channel  260 . The flange  268  defines the shoulders  266  on both sides of the flange  268  that extend radially inward from a radially outermost portion of the interior surface  264 . The flange  268  has a smaller diameter than the interior surface  264 . In alternative embodiment, rather than a flange extending into the channel  260 , a groove may be recessed from the interior surface  264  that has a diameter that is larger than the diameter of the interior surface  264 . The groove may define the shoulders. Other types of features may be provided in the channel  260  that interact with the organizer bar  142  to position the contact module body  240  with respect to the organizer bar  142 . 
     The contact module body  240  includes an outer perimeter defined by the front  250 , the bottom  252 , the rear  254  and the top  256 . The channel  260  is recessed into the contact module body  240  interior of the outer perimeter of the contact module body  240 . The organizer bar  142 , when received in the channel  260 , is contained entirely within the outer perimeter of the contact module body  240 . An outer surface of the organizer bar  142  is positioned below the top  256  and forward of the rear  254 . The channel  260  has an upper wall  270  and a rear wall  272 . An opening  274  is defined between the upper wall  270  and the rear wall  272 . The opening  274  provides access to the channel  260 . The organizer bar  142  is loaded into the channel  260  through the opening  274 . When the organizer bar  142  is in the channel  260 , the upper wall  270  extends above a portion of the organizer bar  142 . A portion of the rear wall  272  extends rearward of or behind a portion of the organizer bar  142 . The upper wall  270  restricts removal of the organizer bar  142 . The rear wall  272  restricts removal of the organizer bar  142 . In an exemplary embodiment, the width of the opening  274  is less than a diameter of the organizer bar  142 . When the organizer bar  142  is loaded into the channel  260 , the upper wall  270  and/or the rear wall  272  may be at least partially deflected allowing the organizer bar  142  to pass through the opening  274  into the channel  260 . The organizer bar  142  may be snapped into the channel  260  and held therein by the upper wall  270  and the rear wall  272 . 
     In an exemplary embodiment, the organizer bar  142  is manufactured from a dielectric material, such as a plastic material. Optionally, the organizer bar  142  may be manufactured from a dielectric material having a similar dielectric constant as the dielectric material of the contact module body  240 . Having the organizer bar  142  manufactured from dielectric material, the organizer bar  142  does not negatively impact the electrical characteristics of the header assembly  104 . 
     The organizer bar  142  extends along a longitudinal axis  280 . The organizer bar  142  has an outer surface  282  having a generally circular cross-section. The outer surface  282  of the organizer bar  142  is stepped and includes a plurality of shoulders  284 . In the illustrated embodiment, the organizer bar  142  includes a plurality of grooves  286  therein that define the stepped outer surface  282 . The grooves  286  define the shoulders  284 , which extend radially inward from a radially outermost portion of the outer surface  282 . When the organizer bar  142  is loaded into the channel  260 , the flanges  268  are received in the grooves  286 . The shoulders  266  engage the shoulders  284  to hold the position of the contact module body  240  with respect to the organizer bar  142 . In an alternative embodiment, rather than grooves  286 , the organizer bar  142  may include other features, such as flanges or posts extending outward from the outer surface  282  that are configured to extend into complementary features in the channel  260  to longitudinally position the contact module  128  with respect to the organizer bar  142 . 
     When the organizer bar  142  is securely engaged in the channels  260 , each of the contact modules  128  is held in place relative to the other contact modules  128 . The organizer bar  142  holds the true position of the contact tails  248  for mounting to the circuit board  108 . 
     The longitudinal positions of the contact modules  128  are controlled by the organizer bar  142 . For example, the rears  254  of the contact module bodies  240  are properly spaced apart and held by the organizer bar  142 , while the fronts  250  of the contact module bodies  240  are held by the front housing  122 . The organizer bar  142  and the front housing  122  cooperate to orient the contact modules  128  along parallel planes. With the contact modules  128  properly positioned, the contact tails  248  of the contact modules  128  are properly aligned for loading into corresponding vias when the header assembly  104  is mounted to the circuit board  108 . 
       FIG. 3  is a side view of the receptacle assembly  102 , showing the organizer bar  140  installed in the contact modules  118 . The organizer bar  140  is contained within the outer perimeter defined by the contact module  118 . For example, the organizer bar  140  is positioned below a top  365  of the contact module  118  and is positioned forward of a rear  354  of the contact module  118 . Having the organizer bar  140  extending through all of the contact modules  118  helps to hold relative movement of the contact modules  118  with respect to one another. For example, the organizer bar  140  holds the horizontal positions (e.g., front to back positions) along an axis  300  with respect to one another. The organizer bar  140  holds the vertical positions (e.g., top to bottom positions) of the contact modules  118  with respect to one another along an axis  302 . Engagement between shoulders of the organizer bar  140  and shoulders defined within channels  360  of the contact modules  118  holds the side to side positions of the contact modules  118 . 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. 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.