Patent Publication Number: US-10784623-B2

Title: Electrical connector

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application is a continuation application of prior application Ser. No. 16/190,809, filed on Nov. 14, 2018, which claims the benefit of priority under 35 U.S.C. § 119(e) to Provisional Patent Application No. 62/588,593, filed on Nov. 20, 2017, and is also a Continuation-In-Part of International Patent Application No. PCT/US2017/047800, filed on Aug. 21, 2017, which claims priority to Provisional Patent Application No. 62/377,859, filed on Aug. 22, 2016, all of the foregoing applications being herein incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to an electrical connector for connecting electronic and/or electrical parts that may be misaligned. 
     BACKGROUND 
     In an electronic/electric system, it is necessary to establish electrical connections between constituent parts of the system. Often, these parts are relatively rigid and have fixed locations where the parts are to be connected together. For example, the parts that are to be connected together may be printed circuit boards (PCBs) and the connection locations may be plated through-holes in the PCBs. While each PCB may be produced in compliance with strict tolerances, the connection locations between the PCBs may nonetheless become misaligned due to tolerance stacking or other reasons. 
     A misalignment between the connection locations of parts can cause mating problems when the parts are connected together (or attempted to be connected together). For example, as set forth above, one or both of the parts may be a PCB with plated through-holes as connection points. In such a situation, a connector is typically secured to the through-holes using soldering or press-fit connections. Such connections, which are rigid and relatively fragile, can be physically damaged by errant forces that are produced when the misaligned parts are brought together. Even if the parts are not damaged, the electrical connections may not be as robust as they should be, due to the misalignment. 
     Based on the foregoing, it would be desirable to provide an electrical connector for electrically connecting parts, wherein the connector accommodates misalignment between the parts. 
     SUMMARY 
     In accordance with the disclosure, a connector is provided for connection to a substrate for mounting electronic devices and/or electrical devices. The connector includes a housing having opposing first and second ends with openings, respectively, and a plurality of wall structures that includes a first wall structure having a notch or a slot formed therein. A plurality of monolithic coupling contacts are disposed within the housing. Each of the coupling contacts includes a pair of elements having opposing first and second end portions, respectively. The elements in each pair are joined together, intermediate the first and second end portions. The first end portions are separated by a first space and the second end portions are separated by a second space. The coupling contacts are arranged in a stack in the housing such that the first spaces are aligned to form a first receiving groove in the stack, which is disposed at the first end of the housing, and the second spaces are aligned to form a second receiving groove in the stack, which is disposed at the second end of the housing. A monolithic mounting contact extends into the housing and has a bar section joined to a plurality of fastening structures that are adapted for securement to the substrate. The bar section is at least partially disposed in the second receiving groove in the stack and extends through the notch or the slot of the first wall structure so that an outer portion of the bar section is disposed outwardly from the first wall structure. 
     Also provided in accordance with the disclosure is a coupler for connecting together rigid structures. The coupler includes a housing having opposing first and second ends with openings, respectively, and a plurality of wall structures that includes first and second wall structures. Each of the first and second wall structures has a slot formed therein, with the slots being aligned. The first wall structure has a projection joined thereto and extending therefrom. The projection has an engagement structure and is adapted for securement within an opening in the substrate. A plurality of monolithic coupling contacts is disposed within the housing. Each of the coupling contacts includes a pair of elements having opposing first and second end portions, respectively. The elements in each pair are joined together, intermediate the first and second end portions. The first end portions are separated by a first space and the second end portions are separated by a second space. The coupling contacts are arranged in a stack in the housing such that the first spaces are aligned to form a first receiving groove in the stack, which is disposed at the first end of the housing, and the second spaces are aligned to form a second receiving groove in the stack, which is disposed at the second end of the housing. The first and second receiving grooves are adapted to receive the rigid structures therein, respectively. The second receiving groove is aligned with the slots of the first and second wall structures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where: 
         FIG. 1  shows a perspective view of a coupler of the disclosure; 
         FIG. 2  shows a partially disassembled perspective view of the coupler with a stack of contact plates removed from a housing; 
         FIG. 3  shows a plan view of one of the contact plates; 
         FIG. 4  shows a perspective view of a mounting contact for connection to the coupler; 
         FIG. 5  shows a perspective view of a connecting contact for connection to a substrate; 
         FIG. 6  shows a perspective view of a pair of printed circuit boards connected together by the coupler of  FIG. 1 , in combination with the mounting contact of  FIG. 4  and the connecting contact of  FIG. 5 ; 
         FIG. 7  shows a sectional view of the assembly of  FIG. 6 ; 
         FIG. 8  shows a perspective of a lead frame for connection to the coupler of  FIG. 1 ; 
         FIG. 9  shows a perspective view of a second connector formed by the coupler of  FIG. 1  and the lead frame of  FIG. 8 , the second connector being disposed between a bus bar and a printed circuit board; 
         FIG. 10  shows a perspective view of a third connector formed by the coupler of  FIG. 1  and a second lead frame; 
         FIG. 11  shows a perspective view of a fourth connector formed by the coupler of  FIG. 1  and a third lead frame; 
         FIG. 12  shows a partially exploded view of the fourth connector of  FIG. 11 , with the coupler being separated from the third lead frame; 
         FIG. 13  shows a front perspective view of a fifth connector formed by a second coupler and a fourth lead frame; 
         FIG. 14  shows a rear perspective view of the fifth connector; 
         FIG. 15  shows a partially exploded rear perspective view of the fifth connector, with the second coupler being separated from the fourth lead frame; 
         FIG. 16  shows a perspective view of an assembly comprising a pair of substrates, a plurality of third connectors, a plurality of fourth connectors and a plurality of fifth connectors; 
         FIG. 17  shows a front perspective view of a sixth connector formed by a third coupler and a fifth lead frame; 
         FIG. 18  shows a rear perspective view of the sixth connector; 
         FIG. 19  shows a partially exploded front perspective view of the sixth connector; 
         FIG. 20  shows a pair of the sixth connectors secured to a pair of substrates, respectively, with a bar in the process of being connected to the sixth connectors; 
         FIG. 21  shows the sixth connectors secured to the substrates, respectively, with the bar connected between the sixth connectors; 
         FIG. 22  shows a schematic sectional view of the connection of the bar to one of the connectors shown in  FIG. 21 ; 
         FIG. 23  shows a front perspective view of a seventh connector; 
         FIG. 24  shows a front perspective view of an eighth connector; and 
         FIG. 25  shows three of the couplers of  FIG. 1  connecting together a pair of plates. 
     
    
    
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     It should be noted that in the detailed descriptions that follow, identical components have the same reference numerals, regardless of whether they are shown in different embodiments of the present disclosure. It should also be noted that for purposes of clarity and conciseness, the drawings may not necessarily be to scale and certain features of the disclosure may be shown in somewhat schematic form. 
     Spatially relative terms, such as “top”, “bottom”, “lower”, “above”, “upper”, and the like, are used herein merely for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as they are illustrated in (a) drawing figure(s) being referred to. It will be understood that the spatially relative terms are not meant to be limiting and are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the drawings. 
     Referring now to  FIGS. 1 and 2 , there is shown a coupler  10  constructed in accordance with this disclosure. The coupler  10  is comprised of a stack  12  of coupling contacts or contact plates  14  disposed in a housing  16 . Each of the contact plates  14  is a unitary or monolithic structure and is electrically conductive, being composed of a conductive metal, such as a tin plated copper alloy. As best shown in  FIG. 3 , each contact plate  14  includes a pair of irregular-shaped elements or legs  18   a,b . Each leg  18   a,b  includes an upper first portion  22   a,b  with a dog leg configuration and a lower second portion  24   a,b  with a generally L-shaped configuration. The first portion  22   a,b  includes a first end portion  26   a,b  with an inwardly-directed bulge  27   a,b . The first end portion  26   a,b  angles outwardly, relative to a longitudinal center axis L of the contact plate  14 , which extends between the legs  18   a,b . The second portion  24   a,b  includes a second end portion  28   a,b  that extends laterally inward from an outer heel and then, towards the longitudinal center axis L, bends upward. The legs  18   a,b  are joined together by a cross bar  30 , intermediate the first and second end portions  26   a,b ,  28   a,b . The cross bar  30  extends laterally between the legs  18   a,b  and helps give the contact plate  14  a general H-shape. The first end portions  26   a,b  define a first receiving space  34  therebetween, while the second end portions  28   a,b  define a second receiving space  36  therebetween. Each of the first receiving spaces  34  has a wide outer portion and a narrow inner portion, thereby giving the first receiving space a general V-shape. Each of the second receiving spaces  36  is also V-shaped; however, the first receiving space  34  is larger and its V-shape is more pronounced than the second receiving space  36 . The first receiving space  34  adjoins a first inner space  38 , while the second receiving space  34  adjoins a second inner space  40 . 
     As shown, the contact plates  14  are disposed serially, with their planar surfaces adjoining each other, to form the stack  12 . However, in other embodiments, the contact plates  14  may be separated by spaces, respectively. The contact plates  14  are aligned with each other such that the first receiving spaces  34  form a first receiving groove  42  and the second receiving spaces  36  form a second receiving groove  44 . Similarly, the first inner spaces  38  form a first inner passage  46  and the second inner spaces  40  form a second inner passage  48 . The narrowest portion of the first receiving groove  42 , which directly adjoins the first inner passage  46  and is formed by the narrow inner portions of the first receiving spaces  36 , is referred to as the contact zone  49 . The contact zone  49  extends between the bulges  27   a,b  of the contact plates  14 . The first and second receiving grooves  42 ,  44  and the first and second inner passages  46 ,  48  extend in the stacking direction, which is normal to the planar surfaces of the contact plates  14 . The number of contact plates  14  that are used is determined by the amount of electrical current the coupler  10  is designed to handle, with the current carrying capacity of the coupler  19  being increased by increasing the number of contact plates  14  used. Other factors that affect the current carrying capacity of the coupler  10  include the thickness of each contact plate  14 , the type of plating used and the composition of the underlying metal structure. 
     The housing  16  is generally cuboid and is composed of an insulative material, such as plastic. The interior of the housing  16  is hollow and is sized to receive the stack  12  of contact plates  14  in a press fit operation, i.e., the interior is smaller in one or more dimensions than the stack  12 . The housing  16  includes opposing first side walls  54   a,b , opposing second side walls  50   a,b  and opposing first and second ends  58 ,  60 , which are open. The second side walls  50   a,b  each have a rectangular major opening  62  disposed toward the first open end  58  and a rectangular minor opening  64  disposed toward the second end  60 . The first side walls  54   a,b  each have a rectangular major slot  66  disposed toward the first open end  58  and a rectangular minor slot  68  disposed toward the second end  60 . The minor slot  68  is defined by an abutment edge  69  that extends laterally between a pair of parallel edges  70 . The abutment edge  69  is spaced inward from the second end  60 . 
     The contact plates  14  are secured within the housing  16  in a press-fit operation in which the stack  12  as a whole is pressed into the housing  16  through the second open  60 . The resulting interference fit between the stack  12  and the housing  16  secures the contact plates  14  within the housing  16 , but permits pivoting motion of the contact plates  14 , as will be discussed more fully later. 
     The contact plates  14  are disposed within the housing  16  such that the first receiving spaces  34  of the contact plates  14  are aligned with the first end  58  of the housing  16  and the second receiving spaces  36  of the contact plates  14  are aligned with the second end  60  of the housing  16 . In addition, the first receiving groove  42  of the stack  12  is aligned with the major slots  66  in the housing  16  and the second receiving groove  44  of the stack  12  is aligned with the minor slots  68  in the housing  16 . 
     For purposes of facilitating description, components of the coupler  10  may be described with regard to X, Y, Z spatial coordinates, which are as follows: the X-axis extends through the first side walls  54   a,b  of the coupler  10 , the Y-axis extends through the second side walls  50   a,b  of the coupler  10 , and the Z-axis extends through the first and second ends  58 ,  60  of the coupler  10 . 
     The coupler  10  may be used in a variety of applications. In one application, the coupler  10  may be used to physically and electrically connect together two bus bars, with one bus bar being disposed in the first receiving groove  42  (and engaging the contact plates  14  therein) and the other bus bar being disposed in the second receiving groove  44  (and engaging the contact plates  14  therein). In another application (shown in  FIG. 25 ), three of the couplers  10  arranged side-by-side may be used to physically and electrically connect together a pair of L-shaped metal plates  71 ,  73 , with a short leg of the plate  71  being disposed in the first receiving grooves  42  of the couplers  10  (and engaging the contact plates  14  therein) and a short leg of the plate  73  being disposed in the second receiving grooves  44  of the couplers  10  (and engaging the contact plates  14  therein). The major slots  66  and the minor slots  68  in the housing  16  permit the coupler  10  to receive the bus bars from different angles or directions. For example, both the first receiving groove  42  and the second receiving groove  44  may receive a bus bar that is oriented with its longitudinal axis parallel to the X-axis of the coupler  10  or parallel to the Y-axis of the coupler  10 . In this manner, the two bus bars connected by the coupler  10  can be arranged parallel to each other in the direction of the X-axis or the Y-axis, or arranged perpendicular to each other. 
     In another application, the coupler  10  may be used to electrically connect an edge connector of a PCB to a bus bar, an electrical/electronic device, or an edge connector of another PCB. The PCB edge connector may be disposed in the second receiving groove  44 , while a bus bar, bar-like portion of the electrical/electronic device or an edge connector of the other PCB may be disposed in the first receiving groove  42 . 
     In still another application, a mounting contact may be used to mount the coupler  10  to a substrate, such as a printed circuit board (PCB). Different embodiments of the mounting contact may be used, depending on the requirements of a particular application. One embodiment of the mounting contact (designated by the reference numeral  74 ) is shown in  FIG. 4 . The mounting contact  74  is a monolithic structure and is electrically conductive, being composed of a conductive metal, such as a tin plated copper alloy. The mounting contact  74  includes fastening structures  76  joined to a bar section  78 . The bar section  78  is channel-shaped, having a center beam  80  joined between opposing, outwardly-extending arms  82 . A blade  84  is joined to an upper portion of the beam  80  and has beveled surfaces that form an elongated edge. The blade  84  helps guide the beam  80  into the second receiving groove  44  and the second inner passage  48  of the stack  12  of contact plates  14 . 
     The fastening structures  76  are joined to a lower portion of the beam  80  and extend outwardly therefrom, in a direction opposite the arms  82 . Each fastening structure  76  may have an eye-of-the-needle (EON) type of press-fit construction. With this type of construction, each fastening structure  76  includes a center piercing  86  forming a pair of beams  88  that bow outwardly and are joined at an outer tip  90  and at an inner neck  92 , which is joined to the beam  80 . Each fastening structure  76  is adapted to be press-fit into a hole in a substrate, such as the plated hole in the PCB shown in  FIG. 7 . As the fastening structure  76  is being press-fit into the hole, the beams  80  initially deflect inward and then resiliently move outward to provide a normal force against the PCB hole, thereby providing a reliable physical and electrical connection. 
     The fastening structures used in the mounting contact  74  are not limited to having an EON-type of press fit construction. Instead, fastening structures having a different press-fit construction may be used, or the fastening structures may simply be elongated pins that are soldered into the holes of a PCB. In still another embodiment, the mounting contact  74  may have a single fastening structure that includes a mount joined to the beam  80 , wherein the mount has a lower enlarged planar surface that may be sintered or soldered to a metal plate of an insulated metal substrate, such as a metal core printed circuit board. 
     The coupler  10  may be used with a connecting contact to connect together two substrates, such as two PCBs, especially when higher currents (30 amps or greater) are involved. Referring now to  FIG. 5 , such a connecting contact  90  is shown. The connecting contact  90  has the same construction as the mounting contact  74 , except the connecting contact  90  has a bar section  92  that is different from the bar section  78 . More specifically, the bar section  92  only has a center beam  94 , without any outwardly-extending arms. 
     Referring now to  FIGS. 6 and 7 , the coupler  10 , the mounting contact  74  and the connecting contact  90  are shown connecting together two PCBs  100 ,  102 , each of which has a plurality of plated through-holes that are electrically conductive. The process of connecting together the PCBs  100 ,  102  begins with the coupler  10  and the mounting contact  74  being connected together and mounted to the PCB  100 , and the connecting contact  90  being mounted to the PCB  102 . In this regard, it is noted that the mounting contact  74  may be connected to the coupler  10  before or after the mounting contact  74  is secured to the PCB  102 . However, the mounting contact  74  is typically connected to the coupler  10  before the mounting contact  74  is secured to the PCB  102 . The PCB  102  is then connected to the PCB  100  by inserting the connecting contact  90  into the coupler  10 . 
     The mounting contact  74  is secured to the coupler  10  by aligning the bar section  78  of the mounting contact  74  with the second receiving groove  44  of the coupler  10  and then applying a force to the mounting contact  74 , while the coupler  10  is held still. The blade  84  guides the beam  80  into the second receiving groove  44  and the second inner passage  48  of the stack  12  of contact plates  14 . The force is released when the beam  80  contacts the abutment edges  69  of the first side walls  54   a,b  defining upper ends of the minor slots  68 . At this point, the beam  80  extends through both the second inner passage  48  and the second receiving groove  44  and adjoins the abutment edges  69  of the first side walls  54   a,b . The arms  82  extend upward, beyond the abutment edges  69 , and adjoin the first side walls  54   a,b . In addition, the second end portions  28   a,b  of the contact plates  14  press against the beam  84 , thereby electrically connecting the coupler  10  to the mounting contact  74 . As will be discussed in more detail below, the combination of the coupler  10  and the mounting contact  74  forms a connector  105  that permits the PCB  100  to be connected to the PCB  102 , even though the PCBs may be misaligned. 
     Since the PCB  102  and the PCB  100  are rigid bodies and they are to be connected with a low Z-space therebetween, there may be some misalignment in the Y-direction between the beam  94  and the first receiving groove  42 . To better illustrate the operation of the connector  105 , the beam  94  is shown as being offset to the left (as viewed from  FIG. 7 ) from the longitudinal center axes L of the contact plates  14 . The connector  105 , however, accommodates this misalignment. As the beam  94  moves into the first receiving groove  42 , the blade  84  contacts sloping inner surfaces of the first end portions  26   a  of the contact plates  14 , which causes the contact plates  14  to pivot about the beam  80  (the X-axis) in a counterclockwise direction (as viewed from  FIG. 7 ) and guide the beam  94  into the contact zone  49 . The major opening  62  in the second side wall  50   a  permits this pivoting by receiving the first end portions  26   a  of the legs  18   a  of the contact plates  14 . The pivotal movement of the contact plates  14  is shown in  FIG. 7  and is about eight and a quarter degrees. Even though the contact plates  14  have pivoted out of their normal position, they still maintain a good physical and electrical connection with the beam  94 , thereby establishing a good physical and electrical connection between the PCB  102  and the PCB  100 . As shown in  FIG. 7 , the beam  94  is pressed between inner surfaces of the first end portions  26   a,b  of the contact plates  14  in the contact zone  49 . 
     It should be appreciated that in addition to accommodating misalignment in the Y-direction, the connector  105  also accommodates misalignment in the X-direction and the Z-direction, as well as angular or twist misalignment in any of the three directions. The alignment of the first receiving groove  42  with the major slots  66  permits the beam  94  to be offset in the X-direction vis-a-vis the first receiving groove  42  and still make a good physical and electrical connection with the contact plates  14 . In the Z-direction, the beam  94  does not need to extend into the first inner passage  46  to the full extent possible to make a good physical and electrical connection. 
     Another advantage provided by the connector  105  is that it accommodates movement between parts that may occur after the parts have been connected. For example, the parts may move relative to each other due to environmental factors, such as temperature, vibration, impact or handling. The connector  105  permits this relative movement, while still maintaining a good electrical and physical connection between the parts. 
     In addition to being well suited to connect together two PCBs, the connector  105  is well suited to connect together other rigid electronic components. In particular, the attributes of the connector  105  make it especially well suited for connecting a bus bar to a PCB to supply power thereto. These attributes of the connector  105  include its small X-Y footprint, its ability to connect together misaligned rigid bodies and its ability to accommodate larger currents. Indeed, the current capacity of the connector  105  is scalable by changing the number of contact plates  14  used and/or changing the thickness, plating or structural composition of the contact plates  14 . Current capacities of 30 amps or more are achievable. When used to connect a bus bar to a PCB, such as the PCB  100 , an end or a portion of the bus bar is disposed within the first receiving groove  42  and the first inner passage  46  such that the enlarged planar surfaces of the bus bar engage the inner surfaces of the first end portions  26   a,b  of the contact plates  14  in the contact zone  49 . Multiple connectors  105  may be used to mount a bus bar to a PCB. 
     Depending on a particular connection between a PCB and bus bar, the connector  105  may be modified to provide more stability against rotating or tipping relative to the PCB as a result of the forces that may be applied by the bus bar. One such modification may be to replace the mounting contact  74  with a different type of mounting contact. For example, the mounting contact  74  may be replaced with the mounting contact or lead frame  120 , which is shown in  FIG. 8 . The lead frame  120  is a monolithic, generally Z-shaped structure and is electrically conductive, being composed of a conductive metal, such as a tin plated copper alloy. The lead frame  120  has a bar section  122  with fastening structures  76  extending outwardly therefrom. The bar section  122  includes a center beam  124  having opposing ends joined by bends  128   130  to arms  132 ,  134 , respectively. The bends  128 ,  130  curve in opposing directions to give the lead frame  120  its Z-shape. A blade  126  is joined to an upper portion of the beam  124  and has beveled surfaces that form an elongated edge. The arms extend upwardly beyond the blade  126 . Two of the fastening structures  76  are joined to lower portions of the arms  132 ,  134 , respectively, and extend downwardly therefrom. A third (or center) fastening structure  76  is joined to a lower portion of the beam  124  and extends downwardly therefrom. A pair of supports  138  are also joined to the lower portion of the beam  124  and extend downwardly therefrom. The supports  138  bracket the center fastening structure  76 . 
     Referring now to  FIG. 9 , the lead frame  120  is shown mounted to the coupler  10  to form a connector  205 , which helps physically and electrically connect a bus bar  140  to a PCB  142  to provide power thereto. Although not shown, multiple connectors  205  may be used to mount the bus bar  140  to the PCB  142 . The lead frame  120  is mounted to the coupler  10  by inserting the beam  124  into the second receiving groove  44  and the second inner passage  48  of the coupler  10 . At the junctures with the bends  128 ,  130 , the beam  124  also adjoins the abutment edges  69  of the first side walls  54   a,b  of the housing  16 . With the beam  124  so positioned, the arms  132 ,  134  are disposed against the first side walls  54   a,b  of the coupler  10 , respectively. However, the first arm  132  is positioned against the first side wall  54   b , toward the second side wall  50   a , while the second arm  134  is positioned against the first side wall  54   a , toward the second side wall  50   b.    
     In the connector  205 , the fastening structures  76  are not arranged in the direction of the X-axis, parallel to the second receiving groove  44 , as in the coupler  105 . Instead, the fastening structures  76  are arranged diagonal to the X-axis. Moreover, the fastening structures  76  are not all positioned with their widths (beam to beam) extending in the direction of the X-axis, as in the coupler  105 . Instead, the outer fastening structures  76  are positioned with their widths extending in the direction of the Y-axis, while the middle fastening structure  76  (joined to the beam  124 ) is positioned with its width extending in the direction of the X-axis. When the connector  205  is mounted to the PCB  142  by press-fitting the fastening structures  76  into the plated holes  146  of the PCB  142 , the foregoing arrangement of the fastening structures  76  helps prevent the connector  205  from pivoting about the X-axis and otherwise moving due to torsional and other forces applied by the bus bar  140 . In this regard, it should be noted that when the connector  205  is mounted to the PCB  142 , the supports  138  of the lead frame  120  contact the surface of the PCB  142  and help provide additional support for and stability to the connector  205 . 
     It should be appreciated that the lead frame  120  in the connector  205  may be modified to have a different configuration. For example, instead of the bends  128 ,  130  curving in opposing directions, the bends  128 ,  130  may curve in the same direction, which would give the lead frame  120  a general U-shape. Still another example would be having only one of the bends  128 ,  130  so that the lead frame  120  has a general L-shape. 
     It should also be appreciated that the lead frame  120  in the connector  205  may be modified to have a greater or lesser number of fastening structures  76 . In addition, other types of fastening structures may be used. For example,  FIG. 10  shows a modified connector  205   a  with a modified lead frame  120   a  having elongated pins  150  in lieu of the fastening structures  76 . In order to mount the connector  205   a  to a substrate with holes (such as a PCB), the pins  150  are inserted into the holes and soldered, respectively. Another example is shown in  FIG. 11  in which a connector  205   b  has a modified lead frame  120   b . As best shown in  FIG. 12 , the lead frame  120   b  has mounts  152  in lieu of the fastening structures  76 . Each mount  152  is L-shaped and includes an elongated foot  154  joined at a bend to a short leg  156 . The legs  156  are joined to, and extend from, the bar section  122 . More specifically, two of the mounts  152  are joined to lower portions of the arms  132 ,  134 , respectively, and extend downwardly therefrom, while a third (or center) mount  152  is joined to a lower portion of the beam  124  and extends downwardly therefrom. The foot  154  of the center mount  152  extends in the direction of the Y-axis, while the feet  154  of the other two mounts  152  extend in the direction of the X-axis, but are offset from each other. Bottom surfaces of the feet  154  are planar to facilitate their attachment, such as by soldering or sintering, to a metal plate of an insulated metal substrate, such as a metal core printed circuit board. 
     In one embodiment, pads or layers of a dry sintering compound comprising silver particles may secured to the bottom surfaces of the feet  154 , respectively, by adhesive or by the application of pressure and partial sintering. In this embodiment, when the lead frame  120   b  is to be used for making a connection to a metal substrate, the lead frame  120   b  is first secured to the metal substrate by pressing the sintering compound layers on the feet  154  against the metal substrate and then heating the lead frame  120   b  and the metal substrate to an elevated temperature that sinters the sintering compound layers, thereby securing the lead frame  120   b  to the metal substrate. Once the lead frame  120   b  is secured to the metal substrate and the combination has sufficiently cooled, the coupler  10  is connected to the lead frame  120   b  by aligning the second receiving groove  42  of the coupler  10  with the bar section  122  of the lead frame  120   b  and then pressing the coupler  10  and the lead frame  120   b  together. 
     In the embodiment wherein the mounting contact  74  is modified to have a single mount with an enlarged planar surface, a pad or layer of a dry sintering compound may be secured to the enlarged planar surface by adhesive or by the application of pressure and partial sintering. The modified mounting contact  74  with the sintering compound may be secured by sintering to a metal substrate and then attached to the coupler  10 , as described above with regard to the lead frame  120   b.    
     As shown in  FIG. 9 , the connector  205  may be used to mount a bus bar to a PCB so that the enlarged planar surfaces and the short lateral edges of the bus bar are disposed perpendicular to the plane of the PCB, while the longitudinal edges of the bus bar are parallel to the plane of the PCB. In order to mount a bus bar to a PCB in orientations different than this, connectors constructed in accordance with other embodiments may be provided. These embodiments are described below. 
     Referring now to  FIGS. 13-15 , there is shown a connector  160  comprising a mounting contact or lead frame  162  connected to a coupler  164 . The coupler  164  has a construction similar to that of the coupler  10 ; however the coupler  164  has a housing  166  instead of the housing  16 . The housing  166  is generally cuboid and is composed of an insulative material, such as plastic. The interior of the housing  166  is hollow and is sized to receive the stack  12  of contact plates  14  in a press fit operation, i.e., the interior is smaller in one or more dimensions than the stack  12 . The housing  166  includes opposing first side walls  168   a,b , a second side wall  170  and opposing first and second ends  172 ,  174 . The housing  166  defines an interior cavity, which is accessible through the first and second ends  172 ,  174 . The first and second ends  172 ,  174  are open; however, an interior wall  176  is spaced inward from the second end  174 . The second side wall  170  has a rectangular major opening  178  disposed toward the first end  172 . Opposite the second side wall  170 , the housing  166  is open, except for an edge of the interior wall  176 . The first side walls  168   a,b  each have a rectangular major slot  180  disposed toward the first end  172  and a smaller notch  184  disposed toward the second end  174  (shown best in  FIG. 15 ). Each notch  184  is formed by an abutment edge  186  disposed at about a right angle to another edge  188 . The abutment edges  186  are spaced inward from the second end  174 . 
     The stack  12  of the contact plates  14  are secured within the housing  166  in a press-fit operation in which the stack  12  as a whole is pressed into the housing  166  through the second end  174 . The resulting interference fit between the stack  12  and the housing  166  secures the contact plates  14  within the housing  166 , but permits pivoting motion of the contact plates  14 . 
     The contact plates  14  are disposed within the housing  166  such that the first receiving spaces  34  of the contact plates  14  are aligned with the first end  172  of the housing  166  and the second receiving spaces  36  of the contact plates  14  are aligned with the second end  174  of the housing  166 . In addition, the first receiving groove  42  of the stack  12  is aligned with the major slots  180  in the housing  166 . 
     The lead frame  162  is a monolithic, generally Z-shaped structure and is electrically conductive, being composed of a conductive metal, such as a tin plated copper alloy. The lead frame  162  has a bar section  190  with fastening structures  76  extending outwardly therefrom. The bar section  190  includes a center beam  192  having an end joined by a bend to an arm  194  and another end joined by a bend and an extension  195  to an arm  196 . The beam  192  extends through the notches  184  in the housing  166  and adjoin the abutment edges  186  thereof. The bends curve in opposing directions to give the lead frame  162  its Z-shape. The bar section  190  also includes an L-shaped member  200 , which is joined to an upper portion of the beam  192 . The member  200  comprises a tongue  202  joined at a bend to a base  204 . The tongue  202  extends through the second receiving groove  44  and into the second inner passage  48  of the coupler  164 . The member  200  extends upwardly beyond the arms  194 ,  196 . Two of the fastening structures  76  are joined to lower portions of the arms  194 ,  196 , respectively, and extend downwardly therefrom. A third (or center) fastening structure  76  is joined to a lower portion of the beam  192  and extends downwardly therefrom. It should be appreciated that other fastening structures may be used in lieu of the fastening structures  76 . For example, the pins  150  or the mounts  152  may be used instead of the fastening structures  76 . 
     The construction of the connector  160 , with the fastening structures ( 76 , etc.) each disposed at a right angle to the first receiving groove  42  provides a configuration that enables the connector  160  to mount a thin, flat structure (such as a power bus bar) to a substrate (such as a circuit board) such that the structure and the substrate are paralleled to each other. An example of this is shown in  FIG. 16 , to which reference is now made. An assembly  208  is shown comprising a pair of substrates  210 ,  212  having a plurality of different types of connectors mounted thereto, some of which connect substrates  210 ,  212  together. Three connectors  160  are shown mounted to the substrate  210 , which may, by way of example, be a printed circuit board. The fastening structures  76  of each connector  160  are shown secured within holes (such as plated holes) formed in the substrate  210 . The connectors  160  are spaced apart and arranged in a row located proximate to a first edge  214  of the substrate  210 . The first receiving grooves  42  of the connectors  160  are aligned and face outwardly toward the first edge  214 . A bar  216  (such as a power bus bar) extends into and through the aligned first receiving grooves  42 . As shown, planar major surfaces of the bar  216  are disposed parallel to an upper surface of the substrate  210 . An edge  218  of the bar  216  is aligned with the first edge  214  of the substrate  210 . The bar  216  is composed of a conductive material, such as copper and, thus, makes electrical connections with the connectors  160 , respectively. 
     The assembly  208  also includes a pair of connectors  205   a  that help connect the substrates  210 ,  212  together. A bottom one of the connectors  205   a  is mounted to the substrate  210 , while a top one of the connectors  205   a  is mounted to the substrate  212 . The pins  150  of the bottom one of the connectors  205   a  are soldered into plated holes in the substrate  210  and the pins  150  of the top one of the connectors  205  are soldered into plated holes in the substrate  212 . The connectors  205   a  (and more specifically their first receiving grooves  42 ) face each other and are aligned. A metal bar  222  (such as a copper bus bar) extends vertically between the top and bottom ones of the connectors  205   a  and electrically connects them together. A top end of the bar  222  extends into the first receiving groove  42  and the first inner passage  46  of the top one of the connectors  205   a , while a bottom end of the bar  222  extends into the first receiving groove  42  and the first inner passage  46  of the bottom one of the connectors  205   a . The bar  222  may be installed, before the substrates  210 ,  212  are secured in position relative to each other, by vertically inserting both (or one of) the top and bottom ends of the bar  222  through the first ends  58  of the housings  16  of the connectors  205   a  into the first receiving grooves  42  and the first inner passages  46 . Alternately, the bar  222  may be installed, after the substrates  210 ,  212  are secured in position relative to each other, by horizontally sliding the top and bottom ends of the bar  222  through the major slots  66  of the housings  16  into the first receiving grooves  42  and the first inner passages  46  of the connectors  205   a.    
     The assembly  208  also includes a pair of connectors  205   b  (only one of which is shown) that help connect the substrates  210 ,  212  together. A bottom one of the connectors  205   b  is mounted to the substrate  210 , while a top one of the connectors  205   b  is mounted to the substrate  212 . The feet  154  of the mounts  152  are secured by sintering or soldering to metal pads (not shown) of the substrates  210 ,  212 , respectively. The connectors  205   b  (and more specifically their first receiving grooves  42 ) face each other and are aligned. A metal bar  224  (such as a copper bus bar) extends vertically between the top and bottom ones of the connectors  205   b  and electrically connects them together. A top end of the bar  224  extends into the first receiving groove  42  and the first inner passage  46  of the top one of the connectors  205   b , while a bottom end of the bar  224  extends into the first receiving groove  42  and the first inner passage  46  of the bottom one of the connectors  205   b . In the same manner as the bar  222  and the connectors  205   a , the bar  224  may be installed before or after the substrates  210 ,  212  are secured in position relative to each other. 
     As described above, the assembly  208  shows how connectors  160 ,  205   a,b  may be used to mount bus bars to a substrate so as to extend normal or parallel to the substrate, and also how they may be used to connect together two parallel substrates. 
     Referring now to  FIGS. 17-19 , there is shown another connector  230  that is especially suited for mounting a bar to a substrate so as to extend perpendicular to the substrate. The connector  230  comprises a mounting contact or lead frame  234  connected to a coupler  236 . The coupler  236  has a construction similar to that of the coupler  10 ; however the coupler  236  has a housing  238  instead of the housing  16 . The housing  238  is generally cuboid and is composed of an insulative material, such as plastic. The interior of the housing  238  is hollow and is sized to receive the stack  12  of contact plates  14  in a press fit operation, i.e., the interior is smaller in one or more dimensions than the stack  12 . The housing  238  includes opposing first side walls  240   a,b , opposing second side walls  242   a,b  and opposing first and second ends  244 ,  246 . The housing  238  defines an interior cavity that is accessible through the first and second ends  244 ,  246 , which are open. The second side walls  242   a,b  each have a rectangular major opening  248  disposed toward the first end  244 . The first side wall  240   b  has a rectangular major slot  250  disposed toward the first end  244 , while the first side wall  240   a  has a minor slot  254  disposed toward the second end  246  (shown best in  FIG. 19 ). The minor slot  254  is formed by an abutment edge  256  that extends laterally between a pair of parallel edges  260 . The abutment edge  256  is spaced inward from the second end  246 . 
     The housing  238  further includes a snap-fit projection  264  and a pair of supports  266  that are integrally joined to the first side wall  240   a  and extend outwardly therefrom. The snap-fit projection  264  and the supports  266  are located toward the first end  244 , with the snap-fit projection  264  being at least partially disposed between the supports  266 . The snap-fit projection  264  includes a cylindrical body  268  joined to a rounded head  270 . A slot extends longitudinally through the head  270  and most of the length of the body  268  so as to form a pair of spaced-apart sections  272  having rounded head portions, respectively. The sections  272  are resiliently movable toward each other. As will be described more fully below, the snap-fit projection  264  is configured to be inserted into a mounting hole in a substrate, such as the substrate  274  (shown in  FIG. 20 ). 
     The stack  12  of the contact plates  14  are secured within the housing  238  in a press-fit operation in which the stack  12  as a whole is pressed into the housing  166  through the second end  246 . The resulting interference fit between the stack  12  and the housing  238  secures the contact plates  14  within the housing  238 , but permits pivoting motion of the contact plates  14 . 
     The contact plates  14  are disposed within the housing  238  such that the first receiving spaces  34  of the contact plates  14  are aligned with the first end  244  of the housing  238  and the second receiving spaces  36  of the contact plates  14  are aligned with the second end  246  of the housing  238 . In addition, the first receiving groove  42  of the stack  12  is aligned with the major slot  250  in the housing  238 . 
     The lead frame  234  is a monolithic, generally Z-shaped structure and is electrically conductive, being composed of a conductive metal, such as a tin plated copper alloy. The lead frame  234  has a bar section  276  with fastening structures  76  extending outwardly therefrom. The bar section  276  includes a center beam  278  having ends joined by bends to arm  280 ,  282 , respectively. The bends curve in opposing directions to give the lead frame  234  its Z-shape. The bar section  276  also includes an elongated tab or tongue  286 , which is joined to a lower portion of the beam  278 . The tongue  286  extends through the minor slot  254  in the housing  238 , as well as the second receiving groove  44  and the second inner passage  48  of the stack  12  of plates  14 . Inside the minor slot  254 , the tongue  286  adjoins the abutment edge  256  of the housing  238 . Two of the fastening structures  76  are joined to upper portions of the arms  280 ,  282 , respectively, and extend upwardly therefrom. A third (or center) fastening structure  76  is joined to an upper portion of the beam  278  and extends upwardly therefrom. It should be appreciated that other fastening structures may be used in lieu of the fastening structures  76 . For example, the pins  150  or the mounts  152  may be used instead of the fastening structures  76 . 
     Referring now to  FIGS. 20, 21 , two of the connectors  230  are shown being used to connect a substrate  274  to a substrate  290 . Each connector  230  is secured to its respective substrate ( 274 ,  290 ) by the fastening structures  76 , as well as the snap-fit projection  264 . In this regard, each substrate ( 274 ,  290 ) includes three holes  292  for the fastening structures  76  and a larger hole  294  for the snap-fit projection  264 . The holes  294  have diameters that are smaller than the diameters of the heads  270 . To mount each connector  230  to its substrate ( 274 ,  290 ), the connector  230  is positioned such that the fastening structures  76  are aligned with the holes  292 , respectively, and the head  270  of the snap-fit projection  264  is aligned with the hole  294 . When a force is applied to move the connector  230  and the substrate ( 274 ,  290 ) together, the beams  80  of the fastening structures  76  deflect inward to enter the holes  292  and the sections  272  of the snap-fit projection  264  deflect inward as their head portions contact an edge of the substrate ( 274 ,  290 ) defining the hole  294 . The deflection of the sections  272  decreases the diameter of the head  270 , which permits the head  270  to enter and pass through the hole  294 , emerging on the other side of the substrate ( 274 ,  290 ), where the sections  272  resiliently move outward to return the head  270  to its original diameter. At this point, the substrate ( 274 ,  290 ) is trapped between the head  270  and the supports  266 , which, together with the fastening structures  76 , secure the connector  230  to the substrate ( 274 ,  290 ). In addition, the snap-fit projection  264  helps prevent the connector  230  from rotating relative to the substrate ( 274 ,  290 ). The supports  266  abut the substrate ( 274 ,  290 ) to further provide support and stability to the connection between the connector  230  and the substrate ( 274 ,  290 ). 
     With the connectors  230  secured to the substrates  274 ,  290 , as described above, a bar  300  (such as a bus bar) may be mounted to the connectors  230  to electrically and physically connect together the substrates  274 ,  290 . The bar  300 , which is composed of a conductive material (such as copper) is elongated and has first and second lateral edges  302 ,  304  and first and second longitudinal edges  306 ,  308 . A pair of spaced-apart first and second retention dimples  310 ,  312  are formed in the bar  300 , proximate to the first longitudinal edge  306 . The first retention dimple  310  is located proximate to the juncture of the first longitudinal edge  306  with the first lateral edge  302 , while the second retention dimple  312  is located proximate to the juncture of the first longitudinal edge  306  with the second lateral edge  304 . The thickness of the bar  300  at the first and second retention dimples  310 ,  312  is greater than the width of the contact zones  49  in the connectors  230 , which helps retain ends of the bar  300  in the connectors  230 , as will be more fully discussed below. 
     In order to mount the bar  300  to the connectors  230 , the substrates  274 ,  290  are first positioned to align the connectors  230  with each other. The bar  300 , with the first longitudinal edge  306  facing the connectors  230  is then moved horizontally into the receiving grooves  42  of the connectors  230 , respectively, through the first ends  244  and the major slots  250  of the housings  238 . The bar  300  is further moved through the receiving grooves  42  and into the contact zones  49  of the connectors  230 , respectively, thereby causing the first and second retention dimples  310 ,  312  to move the upper first portions  22   a,b  of the contact plates  14  outward, which allows the first and second retention dimples  310 ,  312  to move into the first inner passages  46 , respectively. Once the first and second retention dimples  310 ,  312  are inside the first inner passages  46 , the upper first portions  22   a,b  of the contact plates  14  move back inward, trapping the first and second retention dimples  310 ,  312  inside the first inner passages  46 , respectively, as shown in  FIG. 22 . As a result, the bar  300  is secured to the connectors  230  and can only be removed by applying a pulling force to the bar  300  to move the first and second retention dimples  310 ,  312  back through the contact zones  49 . 
     It should be appreciated that the bar  300  is not limited to use with the connector  230 . Instead, the bar  300  may be used with any of the connectors disclosed herein (e.g., connectors  105 ,  160 ,  205 ,  230  etc.). Moreover, for a bar that is to be mounted to connectors with its lateral edges (instead of a longitudinal edge) inserted into the first receiving grooves  42  and the first inner passages  46 , the bar may be provided with dimples located toward the lateral edges of the bar, as opposed to the longitudinal edge of the bar. Also, a bar may be provided with more than two dimples. For example, the bar  216  (shown in  FIG. 16 ) may be provided with three dimples that are aligned with the three connectors  160 , respectively. 
     It should also be appreciated that in lieu of providing a bar with protuberances to facilitate retention in the connectors of this disclosure, a bar may be constructed to have an overall thickness that is greater than the width of the contact zones  49  in the connectors. Such a bar would have depressions or holes instead of protuberances. In each connector, when the bar is inserted into the contact zone  49  between the bulges  27   a,b , the bar would move the upper first portions  22   a,b  of the contact plates  14  outward until the depression or hole was located between the bulges  27   a,b , at which point, the bulges  27   a,b  would move inward, to be partially disposed within the depression or hole. In this manner, the bulges  27   a,b  would retain the bar in the connector. 
     The connector  230  may be modified to have different variations. One such variation is connector  320  shown in  FIG. 23  and another variation is connector  322  shown in  FIG. 24 . 
     The connector  320  has the same construction as the connector  230 , except the connector  320  has a housing  323  with a pair of supports  324 , instead of the supports  266 . The supports  324  are integrally joined to the first side wall  240   a  and extend outwardly therefrom. Each support  324  has a sloping front edge  326  and a horizontal top edge  328  that abuts a substrate when the connector  320  is mounted to the substrate. Unlike the supports  266 , the supports  324  are disposed toward the second end  246  of the housing  323 . The beam  278  of the lead frame  234  and the minor slot  254  in the housing  322  are located between the supports  324 . 
     The connector  322  differs from the connector  230  by having a stack  330  of plates  14  that is smaller than the stack  12  and a housing  332  that is smaller than the housing  238 . In addition, the connector  322  has a pair of snap-fit connectors  336 , instead of the single snap-fit connector  264 , and has supports  338 , instead of the supports  266 . The snap-fit connectors  336  and the supports  338  are integrally joined to the first side wall  240   a  and extend upwardly therefrom. The snap-fit connectors  336  are disposed toward the first end  244  of the housing  332  and the second side walls  242   a,b , respectively. Each snap-fit connector  336  has a resiliently deflectable upper body  340  joined to a partially rounded head  342 . The upper bodies  340  are configured to deflect inward, towards each other, when pressed into holes in a substrate and then spring back when the heads  342  clear the holes on the other side of the substrate, trapping the substrate between the heads  342  and the supports  338 . The supports  338  are disposed toward the second end  246  of the housing  332  and are spaced inward from the second side walls  242   a,b . The beam  278  of the lead frame  234  and the minor slot  254  in the housing  322  are partially disposed between the supports  338 . Top surfaces of the supports  338  abut a substrate when the connector  322  is mounted to the substrate. 
     Since the stack  330  of the connector  322  is smaller (i.e., has less plates  14 ) than the stack  12  of the connector  230 , the connector  322  is constructed to carry less current than the connector  230 . Indeed, in certain embodiments, the connector  322  has a current rating of 40 amps, while the connector  230  has a rating of 60 amps. 
     In the embodiments described above, each of the couplers is shown as an individual unit having a single housing that contains a stack of coupling contacts or contact plates. While the couplers may be interconnected, such as by one or more bars or plates, as shown in  FIG. 16  or  FIG. 25 , the couplers are not directly secured together. It should be appreciated that in other embodiments, however, a plurality of couplers may be directly secured together. For example a plurality of couplers may have their housings secured together to form a multiplex connector that connects a plurality of pairs of components together. The housings may be integrally joined together in a unitary molded plastic structure that serves to support and maintain the spatial relationship of the couplers. While their housings are secured together, the couplers each contain an individual stack of coupling contacts. The couplers may be of the same size and construction or may be of different sizes and constructions. 
     It is to be understood that the description of the foregoing exemplary embodiment(s) is (are) intended to be only illustrative, rather than exhaustive. Those of ordinary skill will be able to make certain additions, deletions, and/or modifications to the embodiment(s) of the disclosed subject matter without departing from the spirit of the disclosure or its scope.