Patent Publication Number: US-7591683-B2

Title: Contact terminal, extender with improved ground contact, and method for making the extender

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a continuation-in-part of U.S. patent application Ser. No. 11/810,814 (hereinafter referred to as the &#39;814 application), filed on Jun. 7, 2007, now U.S. Pat. No. 7,497,739 the contents of each of which are hereby incorporated by reference. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to an extender, and more particularly to an extender for coupling an electrical device to a backplane and featured with a ground contact simultaneously interconnecting the electrical device, the backplane, and a circuit substrate on which the extender is mounted. 
   2. Description of the Related Art 
   U.S. Pat. No. 6,071,150 issued to Tang et al. on Jun. 6, 2000, discloses an extender ( 10 ) including a male section ( 12 ) and a female section ( 14 ) assembled together to be coupled between a female connector on a backplane in the computer and a male connector on a hard disk drive for establishing signal transmission between the hard disk drive and the backplane through the interconnections of such male and female sections. Specifically, the female section defines a female interface adapted for mating with the male connector from the hard disk drive, the male section defines an opposite male interface adapted to mate with the female connector from the backplane of the computer, and a plurality of contacts are configured to extend from the female interface towards the male interface for electrically connecting the female section with the male section. This configuration typically enables the female or male interface to supply one voltage for the male connector of the hard disk drive, or the female connector of the backplane. 
   U.S. Pat. No. 6,918,774 issued to Wu on Jul. 19, 2005 discloses an electrical connector ( 1 ) includes a dielectric housing ( 2 ) including front and rear housing portions ( 20 ,  22 ) each defining a number of juxtaposed channels ( 202 ) therein and an intermediate housing portion ( 24 ) interconnecting the front housing portion with the rear housing portion. A number of elongate circuit boards ( 3 ) are side by side retained in the housing along a second direction perpendicular to the first direction. The circuit boards include front and rear mating edges ( 30 ,  32 ) respectively received in the channels of the front and the rear housing portions for mating with complementary components. 
   U.S. Pat. No. 6,663,434 issued to Wu on Dec. 16, 2003 discloses an extender ( 10 ) includes a female portion ( 12 ) and a male portion ( 14 ) adapted to be back-to-back assembled. The female portion comprises a first housing ( 16 ) defining two slots ( 28 ) and a plurality of first contacts ( 18 ,  19 ). A plurality of first passageways ( 30 ) is defined in the first housing and communicates with the slots. The first contacts are retained into the first passageways. The male portion comprises a second housing ( 40 ) having a pair of tongues ( 46 ) and a plurality of second contacts ( 41 ). The tongues define a plurality of positioning slits ( 52 ,  53 ) for receiving the second contacts. Each of the first contacts is aligned and cooperated with a corresponding second contact to form a transmission path. Two pairs of latch devices ( 35 ,  60 ) are provided on opposite ends of the female portion and male potion for fastening each other. 
   In the past, the electrical device, such as a hard disk data storage, and a backplane on which the device is electrically interconnected, generally carry the same voltage, i.e. both are operated under the substantially identical working environment. However, when data transmission rate becomes faster and faster, their working environments have to change also so as to meet the requirements. 
   Among the contact terminals provided within the extender, some of them are assigned for transmitting data, and some of them are designated for providing power or working voltage from the backplane to the hard disk drive. In the past, both the hard disk drive and the back plane are operated under the same working voltage, typically 5 VDC. However, when the spindling speed of the hard disk drive become faster and faster, their working voltage is also increased from 5 VDC to 12 VDC. 
   The present problem the users confront, is that the female or male interface substantially requires an electronic device of a first predetermined voltage to be equipped therewith, while the electronic component available for the users has a second predetermined voltage. In other words, the conventional configuration has no capability to provide a flexible connection to different types of electronic devices, which may require voltages of different amounts. 
   In the previously filed &#39;814 application, applicant initiated a novel design such that a first mating interface of an extender can be supplied a first working voltage, and a second mating interface of the extender can be supplied with a second working voltage transformed by a circuitry provided by the extender, and which is different to the first working voltage, and which indeed meets the current requirements and resolve the issues. 
   Currently, the hard disk drives available in the market can be operated under two different working voltages, i.e. 5 VDC and 12 VDC. On the other hand, the working voltage provided from the backplane can be either 5 VDC and 12 VDC. Unless there is an transforming arrangement on the extender, it is very much likely that the hard disk drive may not properly and functionally work along with the backplane, if the working voltages therebetween are different. 
   In addition, when the requirement regarding to the data transmission rate becomes higher and higher, differential pair of signal contacts are used, and once the differential pair of contacts are used, grounding or shielding of the differential pair of contacts becomes a new challenge to resolve. None of the above described prior arts consider the use of differential pair of contacts. In addition, a grounding arrangement between the first and second mating interfaces, and a circuit substrate on which the extender is mounted is not provided as well. 
   SUMMARY OF THE INVENTION 
   A major object of an embodiment of the present invention is to provide an electrical connector assembly for a flexible connection to electronic devices of requiring different predetermined voltages. 
   Still, it is an object of the present invention to provide a ground contact in which a first mating interface, a second mating interface, and a circuit substrate on which the connector is mounted are electrically and simultaneously interconnected providing robust and reliable shielding for the data transmitted with high speed. 
   An electrical connector assembly made according to an embodiment of the present invention comprises a female connector and a male connector assembled together to be electrically connected to a printed circuit board. The female connector includes a first mating face that interfaces with a mating face of a corresponding connector mounted on a hard disk drive. The male connector includes a second mating face opposite to the first mating face and adapted to mate with a connector mounted on a backplane. The connector assembly includes a mounting face that is orthogonal to the first and second mating faces and adapted to mate with the printed circuit board. The printed circuit board supplies two predetermined voltages for the female connector and/or the male connector, thereby achieving a flexible connection for the connector assembly to different types of hard disk and backplane. 
   According to one aspect of the present invention, the female connector includes a first insulative housing that has a first mating face and a first abutment face opposite to the female mating face. The female connector further comprises two contact modules that respectively having a first row of contacts insert molding to a first base and a second row of contacts insert molding to a second base. Each of the first row of contacts includes a first contact engaging portion which accessible from the first mating face of the female connector. Each of the second row of contacts includes a plurality of differential pairs of signal contact and a plurality pairs of ground contact with the pairs of signal contacts arranged therebetween. Each of the differential pairs of signal contact has a first contact engaging portion which accessible from the first mating face, and includes a second contact engaging portion extending away from the first engaging portion and accessible from the second mating face. The ground contact comprises a middle portion, a first contact engaging portion extends from the middle portion which be accessible from the first mating face, a second contact engaging portion extending from the middle portion and opposed to the first engaging portion and accessible from the second mating face, and a tail portion extending from the middle portion that is orthogonal to the first and second contact engaging portion for electrical connection to the printed circuit board. The ground contact further includes several separated wing portions extending from the middle portion and toward the adjacent differential pair signal contacts. 
   Yet, still according to another aspect of the present invention, the male connector includes a second insulative housing that has a second mating face and a second abutment face opposite to the second mating face. A plurality of passageways extend from the mating face to the abutment face for receiving the second engaging portion of the two rows of contacts from the female connector and a plurality of contacts that extend from the second mating face toward the mounting face. Each contact is a right angle configuration, with a second contact engaging portion which accessible from the second mating face, and a tailing portion extending orthogonal to the first contact engaging portion to be electrical connection to the printed circuit board. 
   Yet, still according to another aspect of the present invention, the first abutment face of the female connector and the second abutment face of the male connector include interengaging elements extending therefrom for fastening the female connector to the male connector. In addition, the connector assembly further includes a middle cover disposed on a top region between the female connector and the male connector, and a middle spacer on a bottom region between the female connector and the male connector. The middle spacer defines a plurality of through holes for receiving the tailing portions of the contacts to be penetrated therethrough so as to be electrical connection to the printed circuit board. 
   Due to the printed circuit board of providing two predetermined voltage for the first connector and/or the second connector, the mating face or the mating surface is capable of being coupled to the electronic devices of requiring different predetermined voltages. Thus, the electrical connector assembly provides a flexible connection to any commodity devices of different predetermined voltages. 
   Other features and advantages of the present invention will become more apparent to those skilled in the art upon examination of the following drawings and detailed description of preferred embodiments. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an assembled, perspective view of a connector assembly to an embodiment of the present invention. 
       FIG. 2  is an exploded, perspective view of the connector assembly to an embodiment of the present invention. 
       FIG. 3  is an exploded, perspective view of a contact module assembly of the connector assembly to an embodiment of the present invention. 
       FIG. 4  is an isometric view of a ground contact of the connector assembly to an embodiment of the present invention. 
       FIG. 5  is an assembled, perspective view of the contact module assembly of the connector assembly to an embodiment of the present invention. 
       FIG. 6  is a perspective view of a female connector of the connector assembly to an embodiment of the present invention. 
       FIG. 7  is a partial of perspective view of the connector assembly to an embodiment of the present invention. 
       FIG. 8  is a perspective view of a male connector of the connector assembly to an embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   As shown in  FIGS. 1 and 2 , a connector assembly  1  made in accordance with the present invention comprises a female connector  2  and a male connector  3  assembled together and is intended to be mounted onto a printed circuit board  9 . The female connector  2  includes a first mating face  21  that interfaces with a mating face of a corresponding connector mounted on a hard disk drive (not shown). The male connector  3  includes a second mating face  31  opposite to the first mating face  21  and adapted to mate with a connector mounted on a backplane (not shown). Of course, it should be appreciated that interfacing of hard disk and backplane is merely a typical embodiment of the present invention, and it is appreciated that the present invention can be also used with other interface, such as a cable assembly and a hard disk, and other interconnection currently available in the market. The connector assembly further includes a mounting face  11  that is orthogonal to the first and second mating faces  21 ,  31  to be adapted to face with the printed circuit board  9 . Typically, according to an embodiment of the present invention, the printed circuit board  9  supplies two or more than two predetermined voltages to the female connector  2  and/or the male connector  3 , respectively, thereby achieving a flexible connection for the connector assembly  1  to different types of hard disk and backplane. 
   Referring now to  FIGS. 3-6 , the female connector  2  made in accordance with the present invention includes a first insulative housing  20  that has the first mating face  21  and a first abutment face  23  opposite to the first mating face  21 . The female connector  2  further comprises two contact modules  25 ,  29  that respectively have a first row of contacts insert-molded to a first base  22  and a second row of contacts insert-molded to a second base  24 . The first row of contacts  4  is configured by a first type of contact  41  which extends from the female connector  2  to the male connector  3 , and a second type of contact  45  which is arranged within the female connector  2  only. Each of the first type of contacts  41  includes a first contact engaging portion  411  which is accessible from the first mating face  21  of the female connector  2 , and includes a second contact engaging portion  413  extending away from the first engaging portion  41  and is accessible from the second mating face  31  of the male connector  3  when assembled therein. Each of the second type of contacts  45  includes a first contact engaging portion  451  which is accessible from the first mating face  21  of the female connector  2 , and a tail portion  455  that is orthogonal to the first contact engaging portion  451  and extends to the mounting face  11  for electrical connection to the printed circuit board  9 . 
   Each of the second row of contacts  5  includes a plurality of differential pairs of signal contact  51 , a plurality pairs of ground contact  53  with the pairs of signal contacts  51  arranged therebetween, and a plurality of signal/power contacts  55 ,  57 . Each of the differential pairs of signal contact  51  includes a median portion which are covered with molded material  510 , according to a preferred embodiment, it is a plastic material, a first contact engaging portion  511  extending from the median portion and which is accessible from the first mating face  21 , and a second contact engaging portion  513  extending away from the first engaging portion  511  and which is accessible from the second mating face  31 . 
     FIG. 4  illustrates an exemplary ground contact  53  which not only extends between the female and male connectors, but also includes a tail portion  535  extending downwardly and adapted to be mounted onto a printed circuit board. The ground contact comprises a median portion  530 , a first contact engaging portion  531  extends from the median portion  530  which could be accessible from the first mating face  21 , a second contact engaging portion  533  extending from the median portion  530  and opposed to the first engaging portion  531  and which is accessible from the second mating face  31 , and the tail portion  535  extending from the median portion  530  that is orthogonal to the first and second contact engaging portion  531 ,  533  for electrical connection to the printed circuit board  9 . The ground contact further includes several separated wing portions  537  extending from the median portion  530  and toward the adjacent differential pair signal contacts  51 , creating preferably electrical coupling with respect to those differential pair contacts. The wing portions  537  are arranged such that some of the adjacent wing portions  537  defines an opening. 
   The signal/power contacts is configured by a first type of contact  57  which extends from the female connector  2  to the male connector  3 , and a second type of contact  55  which is arranged within the female connector  2  only. The first type of contact  57  includes a first contact engaging portion  571  which is accessible from the first mating face  21  of the female connector  2 , and a second contact engaging portion  573  extending away from the first engaging portion  571  and is accessible from the second mating face  31  of the male connector  3  when assembled therein. The second type of contacts  55  includes a first contact engaging portion  551  which is accessible from the first mating face  21  of the female connector  2 , and a tail portion  555  that is orthogonal to the first contact engaging portion  551  and extends to the mounting face  11  for electrical connection to the printed circuit board  9 . 
   As shown in  FIGS. 5-7 , the contact modules  25 ,  29  are assembled together to be a module assembly. It can be noted that part of the tail  455  of the second type of contact  45  is shifting away from the middle line of the first contact engaging portion  451 , so as to sidestep the median portion  530  of the ground contact  53  to connect to the print circuit board  9 . Pairs of locking blocks  221  are formed on the base  22 ,  23  so as to be engaged to correspondent pairs of cavities  201  of the first insulative housing  20  for fastening the module assembly to the first insulative housing  20 . 
   With respect to  FIG. 8 , the male connector  3  includes a second insulative housing  30  that has a second mating face  31  and a second abutment face  33  opposite to the second mating face  31 . A plurality of passageways  34  extend from the mating face  31  to the abutment face  33  to receiving the second engaging portion  43 ,  513 ,  533 ,  553  of the two rows of contacts  4 ,  5  from the female connector and a plurality of contacts  6  that extend from the second mating face  31  toward the mounting face  11 . Each of the contacts  6  has a right angle configuration, with a second contact engaging portion  63  which is accessible from the second mating face  31 , and a tailing portion  65  extending orthogonal to the first contact engaging portion  63  to be electrical connection to the printed circuit board  9 . 
   Referring to FIGS.  2  and  6 - 8 , the first abutment face  23  of the female connector  2  and the second abutment face  33  of the male connector  3  include interengaging elements extending therefrom for fastening the female connector  2  to the male connector  3 . More specifically, the second abutment face  33  of the male connector  3  has a pair of indents  36  extending thereinto for latchably receiving the inwardly oriented latches  26  disposed adjacent to two ends of the first abutment face  23  of the female connector  2 . A pair of alignment posts  38  extending outwardly therefrom for being engagably received within alignment slots  28  of the first abutment face  23 . A pair of metal latches  37  secured in the side wall of the male connector  3  for locking a pair of metal plates  27  securely to adjacent two ends of the female connector  2 . Therefore, the male connector  3  and the female connector  2  could be assembled together. In addition, the connector assembly further includes a middle cover  7  disposed on a top region between the female connector  2  and the male connector  3 , and a middle spacer  8  on a bottom region between the female connector  2  and the male connector  3 . The middle spacer  8  defines a plurality of through holes  81  for receiving the tailing portions  45 ,  535 ,  555 ,  65  of the contacts  4 ,  5 ,  6  to be penetrated therethrough so as to be electrical connection to the printed circuit board  9 . 
   The manufacturing procedures of the present invention starts from assembling the female connector  2 . First, provide the first contact module  25  including the first row of contacts  4 , provide the second contact module  29  including the second row of contacts  5 , and mold the first and second contact modules together to be a module assembly. Then, assemble the module assembly into the first housing  20  and let the first contact engaging portion  41 ,  511 ,  531 ,  551  accessible from the first mating interface  21 . As a result, the female connector shown in  FIG. 6  is obtained. 
   Next, provide the male connector  3  with a plurality of contacts  6  that includes a second contact engaging portion  63  secured in the passageways  34  and accessible from the second mating face  31 , then assemble the male connector  3  to the female connector  2  by inserting the second contact engaging portion  413 ,  513 ,  533 ,  573  of contacts  4 ,  5  of the female connector  2  to the passageways  34  and accessible from the second mating face  31 of the male connector  3 , and the first abutment  23  of the female connector  2  confronts the second abutment  33  of the male connector. 
   Finally, attach the middle cover  7  on the top region between the female connector  2  and the male connector  3 , and assemble the middle spacer  8  with through holes on a bottom region between the female connector  2  and the male connector  3  for receiving the tail portions  45 ,  535 ,  555 ,  65 . Therefore, the connector assembly is completely. 
   While the present invention has been described with reference to preferred embodiments, the description of the invention is illustrative and is not to be construed as limiting the invention. Various of modifications to the present invention can be made to preferred embodiments by those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.