Patent Publication Number: US-8979595-B2

Title: Electrical connector and method of manufacture

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to an electrical connector, and more specifically, to an electrical connector that improving the mating means thereof, wherein providing a solution to a long-term mating cycle nearly leads to fail the elasticity of contact arms; moreover, to avoid like cycle bringing dead pins or else problems. 
     2. Description of the Related Art 
     An electrical socket, early disclosed in Taiwan Patent No. M346928, is provided of which includes an insulative housing, an eSATA terminals installed on the top of the tongue of the insulative housing and an plurality of USB terminals installed on the bottom of said tongue. The eSATA terminals address the conformation with an eSATA standard; the plurality of USB terminals address the conformation basically with an USB2.0 standard and further with an USB3.0 standard which is able to perform higher speeds of transmission. Therefore, the electrical socket adapts to be used in miscellaneous type of connector. 
     The conventional USB3.0 standard is known as transmitting mass data in 5 Gbps bitrates, which keeps its pace to do that by first defining five more pins. These five pins, that ever been stated the principle to make a plug in detail, generally configure as elastic articles, related to non-elastic as the original four pin. The elastic pins are predetermined to contact with the opposite pin of a socket when the plug connector is inserted into such socket by the user. For sake of the resilient feature, an up-side-down exercise is been predictable. However, the duration cycle of withdrawal connector is such concerned by connector maker. Even the duration is up-evaluated; but the lasting of the elasticity was less concerned. Sometimes, the high-profile connection depends that these five pin just can survive after a long-term removing exercise. 
     The conventional connector and now-on product seems to concentrate saving cost of manufacturing the connector. The tiredness of these five elastic pins which brings damages to the stability of connector is still a serious problem of people&#39;s lack aware. 
     SUMMARY OF THE INVENTION 
     For solving the poor situation occurred in the conventional art, therefore, it is necessary to modify and to find an improved means for mating electrical connector, thereto providing a solution to insert different type plugs into identical connector without bringing destructions itself. 
     The present invention is ultimately to provide an electrical connector, comprising: an insulative housing, a plurality of first terminals, a plurality of second terminals and a shell. 
     The insulative housing is engaging with the shell and further includes a tongue extended along a back-to-front direction and a base portion located behind the tongue. The insulative housing configures a hollow chamber in the center of its body, hereunder the area between the tongue and the base portion, the chamber is equally divided into several independent slots by a plurality of ribs, which configures ramping portions in the bottom of slots that ascends the ramping portion to the base portion. 
     A plurality of first terminals is configured on the insulative housing and passes through the slots, wherein each first terminal has an elastic curve-shape contact end, a rear portion and a body portion connecting two. The rear portion is held by the base portion of the insulative housing; the contact end and the body portion are exposed out of the base portion, and locate in the slot. In the section between the contact end and the body portion, a neck, a taper and an engagement are configured in sequence, a preserved space is formed by the leant neck and engagement and under the taper, the engagement extends further into the bottom of slots and remains contacting with the ramping portions. 
     A plurality of second terminals is configured on the insulative housing and crosses with the plurality of first terminals in a transverse direction. Both of the terminals are toward the same direction with an up and down arrangement. A body portion is held by the base portion and ribs of the insulative housing. One end of second terminal extends out of the base portion; the other end passes through the rib and extends to be disposed above of the tongue. 
     The taper of the contact end is generally in a curve-shape; said neck is configured from said body portion and extends upwardly to said taper. The preserved space is formed by the leant neck and said engagement and under said taper. 
     Said body portion is configuring with a flat and an extension. Said flat connects said neck in one end and connects to said extension in the other end. Said extension connects to said rear portion. 
     Said first terminals configure apertures on the two side terminal onto said engagement. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the electrical connector formed in accordance with an embodiment of the invention. 
         FIG. 2  is another perspective view shown in  FIG. 1 . 
         FIG. 3  is an exploded perspective view shown in  FIG. 1 . 
         FIG. 4  is a perspective view of the first terminal of electrical connector formed in accordance with an embodiment of the invention. 
         FIG. 5  is a cross-section view of the electrical connector shown in  FIG. 1 , illustrated the electrical connector standing by inserting an outer plug. 
         FIG. 6  is a cross-section view of the electrical connector shown in  FIG. 5 , illustrated the electrical connector inserting an outer plug. 
         FIG. 7.A  is a side view of the die used to manufacture the electrical connector in accordance with an embodiment of the invention, specified the step (c) thereof. 
         FIG. 7.B  is a closely view of the die used to manufacture the electrical connector shown in  FIG. 7.A , specified the step (c) of method thereof. 
         FIG. 8.A  is a side view of the die used to manufacture the electrical connector in accordance with an embodiment of the invention, specified the step (d) of method thereof. 
         FIG. 8.B  is a closely view of the die used to manufacture the electrical connector shown in  FIG. 8.A , specified the step (d) of method thereof. 
         FIG. 9  is a side view of the die used to manufacture the electrical connector in accordance with an embodiment of the invention, specified the step (e) of method thereof. 
         FIG. 10  is a side view of the electrical connector in accordance with an embodiment of the invention, specified the step (f) of method thereof. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENT(S) 
     This invention is to show a main purpose that is to accomplish a non-cracking terminal mounting in the electrical connector, where it encounters a long-term mating cycle nearly leads to fail the elasticity of contact arms; moreover, to avoid like cycle bringing dead pins or else problems. 
     As shown in  FIGS. 1-3 , an electrical connector comprises: an insulative housing  2 , a plurality of first terminals  3 , a plurality of second terminals  4  and a shell  1 . 
     The insulative housing  2  is engaging with the shell land further includes a tongue  22  extended along a back-to-front (transverse) direction and a base portion  21  located behind the tongue  22 . The insulative housing  2  configures a hollow chamber  23  in the center of its body, hereunder the area between the tongue  22  and the base portion  21 . The chamber  23  is equally divided into several independent slots  232  by a plurality of ribs  231 , which configures ramping portions  2321  in the bottom  234  of slots  232  that ascends the ramping portion  2321  to the base portion  21 . 
     As shown in  FIG. 4 , a plurality of first terminals  3  is configured on the insulative housing  2  and passes through the slots  232 , wherein each first terminal  3  has an elastic curve-shape contact end  32 , a rear portion  31  and a body portion  33  connecting two (the contact end and rear portion). The rear portion  31  is held by the base portion  21  of the insulative housing  2 ; the contact end  32  and the body portion  33  are exposed out of the base portion  21 , and locate in the slot  232 . Moreover, in the section between the contact end  32  and the body portion  33 , a neck  321 , a taper  322  and an engagement  323  are configured in sequence. A preserved space  324  is formed by the leant neck  321  and engagement  323  and under the taper  322 . The engagement  323  extends further into the bottom  234  of slots  232  and remains contacting with the ramping portions  2321 . 
     A plurality of second terminals  4  is configured on the insulative housing  2  and crosses with the plurality of first terminals  3  in a transverse direction. More precisely, both of the terminals  5  are toward the same direction with an up and down arrangement. A body portion  41  is held by the base portion  21  and ribs  231  of the insulative housing  2 . One end of second terminal extends out of the base portion  21 ; the other end passes through the rib  231  and extends to be disposed above of the tongue  22 . 
     Thus, see  FIGS. 5-6 , when the electrical connector is connected with a computer system by the user, (firstly we assume a socket connector mounted inside the computer system, having all elements of which a connector consists) the contact ends  32  of first terminals  3  are pressed, for the sake of its elasticity, to move slightly backward in the range permitted by the space  324 . When the electrical connector is withdrawn from the computer system by the user, the contact ends  32  rebounds until the ramping portions  2321  of the insulative housing  2  stops the engagement  323  at the bottom  234  of slots  232 , and remains contacting with the ramping portions  2321  as beginning. The ramping portions  2321  provide a guarantee of non-cracking terminal that destructions often occur as over-rebound of the terminal so that the terminal is able to keep its elasticity of contact end  32  eventually. 
     The taper  322  of the contact end  32  is generally in a curve-shape; the neck  321  is configured from the body portion  33  and extends upwardly to the taper  322 . The preserved space  324  is formed by the leant neck  321  and engagement  323  and under the taper  322 . By these two characteristics, the first terminal  3  is able to keep its elasticity of contact end  32  when the electrical connector is withdrawn from the computer system by the user. 
     The body portion  33  is selectively configuring with a flat  331  and an extension  332 . The flat  331  connects the neck  321  in one end and connects to the extension  332  in the other end, wherein the angle of both connections is larger than  90  degree. And, the extension  332  connects to the rear portion  31 . The flat  331  and the extension  332  provide an elastic structure between the contact end  32  and the body portion  33 . The engagement  323  configures an aperture  3231  thereof. 
     As shown in  FIGS. 5-6 , when the electrical connector is connected with a computer system by the user, the contact ends  32  of first terminals  3  are pressed (by, we assume, an element of a socket connector, such as a tongue), wherein the contact ends  32  is descending little by little from the engagement  323  up to the taper  322 . This movement remains until the external object is stopped by inside wall of the insulative housing  2 ; and at this point, the contact ends  32  descends almost below the level of the tongue  22 . 
     When the electrical connector is withdrawn from the computer system by the user, the contact ends  32  rebounds until the ramping portions  2321  of the insulative housing  2  stops the engagement  323  at the bottom  234  of slots  232 , and remains contacting with the ramping portions  2321  as beginning. The ramping portions  2321  provide a guarantee of non-cracking terminal that destructions often occur as over-rebound of the terminal so that the terminal is able to keep its elasticity of contact end  32  eventually. 
     The insulative housing  2  is engaging with the shell land further includes a tongue  22  extended along a back-to-front (transverse) direction and a base portion  21  located behind the tongue  22 . The tongue  22  and the base portion  21  are suggested to establish as a step-on structure, where the tongue  22  is comparatively lower than the datum of the base portion  21 . The insulative housing  2  configures a hollow chamber  23  in the center of its body, hereunder the area between the tongue  22  and the base portion  21 . The chamber  23  is equally divided into several independent slots  232  by a plurality of ribs  231 , which configures ramping portions  2321  in the bottom  234  of slots  232  that ascends the ramping portion  2321  to the base portion  21 . The plurality of ribs  231  provides the isolation of those conductive parts. 
     For saving the time to produce the electrical connector in accordance with the present invention, and avoiding the undesired increase of the process cost, a manufacture method was employed, which mainly refers to adopt an insert-molding process attaching the terminals  5  with the insulative housing  2 , such method comprising the steps of: 
     (a) providing a plurality of first terminals  3  and a plurality of second terminals  4 , and leaving the rest, by stamping one single metal material, which a contact end  32 , a rear portion  31  and a body portion  33  configures the first terminals  3 , and which a body portion  41  configures the second terminals  4  and extends one end horizontally, wherein the plurality of second terminals  4  crosses with the plurality of first terminals  3  in a transverse direction; 
     (b) configuring a elastic curve-shape of the contact end  32 , and a neck  321 , a taper  322  and an engagement  323  in sequence in the section between the contact end  32  and the body portion  33 , and configuring both of the terminals  5  being toward the same direction with an up and down arrangement, so as an unfinished metal part  67  be provided; 
     (c) placing (see  FIG. 7  A, B) the unfinished metal part  67  on a hole  66  of a plastic-injecting die  6  reversely, wherein a fender tool  62  and a resisting tool  61  ascend from the bottom, deviating the engagement  323 ; and a shaping tool  65  descends from the top to keep near to the fender tool  62 ; 
     (d) ejecting the plastic (see  FIG. 8  A, B) to form the insulative housing  2  which includes a tongue  22  extended along a back-to-front (transverse) direction and a base portion  21  located behind the tongue  22 , and which configures a hollow chamber  23  in the center of its body, hereunder the area between the tongue  22  and the base portion  21 , wherein the chamber  23  is equally divided into several independent slots  232  by a plurality of ribs  231 , wherein 
     a plurality of first terminals  3  is configured on the insulative housing  2  and passes through the slots  232 , the rear portion  31  is held by the base portion  21  of the insulative housing  2 , the contact end  32  and the body portion  33  are exposed out of the base portion  21 , and locate in the slot  232 , a preserved space  324  is formed by the leant neck  321  and engagement  323  and under the taper  322 , the engagement  323  extends further into the bottom  234  of slots  232 , wherein 
     a plurality of second terminals  4  is configured on the insulative housing  2 , a body portion  41  is held by the base portion  21  and ribs  231  of the insulative housing  2 , one end of second terminal extends out of the base portion  21 , the other end passes through the rib  231  and extends to be disposed above of the tongue  22 , and 
     which configures ramping portions  2321  in the bottom  234  of slots  232  that ascends the ramping portion  2321  to the base portion  21 , located between the shaping tool  65  and the fender tool  62 ; 
     (e) replacing (see  FIG. 9 ) tools, descending a fender tool  62  and a resisting tool  61  from the bottom, ascending a shaping tool  65  from the top, and returning the engagement  323  and contacting with the ramping portions  2321  once again, so as a semi-product  68  be provided; 
     (f) assembling (see  FIG. 10 ) the semi-product  68  with a shell  1 , so the electrical connector is finished thereof. 
     The step (b) further comprises: the taper  322  of the contact end  32  is generally in a curve-shape; the neck  321  is configured from the body portion  33  and extends upwardly to the taper  322 . 
     The step (a) further comprises: the body portion  33  is configuring with a flat  331  and an extension  332 . The flat  331  connects the neck  321  in one end and connects to the extension  332  in the other end. And, the extension  332  connects to the rear portion  31 . The first terminals  3  configure apertures  3231  on the two side terminal onto the engagement  323  thereof. 
     The step (c)-(e) further comprises: a clamping tool  69  retains the body portion  41  of the second terminal  4 . 
     The step (c) further comprises: the shaping tool  65  is installed from a top die  63 ; and the fender tool  62  and the resisting tool  61  are installed from a bottom die  64 . The unfinished metal part  67  is placing reversely in the hole  66  formed on the surface of the bottom die  64 . 
     The base portion  21  configures a plurality of posts  211  in bottom for being quick mounting on a circuit board. 
     The aperture  3231  of first terminal  3  provides the engagement  323  an escape with the second terminal  4 , avoiding intervenes of the terminals  5  for sake of the mini-pitches. 
     As shown in  FIG. 3 , the shell  1  includes gaps  11  for assembling with the insulatvie housing  2 , and a pair of soldering leg  12  for mounting on the circuit board. 
     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.