Patent Publication Number: US-9887480-B2

Title: Contact including deformation preventer for preventing deformation of connector support

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is based upon and claims the benefit of priority of Japanese Patent Application No. 2014-167893, filed on Aug. 20, 2014, the entire contents of which are incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     An aspect of this disclosure relates to a contact. 
     2. Description of the Related Art 
     In an electronic apparatus, boards facing each other at a distance may be electrically connected to a chassis frame of the electronic apparatus, or a pair of boards facing each other at a distance may be electrically connected to each other for frame grounding. Japanese Laid-Open Patent Publication No. 2002-015801, for example, discloses electrically connecting a pair of boards, which face each other at a distance, by using a contact. 
     When the distance between the pair of boards changes, the contact may be excessively pressed by the boards and deformed. When the contact is deformed, a contact point of the contact may be disengaged from an electrode pad provided on the board, and the connection between the board and the contact may be lost. 
     SUMMARY OF THE INVENTION 
     In an aspect of this disclosure, there is provided a contact for connecting a first object and a second object. The contact includes a base to be connected to the first object, a connector to be brought into contact with the second object, a support that supports the connector such that the connector is disposed away from the base, and a deformation preventer that prevents deformation of the support. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a contact; 
         FIGS. 2A through 2E  are a plan view, a left-side view, a front view, a right-side view, and a bottom view of a contact; 
         FIG. 3  is a drawing illustrating a contact disposed between boards; 
         FIG. 4  is a drawing illustrating a contact of an embodiment and a contact of a comparative example; 
         FIGS. 5A and 5B  are a front perspective view and a rear perspective view of a contact; 
         FIGS. 6A through 6E  are a plan view, a left-side view, a front view, a right-side view, and a bottom view of a contact; 
         FIGS. 7A and 7B  are a front perspective view and a rear perspective view of a contact; and 
         FIG. 8  is a front perspective view of a contact. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Embodiments of the present invention are described below with reference to the accompanying drawings. 
     Throughout the accompanying drawings, the same or corresponding reference numbers are assigned to the same or corresponding components, and repeated descriptions of those components are omitted. Unless otherwise mentioned, the drawings do not indicate relative sizes of components. A person skilled in the art may determine actual sizes of components taking into account the embodiments described below. 
     The embodiments described below are examples, and the present invention is not limited to those embodiments. Not all of the features and their combinations described in the embodiments may be essential to the present invention. 
       FIGS. 1 through 5B  are drawings illustrating a contact  1  according to an embodiment. As exemplified by  FIG. 3 , the contact  1  is disposed between a board  100  and a board  101  that are arranged to face each other at a distance, and electrically connects the boards  100  and  101 . 
     For example, each of the boards  100  and  101  may be a printed-circuit board provided in an electronic apparatus, or a chassis frame of an electronic apparatus. 
     As illustrated by  FIGS. 1 through 2E , the contact  1  includes a base  2 , a support  3 , a connector  4 , a protector  6 , and a deformation preventer  7 . When the contact  1  is formed by pressing a flat metal plate, the base  2 , the support  3 , the connector  4 , the protector  6 , and the deformation preventer  7  are formed as a monolithic structure. 
     In the figures, an X1/X2 direction is the width direction of the contact  1 , a Y1/Y2 direction is the longitudinal direction in which the base  2  extends, and a Z1/Z2 direction is a direction that is orthogonal to the plane direction of the base  2 . The X1/X2, Y1/Y2, and Z1/Z2 directions are orthogonal to each other. Also, in the descriptions below, the Y1/Y2 direction may be referred to as a horizontal direction, and the Z1/Z2 direction may be referred to as a vertical direction. Further, the Y1/Y2 direction may be referred to as a Y-direction. 
     The contact  1  may be comprised of a conductive and elastic metal plate including, for example, phosphor bronze, beryllium copper, or stainless steel (SUS). Also, the whole or a part of a surface of the contact  1  may be plated with, for example, nickel, copper, or gold. 
     The contact  1  is fixed to one of the boards  100  and  101 . For example, the contact  1  is fixed by soldering the base  2  to one of the boards  100  and  101 . In the descriptions below, it is assumed that the base  2  is fixed to the board  100 . 
     An electrode pad  102  is provided on a surface of the board  101 . An electrode pad (not shown) is also provided on a surface of the board  100 . The base  2  is connected to the electrode pad on the board  100  by soldering the base  2  to the board  100 . 
     The base  2  is bent at a bent part  10  to form the support  3 . The angle between the base  2  and the support  3  (or the bending angle of the bent part  10 ) is, for example, 90 degrees, and the support  3  rises in substantially the vertical direction from the base  2 . The bending angle of the bent part  10  is not necessarily limited to 90 degrees. 
     The support  3  is bent at a bent part  11  to form the connector  4 . The angle between the connector  4  and the support  3  (or the bending angle of the bent part  11 ) is, for example, 90 degrees. Because the support  3  rises from the base  2 , the connector  4  is supported by the support  3  such that the connector  4  is disposed away from the base  2 . 
     With the bending angle of the bent part  11  set at 90 degrees, the base  2  and the connector  4  are positioned substantially parallel to each other The distance between the base  2  and the connector  4  positioned parallel to each other becomes substantially equal to the length of the support  3  in the Z1/Z2 direction. The bending angle of the bent part  11  is not necessarily limited to 90 degrees. 
     An end of the connector  4 , which is opposite from the bent part  11 , is a free end. Thus, the connector  4  is formed as a cantilever that functions as a spring. 
     A contact point  5  is formed at the end (free end) of the connector  4 . The contact point  5  is formed by bending the end of the connector  4  into a substantially U-shape. As illustrated in  FIG. 3 , the contact point  5  is to be brought into contact and electrically connected with the electrode pad  102  formed on the board  101 . 
     When the contact  1  is placed between the boards  100  and  101 , the contact point  5  is pressed by the board  101  (an arrow F in  FIG. 3  indicates the pressing force). With the pressing force F, the connector  4  is elastically deformed, and the contact point  5  is displaced in a direction indicated by an arrow A in  FIGS. 1 and 3 . 
     When the connector  4  is deformed, an elastic restoring force (hereafter simply referred to as a “restoring force”) is generated in the connector  4 . Due to the restoring force, the contact point  5  is biased toward and pressed against the electrode pad  102 . 
     The protector  6  protects the contact point  5 . The protector  6  is formed at an end (the Y1 end) of the base  2  which is opposite from an end at which the bent part  10  is formed. The protector  6  is connected to the base  2  via a bent part  13 . The bending angle of the bent part  13  is, for example, about 90 degrees. 
     The protector  6  covers the contact point  5  over a range of displacement of the contact part  5 . The protector  6  prevents an external force from being applied to the contact point  5  when, for example, the contact  1  is placed between the boards  100  and  101 . The bending angle of the bent part  13  is not necessarily limited to 90 degrees as long as the protector  6  can protect the contact point  5 . 
     Next, the deformation preventer  7  is described. 
     The deformation preventer  7  prevents deformation of the support  3 . The deformation preventer  7  may be provided in or near the support  3 . 
     The deformation preventer  7  is formed, for example, by pressing and punching out a central portion of the base  2  and the support  3  except for a part connected to the support  3 , and by bending the punched-out portion at a bent part  14  such that the punched-out portion extends from the support  3  linearly and obliquely downward toward the base  2 . That is, the deformation preventer  7  is inclined with respect to the support  3 . 
     The deformation preventer  7  includes an inclined part  7 A and a fixed part  7 B that are formed as a monolithic structure. An upper end of the inclined part  7 A is bent at the bent part  14  from the support  3 . Thus, the support  3  and the inclined part  7 A are seamlessly connected to each other. In the descriptions below, an angle θ of the deformation preventer  7  with the base  2  may be referred to as an “inclination angle θ”. 
     A lower end of the inclined part  7 A is bent at a bent part  15  to form the fixed part  7 B. The fixed part  7 B is disposed to be in substantially the same plane with the base  2 . The fixed part  7 B is soldered to the board  100  together with the base  2 . 
     As described above, when the contact  1  is mounted on the board  100 , the base  2  is soldered to the board  100 . When the base  2  is soldered, the fixed part  7 B of the deformation preventer  7  is also soldered and fixed to the board  100 . 
     With the fixed part  7 B fixed to the board  100  by soldering, the deformation preventer  7  functions as a prop for supporting the support  3 . That is, even when a force is applied to cause the support  3  to be displaced around the bent part  10  and fall in a direction indicated by an arrow B in  FIG. 2C  and  FIG. 3 , the deformation preventer  7 , with the fixed part  7 B fixed to the board  100 , supports the support  3  and prevents deformation of the support  3 . 
     The inclination angle θ of the deformation preventer  7  with the base  2  may be set at, but is not limited to, 60 degrees. 
     Next, operation of the contact  1  is described with reference to  FIG. 4 . 
     The left side of  FIG. 4  illustrates operation of the contact  1  when the contact  1  is mounted on the board  100  and pressed by the board  101 . The right side of  FIG. 4  illustrates operation of a contact  20  of a comparative example when the contact  20  is mounted on the board  100  and pressed by the board  101 . The contact  20  does not include the deformation preventer  7 . 
     Except that the contact  20  does not include the deformation preventer  7 , the contact  1  and the contact  20  have substantially the same configuration. Therefore, reference numbers of components of the contact  20  are expressed by adding “−1” to the reference numbers of the corresponding components of the contact  1 . 
     In  FIG. 4 , a dotted line  101 A indicates a position of the board  101  before the board  101  contacts the contact point  5 / 5 - 1 . In the descriptions below, a state of each of the contacts  1  and  20  before the board  101  contacts the contact point  5 / 5 - 1  may be referred to as a “pre-pressed state”. 
     Also in  FIG. 4 , a solid line  101 B indicates a position of the board  101  at which the board  101  presses the contact point  5 / 5 - 1 . In the descriptions below, a state of each of the contacts  1  and  20  when the board  101  is pressing the contact point  5 / 5 - 1  may be referred to as a “pressed state”. 
     In the pre-pressed state, each of the contacts  1  and  20  is not deformed. Accordingly, the support  3 , the connector  4 , and the protector  6  of the contact  1  are substantially in the same shapes as the support  3 - 1 , the connector  4 - 1 , and the protector  6 - 1  of the contact  20  (indicated by dashed-dotted lines in  FIG. 4 ). 
     When the board  101  moves toward the board  100  (in the Z2 direction), the board  101  contacts the contact point  5 / 5 - 1 , and presses the contact point  5 / 5 - 1  toward the board  100 . 
     Because the connector  4 / 4 - 1  has a cantilever structure and has elasticity, when the contact point  5 / 5 - 1  is pressed by the board  100 , the connector  4 / 4 - 1  elastically deforms and is displaced around the bent part  11 / 11 - 1  toward the base  2 / 2 - 1 . That is, in  FIG. 4 , the connector  4 / 4 - 1  is displaced around the bent part  11 / 11 - 1  in a direction indicated by an arrow A/A- 1 . 
     Because the connector  4 / 4 - 1  is seamlessly connected to the support  3 / 3 - 1  at the bent part  11 / 11 - 1 , when the contact point  5 / 5 - 1  is pressed by the board  101  and the connector  4 / 4 - 1  is displaced, the support  3 / 3 - 1  is also displaced around the bent part  10 / 10 - 1  toward the base  2 / 2 - 1  and is inclined in a direction indicated by an arrow B/B- 1 . In the descriptions below, the displacement or the inclination of the support  3 / 3 - 1  in the direction of the arrow B/B- 1 , which is caused when the board  101  presses the contact point  5 / 5 - 1 , may be referred to as a “forward fall” and may be expressed as “fall forward”. 
     Next, operation of the contact  20  not including the deformation preventer  7  is described. 
     When the contact point  5 - 1  is pressed by the board  101 , because the contact  20  does not include the deformation preventer  7  for limiting deformation of the support  3 - 1 , the support  3 - 1  of the contact  20  falls forward. 
     As illustrated in  FIG. 3 , the contact point  5  is electrically connected to the electrode pad  102  on the board  101 . However, with the contact  20  that does not include the deformation preventer  7 , the contact point  5 - 1  is greatly displaced in the Y-direction due to the forward fall and may be disengaged from the electrode pad  102 . When the contact point  5 - 1  is disengaged from the electrode pad  102 , the electrical connection between the board  100  and the board  101  is lost. 
     Next, operation of the contact  1  including the deformation preventer  7  is described. 
     With the contact  1  including the deformation preventer  7 , even when the contact point  5  is pressed by the board  101  and a force is applied to the support  3 , the deformation preventer  7  supports the support  3  and prevents the support  3  from falling forward (in the direction of the arrow B). Also, because the forward fall of the support  3  is prevented, the amount of displacement of the contact point  5  is reduced. For this reason, a displacement L 1  of the contact point  5  of the contact  1  in the pressed state is less than a displacement L 2  of the contact point  5 - 1  of the contact  20  not including the deformation preventer  7  (L 1 &lt;L 2 ). 
     The contact  1  including the deformation preventer  7  can reduce the amount of displacement of the contact point  5  in the Y-direction due to the pressure applied by the board  101 , and improves the reliability of connection between the contact  1  and the board  101 . 
     Also, as illustrated in the right side of  FIG. 4 , when the amount of displacement of the contact point  5 - 1  in the Y-direction is large, it is necessary to provide a space corresponding to the amount of displacement in the contact  20 . This in turn increases the space occupied by the contact  20  on the board  100 . On the other hand, the present embodiment can reduce the amount of displacement of the contact point  5  in the Y-direction and the space occupied by the contact  1  on the board  100 . 
     The contact  1 , including the deformation preventer  7 , can be formed as a monolithic structure by pressing a single metal plate. Accordingly, providing the deformation preventer  7  does not increase the manufacturing costs of the contact  1 . 
     Next, a contact according to another embodiment is described. 
       FIGS. 5A through 6E  illustrate a contact  30  according to another embodiment. The same reference numbers as those in  FIGS. 1 through 4  are assigned to the corresponding components in  FIGS. 5A through 6E , and repeated descriptions of those components are omitted. 
     The contact  30  illustrated by  FIGS. 5A through 6E  includes a deformation preventer  37  having a step. 
     The deformation preventer  37  includes a platform  37 A, a leg  37 B, and a fixed part  37 C that are formed as a monolithic structure. 
     The platform  37 A is connected to the support  3  at a bent part  34 . The platform  37 A extends from the bent part  34  in a horizontal direction (in the Y1/Y2 direction). Accordingly, the platform  37 A is substantially parallel to the base  2 . 
     An end of the platform  37 A opposite from the bent part  34  is bent at a bent part  35  to form an upper end of the leg  37 B. The leg  37 B extends downward (in the Z2 direction) from the bent part  35 . Accordingly, the leg  37 B is substantially perpendicular to the base  2 . 
     A lower end of the leg  37 B is bent at a bent part  36  to form the fixed part  37 C. When the base  2  is soldered to the board  100 , the bent part  36  is also soldered to the board  100 . 
     As illustrated in  FIGS. 5A and 5B , the contact  30  includes extensions  38 A and  38 B extending in the width direction from the corresponding sides of the base  2  to increase an area to be soldered. 
     The deformation preventer  37  having a step can support the support  3  and prevent the support  3  from falling forward. Accordingly, the contact  30  of the present embodiment can reduce the amount of displacement of the contact point  5  in the Y-direction due to the pressure applied by the board  101 , and can improve the reliability of electrical connection between the contact  30  and the board  101 . 
     In the example of  FIGS. 5A through 6E , one step is formed in the deformation preventer  37 . However, the number of steps of the deformation preventer  37  is not limited to one, and two or more steps may be formed in the deformation preventer  37 . 
     The contact  30  of  FIGS. 5A through 6E  also includes a pair of protectors  36 A and  36 B on the sides of the contact point  5  to protect the contact point  5 . Each of the protectors  36 A and  36 B rises from an end of the base  2  which is opposite from an end at which the support  3  is formed, respectively. 
       FIGS. 7A and 7B  illustrate a contact  40  according to another embodiment. 
     The same reference numbers as those in  FIGS. 1 through 6E  are assigned to the corresponding components in  FIGS. 7A and 7B , and repeated descriptions of those components are omitted. 
     The contact  40  includes a deformation preventer  47  that is formed by plastically deforming a part of the support  3 . The deformation preventer  47  is a protrusion that is formed by deforming a part of the support  3  inward (in the Y1 direction). 
     For example, the deformation preventer  47  may be formed at the same time as the contact  40  is formed by pressing a metal plate. Thus, the deformation preventer  47  can be easily formed. 
     Forming the deformation preventer  47  in the support  3  has substantially the same effect as increasing the thickness of the support  3 , and may increase the rigidity of the support  3 . This in turn makes it possible to prevent the support  3  from being displaced toward the base  2  when the contact point  5  is pressed by the board  101 . 
     The deformation preventer  47  is formed in the bent part  10  between the base  2  and the support  3 . Forming a part of the deformation preventer  47  in the bent part  10  improves the rigidity of the bent part  10 , and can prevent the support  3  from being displaced around the bent part  10 . 
     Accordingly, the contact  40  of the present embodiment can reduce the amount of displacement of the connector  4  and the contact point  5  due to the pressure applied by the board  101 , and the reliability of electrical connection between the contact  40  and the board  101  is improved. 
     In the present embodiment, the deformation preventer  47  is formed by plastically deforming the support  3  from the outside toward the inside, i.e., in the Y1 direction. Accordingly, the deformation preventer  47  protrudes inward from the support  3 . 
     However, the direction in which the support  3  is deformed to form the deformation preventer  47  is not limited to the inward direction. For example, the deformation preventer  47  may be formed by deforming the support  3  in the outward direction (the Y2 direction). 
     Also, the deformation preventer  47  is not limited to one, and multiple deformation preventers  47  may be formed in the support  3 . For example, although the deformation preventer  47  is also formed in the bent part  10  positioned below the support  3  in  FIGS. 7A and 7B , the deformation preventer  47  may be formed in the bent part  11  above the support  3 , or in each of the bent part  10  and the bent part  11 . 
       FIG. 8  illustrates a contact  50  according to still another embodiment. 
     The same reference numbers as those in  FIGS. 1 through 7B  are assigned to the corresponding components in  FIG. 8 , and repeated descriptions of those components are omitted. 
     The contact  50  includes deformation preventers  57 A and  57 B that are formed by bending (plastically deforming) side parts of the support  3  inward (in the Y1 direction). The deformation preventers  57 A and  57 B are configured such that their lower ends  58 A and  58 B are in contact with or brought into contact with the base  2 . That is, the deformation preventers  57 A and  57 B may be configured such that the lower ends  58 A and  58 B are in contact with the base  2  or a gap is present between each of the lower ends  58 A and  58 B and the base  2 . 
     For example, the deformation preventers  57 A and  57 B may be formed at the same time as the contact  50  is formed by pressing a metal plate. Accordingly, the deformation preventers  57 A and  57 B can be formed easily. 
     Even when a force is applied by the board  101  to cause the support  3  to fall in a direction indicated by the arrow B, because the lower ends  58 A and  58 B of the deformation preventers  57 A and  57 B contact with the base  2 , deformation of the support  3  is prevented by the deformation preventers  57 A and  57 B. 
     Accordingly, the contact  50  of the present embodiment can reduce the amount of displacement of the connector  4  and the contact point  5  in the Y-direction due to the pressure applied by the board  101 , and the reliability of electrical connection between the contact  50  and the board  101  is improved. 
     Contacts according to the embodiments of the present invention are described above. However, the present invention is not limited to the specifically disclosed embodiments, and variations and modifications may be made without departing from the scope of the present invention. 
     For example, although the fixed parts  7 B and  37 C of the deformation preventers  7  and  37  are fixed by soldering to the board  100  in the above embodiments, the fixed parts  7 B and  37 C may not necessarily be fixed to the board  100 . Instead, the fixed parts  7 B and  37 C may be fixed to the base  2 .