Patent Publication Number: US-6213802-B1

Title: Electrical connector

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to an electrical connector, and especially to an electrical connector for connection with a flexible cable having a stuffer for pressing the flexible cable to engage with terminals of the electrical connector. 
     When a pair of devices to be connected is individually assembled into a computer enclosure and is required to be replaced by an alternative counterpart, a permanent connection method such as soldering is unfavorable. A flexible cable, such as an FPC (Flexible Printed Circuit) or an FFC (Flexible Flat Cable), for providing releasable electrical connection between the devices is one solution for the above problem. The flexible cable is especially useful within a narrow or complicated space of a computer enclosure due to the high adaptability thereof. 
     A conventional connector such as the one disclosed in U.S. Pat. No. 5,738,545 is connected to a flexible cable by pivotally pressing the flexible cable against a plurality of terminals. Therefore, the terminals are connected to the flexible cable and the flexible cable is secured within the connector. However, the pivotal movement requires an actuation space thereby possibly interfering with the other devices within the computer enclosure. In addition, pivotally pressing the flexible cable is likely to cause a frictional sliding of a surface of the flexible cable thereby possibly damaging the flexible cable. Furthermore, the sliding movement of the flexible cable due to the pivotal pressing may cause circuit tracks on the flexible cable to be inaccurately engaged with the corresponding terminals. Thus, false signals may be generated in the circuits. In a worse case, the circuit or a component connected to the circuits may be damaged due to overheating caused by the inaccurate engagement between the flexible cable and the connector. 
     Furthermore, due to current trends, different components of a device are manufactured at different plants. The components are then transported to another plant to complete assembly of the device. Thus, a structure of each component must be suitable for long distance transport. However, a member pivotally mounted to the connector may become damaged during shipping by impacting other parts of the connector or unexpected objects outside the connector. 
     SUMMARY OF THE INVENTION 
     Accordingly, a primary object of the present invention is to provide an electrical connector for connection with a flexible cable having a stuffer for pressing against the flexible cable to contact terminals of the connector. 
     Another object of the present invention is to provide an electrical connector for connection with a flexible cable having a stuffer that can be easily disassembled therefrom for shipping purposes. 
     A further object of the present invention is to provide an electrical connector which can be reliably and properly connected to a flexible cable. 
     To fulfill the above-mentioned objects, an electrical connector for connection with a flexible cable comprises an elongate insulative housing, a plurality of terminals retained in the housing and a stuffer. The housing defines a plurality of passageways between a mating surface and a mounting surface opposite the mating for receiving the terminals. A pair of retention holes is formed in opposite ends of the stuffer corresponding to teeth formed on opposite ends of the housing. Each terminal includes a mating end and an upwardly extending mounting tail. The stuffer is mounted to the housing with the teeth engaging in the holes. A gap is defined between the mating tails of the terminals and the stuffer for receiving an end of the flexible cable with the mating tails contacting corresponding circuit tracks of the flexible cable. The stuffer is downwardly pushed to press against the flexible cable to engage with the mounting portions and secure the end of the flexible cable within the housing. 
     Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGIG 
     FIG. 1 is an exploded view of an electrical connector in accordance with the present invention and a flexible cable; 
     FIG. 2 is an assembled view of FIG. 1 with the flexible cable not yet inserted into the connector; 
     FIG. 3 is a cross-sectional view taken along line  3 — 3  of FIG. 2; 
     FIG. 4 is similar to FIG. 2 with the flexible cable inserted into the connector; 
     FIG. 5 is a cross-sectional view of FIG. 4 with a second connector mated to the electrical connector; 
     FIG. 6 is an exploded view of an electrical connector of a second embodiment of the present invention; 
     FIG. 7 is a cross-sectional view of the assembled connector of FIG. 6 with a flexible cable inserted therein; and 
     FIG. 8 is an exploded view of an electrical connector of a third embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     Referring to FIG. 1, an electrical connector  5  in accordance with the present invention comprises an elongate housing  1 , a plurality of terminals  2  and an insulative stuffer  3 . 
     The housing  1  defines a plurality of passageways  10  between a mating surface  11  and a mounting surface  12  thereof. A pair of retention member  13  rearwardly extends from opposite ends of the housing  1 . A first tooth  130  and a second tooth  131  are formed in vertical alignment on an outer surface of each retention member  13 . An inclined surface is formed on each tooth  130 ,  131 . A pair of projections  14  with inclined surfaces is formed on an upper surface of the housing  1 . A pair of blocks  15  outwardly projects from opposite end of the housing  1  for orienting purposes when the electrical connector  5  mates with a mating connector  6  (FIG.  5 ). 
     The stuffer  3  includes an elongate body  30 , a stop wall  31  and a pair of spring arms  301  at opposite ends of the stop wall  31 . The distance between opposite inner surfaces of the arms  301  is substantially equal to the distance between opposite outer surfaces of the retention members  13 . Each arm  301  defines a first hole  302  and second hole  303  therethrough. The first hole  302  and the second hole  303  are vertically aligned corresponding to the first tooth  130  and the second tooth  131  of the housing  1 . An inclined surface  304  is formed on each arm  301  proximate a distal end thereof for facilitating connection between the stuffer  3  and the housing  1 . 
     Each terminal  2  is unitarily stamped and forms a center portion  20 , three mating ends  22  extending from one end of the center portion  20  and a mating tail  21  upwardly extending from an opposite end of the center portion  20 . The mating tail  21  is upwardly deformed. Locking barbs  200  are formed along lateral edges of the center portion  20  for having an interference fit in the passageways  10  of the housing  1 . The mating tails  21  extend out of the passageways  10  beyond the mounting surface  12  of the housing  1 . 
     Referring to FIG. 2, in assembly, the stuffer  3  is mounted to the housing  1  with the first tooth  130  engaging in the second hole  303 . As shown in FIG. 3, a gap  33  is defined between a bottom surface of the body  30  and the mating tails  21  for receiving an end of a flexible cable  4 . 
     Also referring to FIGS. 4 and 5, the flexible cable  4  is inserted into the gap  33  with the mating tails  21  contacting corresponding circuit tracks (not shown) of the flexible cable  21 . The stop wall  31  of the stuffer  3  is used for abutting an end of the flexible cable  4  entering the connector thereby properly positioning the flexible cable  4  between the housing  1  and the stuffer  3 . The stuffer  3  is then downwardly pushed such that the first tooth  130  engages with the first hole  302  and the second tooth  131  engages with the second hole  303 . The bottom surface of the body  30  abuts against the flexible cable  4  to ensure the circuit tracks of the flexible cable to reliably and accurately engage with the mating tails  21 . 
     The mating connector  6  includes a plurality of contacts  63  for engaging with the mating ends  22  of the terminals  2  and a mating housing  62  for receiving the housing  1 . The projections  14  engage with corresponding apertures  61  defined in the mating housing  62  thereby securing the electrical connector  5  to the mating connector  6 . 
     FIGS. 6 and 7 show an electrical connector  5 ′ of a second embodiment of the present invention. The differences between the electrical connector  5 ′ of the second embodiment and the electrical connector  5  of the first embodiment reside in a portion of the stuffer  3  and a portion of the housing  1 . Therefore, the reference numerals applied in FIGS. 1-5 are used to designate like components of the electrical connector  5 ′. The stuffer  3  forms a plurality of hooks  32  proximate a bottom edge thereof. Correspondingly, an elongate plate  121  extending from the mounting surface  12  of the housing  1  defines a plurality of recesses  1210  along an edge thereof. In assembly, the flexible cable  4  is retained in the housing  1  by the stuffer  3  and is connected to the terminals  2 . The hooks  32  of the stuffer  3  engage with the recesses  1210  of the housing  1  thereby further securing the stuffer  3  to the housing  1 . 
     FIG. 8 shows an electrical connector  5 ″ of a third embodiment of the present invention. The differences between the electrical connector  5 ″ of the third embodiment and the electrical connector  5 ′ of the second embodiment reside in a portion of the housing  1 . Therefore, the reference having been applied in FIGS. 1-7 are used to designate like components of the electrical connector  5 ″. A guiding post  132  upwardly projects from each retention member  13  of the housing  1 . An inner inclined surface  1321  is formed on the guiding post  132 . The guiding posts  132  are used for preventing transverse movement of the flexible cable  4  thereby properly positioning the flexible cable  4  between the housing  1  and the stuffer  3 . 
     Since the stuffer  3  downwardly presses the flexible cable  4 , frictional sliding on a surface of the flexible cable  4  is prevented. Thus, the surface is unlikely to be damaged. In addition, the flexible cable  4  is inserted into the electrical connector  5 ″ and is guided by the stop wall  31  and the guiding posts  132 . The circuit tracks on the flexible cable  4  can be properly engaged with the mating tails  21  of the terminals  2  and generation of false signals is prevented. 
     When the finished connector  5  is required to be transported, the stuffer  3  may be disassembled from each connector  5 . Since the stuffer  3  is not pivotally mounted to the housing  1 , the stuffer  3  would not be damaged by being impacted by other parts of the connector  5  or unexpected objects outside the connector  5  due to vibration. Alternatively, the finished connector  5  may be transported without disassembling the stuffer  3  since the stuffer  3  can be reliably secured to the housing. 
     It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.