Patent Publication Number: US-9899780-B2

Title: RJ and USB connectors with grooved contact pins

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/231,813, filed on Jul. 15, 2015, which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to electrical connectors, in general, and to RJ and USB connectors, in particular. More particularly, the present invention relates to the shape of contact pins used with RJ and USB connectors that, in use, are intended to be mounted on printed circuit boards (PCB). 
     Description of Related Art 
     Many prior art connectors, such as RJ and USB connectors, are designed with straight contact pins that are intended to be inserted into through-holes in printed circuit boards (PCBs) in use. The use of such prior art connectors with straight contact pins is well known in the art. 
     A common problem with insertion of such contact pins in through-holes of PCBs is bending of one or more of the contact pins due during insertion when mounting the connector to the PCB. It would be desirable to avoid this problem by providing a connector with an improved contact pin design. 
     SUMMARY OF THE INVENTION 
     Various preferred and non-limiting examples or aspects of the present invention will now be described and set forth in the following numbered clauses. 
     Clause 1. A female electrical connector comprising: a plurality of walls defining a housing, a female connector inside the housing, and an opening configured to facilitate insertion of a mating male connector into the female connector; contacts of the female connector positioned in the opening of the housing; and contact pins extending from the contacts of the female connector through at least one of the plurality of walls of the housing for connection to a substrate, wherein each contact pin includes a curved or bent portion. 
     Clause 2. The female electrical connector of clause 1, wherein each curved or bent portion comprises: a first, straight section extending in a first direction from one of the contacts; a second section extending from the end of the first section opposite the contact and away from the first direction; a third section extending from the end of the second section opposite the first section and toward the first direction; and a fourth, straight section extending from the end of the third section opposite the second section and in the first direction. 
     Clause 3. The female electrical connector of either clause 1 or 2, wherein: the first and second sections are positioned at a first angle to each other; and/or the second and third sections are positioned at a second angle to each other; and/or the third and fourth sections are positioned at a third angle to each other. 
     Clause 4. The female electrical connector of any of clauses 1-3, wherein: each angle is an obtuse or acute angle; and the transition between at least one of the first and second sections; the second and third section; and the third and fourth sections is sharp, curved, or both. 
     Clause 5. The female electrical connector of any of clauses 1-4, wherein: the second section extends away from the first section at a first, obtuse angle; and the first angle is sharp, curved, or both. 
     Clause 6. The female electrical connector of any of clauses 1-5, wherein: the third section extends away from the second section at a second, obtuse or acute angle; and the second angle is sharp, curved, or both. 
     Clause 7. The female electrical connector of any of clauses 1-6, wherein: the fourth section extends away from the third section at a third, obtuse angle; and the third angle is sharp, curved, or both. 
     Clause 8. The female electrical connector of any of clauses 1-7, wherein the first and fourth sections are aligned. 
     Clause 9. The female electrical connector of any of clauses 1-8, wherein the female connector is a USB connector or an RJ connector. 
     Clause 10. The female electrical connector of any of clauses 1-9, wherein the substrate is a PCB. 
     Clause 11. The female electrical connector of any of clauses 1-10, wherein electromagnetic interference (EMI) shielding defines one or more of the plurality of walls. 
     Clause 12. The female electrical connector of any of clauses 1-11, wherein the EMI shielding: defines a top wall of the housing; and covers side walls of the housing. 
     Clause 13. The female electrical connector of any of clauses 1-12, wherein the contact pins extend from a bottom wall of the housing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an embodiment high profile female (type-A) USB connector; 
         FIG. 2  is top view of the high profile female USB connector of  FIG. 1 ; 
         FIG. 3A  is a front view of the high profile female USB connector of  FIG. 1 ; 
         FIG. 3B  is another front view of the high profile female USB connector of  FIG. 1  including exemplary, non-limiting dimensions; 
         FIG. 4A  is a left side view of the high profile female USB connector of  FIG. 1 ; 
         FIG. 4B  is another left side view of the high profile female USB connector of  FIG. 1  including exemplary, non-limiting dimensions; 
         FIG. 5  is a bottom view of the high profile female USB connector of  FIG. 1  including exemplary, non-limiting dimensions; 
         FIGS. 6A-6F  are schematic views of prior art USB connectors including respective Standard Type-A and Type-B, Mini-A and Mini-B, and Micro-A and Micro-B; 
         FIG. 7  is a perspective view of the example high profile female USB connector of  FIGS. 1-5  showing the top wall, the left side wall, and the back wall; wherein the back wall includes an opening showing contact pins, including curved, grooved, or bent portions; 
         FIG. 8  is a cross-section taken along lines VIII-VIII in  FIG. 3B ; 
         FIG. 9  is a cross-section of an example low profile female USB connector having a contact pin, including a curved, grooved, or bent portion; 
         FIG. 10  is a cross-section of a high profile female RJ connector having a contact pin, including a curved, grooved, or bent portion; 
         FIG. 11  is a cross-section of a low profile female RJ connector having a contact pin, including a curved, grooved, or bent portion; 
         FIG. 12A  is an isolated view of an example single contact pin coupled to a contact, wherein the contact pin includes a curved portion; and 
         FIG. 12B  is an isolated view of another example single contact pin coupled to a contact, wherein the contact pin includes a bent portion. 
     
    
    
     DESCRIPTION OF THE INVENTION 
     The following examples will be described with reference to the accompanying figures, where like reference numbers correspond to like or functionally equivalent elements. Persons of ordinary skill in the art will realize that the following examples are illustrative only and that are not in any way limiting. Other examples will readily suggests themselves to such skilled persons. 
     The dimensions shown in the figures are in millimeters (mm) and are representative of the example connector described herein. However, these dimensions are not to be construed in the limiting sense since the use of other dimensions are envisioned. 
     With reference to  FIGS. 1-5 , a high profile USB connector  2  includes a housing  4  having a top wall  6 , a bottom wall  8 , a left side wall  10 , a right side wall  12 , a back wall  14 , and a front wall  16 . 
     Connector  2  includes a female USB connector  20  inside of housing  4 . Front wall  16  of housing  4  includes an opening  22  having a height H and a width W configured to facilitate insertion of a mating male USB connector  24  into female USB connector  20  when male USB connector  24  is moved in the direction of arrow  18  into female USB connector  20 . 
     Female USB connector  20  includes contacts  28 A- 28 D disposed on a top surface of a USB printed circuit board (PCB)  30  which is positioned inside the cavity opening  22  of female USB connector  20 . Female USB connector  20  also includes contact pins  26 A- 26 D which extend from contacts  28 A- 28 D, respectively through female USB connector  20  through at least one of the walls of housing  2 , e.g., bottom wall  8 , for connection to a substrate, such as, for example, a mounting PCB  32 . 
     Housing  4  includes electromagnetic interference (EMI) shielding  36  on one or more of the walls of housing  4 , e.g., without limitation, walls  6 ,  10 ,  12 ,  14 , and, optionally, wall  8 .  FIGS. 2, 3B, 4B, and 5  include exemplary dimensions of connector  2 . These dimensions, however, are not to be construed as limiting the invention. 
     Extending from bottom wall  8  of housing  4  is one or more snap fit connections  38 . Each snap fit connection  38  includes at least a partial rim  40  and a distal end  42  that is adapted to compress laterally upon initial insertion into an opening  34  of mounting PCB  32  and expand laterally upon passage of partial rim  40  through said opening  34 . The construction and operation of snap fit connection  38  is known in the art. 
     Shielding  36  includes one or more shield tabs  44  coupled to shielding  36  and extending from housing  2 , e.g., away from bottom wall  8 , for receipt and affixing in mating receptacles (not shown) of mounting PCB  32  by any means known in the art, e.g., press fit, soldering, etc. 
     Desirably, female USB connector  20  is positioned horizontally in housing  2 . However, it is envisioned that female USB connector  20  can be positioned vertically in housing  2 . 
     Desirably, a distance between an exterior of bottom wall  8  of housing  2  and a bottom surface of one of the contacts  28  that is closest to said exterior bottom wall  8  is at least 1.5×H, where H is the height of opening  22 . More desirably, the distance between exterior bottom wall  8  and the bottom surface of one of the contacts  28  is at least 2×H and, more preferably, 3×H—all as shown in  FIG. 3A . 
     As shown best in  FIG. 4A , front wall  16  of housing  2  includes, between cavity opening  22  and bottom wall  8 , an optional section  46  that is recessed toward back wall  14  of housing  2 , whereupon female USB connector  20  is cantilevered over a space in front of recessed section  46  of front wall  16 . The construction of housing  4  with front wall  16  having recessed section  46  and with female USB connector  20  cantilevered over the space in front of recessed section  46  of front wall  16 , however, is not to be construed as limiting the invention since it is envisioned that recessed section  46  can be omitted whereupon housing  4  has more of a box-like shape. 
     As can be seen, between female USB connector  20  and the exterior of bottom wall  8  of housing  4 , housing  4  does not house another connector. In other words, no other connector of any type resides between female USB connector  20  and bottom wall  8  of housing  4 . 
     With reference to  FIGS. 7 and 8  and with continuing reference to all previous FIGS., each contact pin  26  can include a curved, grooved, or bent portion or segment  50  along the length of contact pin  26  between contact  28  and a distal end  27  of said contact pin  26 . For example, contact pin  26   a  includes curved or bent portion  50   a ; contact pin  26   b  includes curved or bent portion  50   b ; contact pin  26   c  includes curved or bent portion  50   c ; and contact pin  26   d  includes curved or bent portion  50   d.    
     It has been observed that when mounting prior art USB connectors onto mounting PCB  32  the straight contact pins of such connectors were prone to bending during insertion into through-holes  53  of the mounting PCB  32 . A benefit of having a contact pin  26  include a curved or bent portion  50  is increased ability to avoid bending of the contact pin  26  during insertion into a through-hole. Moreover, where a connector has a number of contact pins with curved or bent portions  50 , such contact pins stay aligned better with each other without bending during insertion of said contact pins into through-holes in mounting PCB  32 . 
     In an example, each curved or bent portion  50  resides within housing  4  or within an outline of housing  4 . In the example shown in  FIG. 7 , housing  4  has an open back wall  14 . However, this is not to be construed in a limiting sense since it is envisioned that back wall  14  of housing  4  can be enclosed whereupon contact pins would not be visible via said enclosed back wall. 
     As shown in the cross-section of  FIG. 8 , which is a cross-section taken along lines VIII-VIII in  FIG. 3B , each contact  28  includes a bent portion  52  that mates with a corresponding contact of a mating male USB connector  24  in a manner known in the art. In  FIG. 8 , contact  28 A is shown as including bent portion  52 A. It is to be appreciated that each bent portion  52  may not be the same and can serve a different purpose as curved or bent portion  50  of a contact pin  26 . To this end, curved or bent portion  50 , which can be part of an otherwise straight section of the contact pin  26 , is provided in a space between a pair of channels of the housing through which straight sections of the contact pin on opposite sides of the curved or bent portion pass, and the curved or bent portion of each contact pin is free to move in said space to make the corresponding contact pin  26  less prone to bending during insertion into through-holes in mounting PCB  32  and to enable adjacent contact pins  26  to remain better aligned with each without bending during insertion into through-holes  53  of mounting PCB  32 . 
     In an example, each curved or bent portion  50  can facilitate the formation of each contact pin  26  as short as possible within housing  4 , which can be helpful for forming low profile connectors which have a reduced housing height. Moreover, each curved or bent portion  50  facilitates proper alignment of the corresponding contact pin  26  and contact  28  during assembly of connector  2 . 
     Furthermore, the use of the curved or bent portion  50  of each contact pin  26  provides said contact pin  26  with additional strength to keep it from bending inside housing  4  and the portion of contact pin  26  outside of housing  4  from bending during insertion into a through-hole  53  of mounting PCB  32 . Moreover, the curved or bent portion  50  of each contact pin  26  enables the formation of longer contact pins  26  of connectors  2  when stacked together in a common housing, whereupon this added length facilitates contact pins  26  being less prone to bending during insertion into through-holes in a mounting PCB  32  which, in-turn, facilitates insertion of the distal end of each contact pin  26  in a through-hole  53  of mounting PCB  32 . Another advantage of the curved or bent grooved portion  50  of each contact pin  26  is improved assembly, wherein said curved or bent portion  50  avoids deformation of contact pin  26  during the assembly of connector  2 . 
     As can be seen in  FIG. 8 , the position of curved or bent portion  50  does not reside in the portion of opening  22  of connector  2 . Rather, curved or bent portion  50  resides in a section outside of opening  22  between contact  28  and the distal end of contact pin  26 . 
     While  FIGS. 7 and 8  show the curved or bent portion  50  of contact pin  26  located in back wall  14  of housing  4 , this is not to be construed in a limiting sense since it is envisioned that the location of each curved or bent portion  50  of contact pin  26  in different style RJ connectors can be located elsewhere. For example, in an RJ connector intended for vertical mounting, the curved or bent portion  50  of contact pin  26  can reside external to housing  4 . 
     In the example shown in  FIGS. 7 and 8 , one or more contact pins  26  can reside in a series of channels of housing  4 , e.g., without limitation, channels  54 - 1 ,  54 - 2 , and  54 - 3  formed by adjacent pairs of projections, e.g., ( 56 - 1   a ,  56 - 1   b ); ( 56 - 2   a ,  56 - 2   b ); and ( 56 - 3   a ,  56 - 3   b ), respectively. In this example, each curved or bent portion  50  resides in a horizontal space  57  between projections ( 56 - 1   a ,  56 - 1   b ) and ( 56 - 2   a ,  56 - 2   b ). However, this is not to be construed in a limiting sense since it is envisioned that each curved or bent portion  50  can alternatively reside in the space  59  between projections ( 56 - 2   a ,  56 - 2   b ) and ( 56 - 3   a ,  56 - 3   b ), as shown in phantom by reference number  58   a  in  FIG. 8 , or any other suitable and/or desirable position along the length of contact pin  26 . In addition, while each contact pin  26  has been described as having a single curved or bent portion  50 , it is envisioned that each contact pin  26  can include multiple curved or bent portions along its length, as shown in phantom by reference numbers  50   a  and  58   a  (in phantom) in  FIG. 8 . Where a contact pin  26  includes multiple curved or bent portions, each curved or bent portion can extend in the same or a different direction. 
     With reference to  FIG. 9  and with continuing reference to  FIGS. 1-5, 7, and 8 , the use of contact pins  26  having curved or bent portions  50  is not limited to the high-profile USB connector  2  previously described. To this end, a low-profile USB connector  2 ′ can also include one or more contact pins  26 ′ that can include one or more curved or bent portions  50 ′ between the corresponding contact  28  and a distal end of contact pin  26 ′ that, in use, is mounted through a through-hole  53  of mounting PCB  32 . In an example, the curved or bent portion  50 ′ of contact pin  26 ′ of the low-profile USB connector  2 ′ shown in  FIG. 9  is included within housing  4 ′ or within the outline of housing  4 ′. However, this is not to be construed in a limiting sense. 
     In an example, because of its low profile, low-profile USB connector  2 ′ can exclude channels  54  between adjacent pairs of projections  56 , as shown in  FIG. 7 . However, this is not to be construed in a limiting sense since it is envisioned that one or more channels  54  can be provided in low-profile USB connector  2 ′ to aid an alignment of each contact pin  26 ′ and the curved or bent portion  50 ′ thereof. 
       FIG. 9  shows a single contact  28  and corresponding contact pin  26 ′ of low-profile USB connector  2 ′. However, this is not to be construed in a limiting sense since, in practice, low-profile USB connector  2 ′ will have a plurality, for example, four, contacts  28 ′ and four corresponding contact pins  26 ′, like the high-profile USB connector  2 , shown in  FIG. 7 . 
     With reference to  FIG. 10 , and with continuing reference to all previous figures, in another example, an RJ female connector  60 , shown in cross-section in  FIG. 10 , includes RJ-type contacts  62  inside an RJ-shaped cavity opening  66  of RJ connector  60 . Cavity opening  66  is configured to mate with a mating male RJ-type connector (not shown). Female RJ connector  60  also includes contact pins  64 , which extend from contact  62 . In  FIG. 10 , a single contact  62  and corresponding contact pin  64  are shown. However, it is to be appreciated that female RJ connector  60  can include a plurality of contacts  62  and contact pins  64 . In an example, female RJ connector  60  can include eight contacts  62  and eight corresponding contact pins  64 . However, this is not to be construed in a limiting sense. 
     In the cross-sectional side view of high-profile female RJ connector  60  shown in  FIG. 10 , contact pin  64  can include a curved or bent portion  68  anywhere along its length between contact  62  and a distal end of contact pin  64 . In another example, contact pin  64  can include curved or bent portion  68  and one or more additional curved or bent portions  70  (shown in phantom). 
     In an example, the plurality of contact pins  64  of female RJ connector  60  can be positioned one behind the other in the view shown in  FIG. 10 . However, this is not to be construed in a limiting sense since it is envisioned that the plurality of contact pins  64  can be arrayed in any suitable and/or desirable manner. Similar comments apply in respect of the contact pins  26  and  26 ′ of the high and low profile USB connectors  2  and  2 ′ discussed above. 
     In an example, each contact pin  64  resides within the housing  72  or an outline of housing  72  of high-profile RJ connector  60 . However, this is not to be construed as in a limiting sense since it is envisioned that one or more or all of contact pins  64  can reside outside of housing or the outline of housing  72 . Similar comments apply in respect of the contact pins  26  and  26 ′ of the high and low profile USB connectors  2 ,  2 ′ discussed above. 
     With reference to  FIG. 11  and with continuing reference to  FIG. 10 , the use of curved or bent portions  68  of contact pin  64 , shown in  FIG. 10 , is also applicable to a low-profile RJ connector  60 ′, shown in  FIG. 11 . 
     It is to be understood that the low-profile female RJ connector  60 ′ shown in  FIG. 11  includes a plurality of contacts  62 ′ and corresponding contact pins  64 ′, with each contact pin  64 ′ including a curved or bent portion  68 ′. 
     In  FIG. 10 , a distance between an exterior bottom wall  74  of housing  72  and a bottom surface of one of the contacts  62  that is closest to said exterior bottom wall  74  is at least 1.5×H, where H is the height of RJ opening  66 . In another example, the distance between exterior bottom wall  74  and the bottom surface of one of the contacts  62  can be at least 2×H. In another example this distance can be at least 3×H. 
     In an example, the high profile USB and RJ connectors  2  and  60  shown in  FIGS. 8 and 10  are similar in many respects, with at least the following exceptions: high profile USB connector  2  includes a USB-shaped opening  22  while high profile RJ connector  60  includes an RJ-shaped opening  66 . Moreover, high profile USB connector  2  includes USB-style contacts  52  while high profile RJ connector  60  includes RJ-style contacts  62 . Similar comments apply in respect of the low-profile female USB connector  2 ′ and the low-profile female RJ connector  60 ′, shown in  FIGS. 9 and 11 , respectively. 
     As can be seen in  FIGS. 8 and 10 , the high-profile female USB and RJ connectors  2 ,  60  have their respective cavity openings  22 ,  66  positioned in elevated spaced relation to a surface of a substrate (e.g., mounting PCB  32 ) to which the high-profile connector is mounted. This higher elevation enables the connector to be mounted away from an edge of the substrate while still enabling plugging and unplugging of the mating male connector into the female cavity opening. This higher elevation also facilitates mounting of one or more components to the substrate below and in front of the female cavity opening while also enabling plugging and unplugging of the mating male connector into the female cavity opening above said components. 
     Regardless of the type of connector, namely, USB or RJ, the one or more curved or bent portions of each contact pin avoids bending of the contact pin during insertion into a through-hole of a mounting PCB and enables a number of contact pins of the connector to stay more aligned relative to each other without bending during insertion of said contact pins into the through-holes of the PCB. While the contact pins described herein are illustrated and described as extending from a bottom wall of each illustrated connector, as discussed above, it is also envisioned that the contact pins, including one or more curved or bent portions, can extend from a back wall of one or more of the example connectors disclosed herein, e.g., where said connectors are intended for mounting with the cavity opening facing upward, away from the mounting surface of the mounting PCB. 
     The one or more curved or bent portions of each contact pin described also herein enable the contact pin to be as short as possible inside the housing, which is beneficial for low and high profile connectors. 
     In an example, each curved or bent portion of a single contact pin or the curved or bent portions of different contact pins can be the same or a different size depending on the length of the contact pin. Advantages of the curved or bent portions of contact pins of various lengths is that for a housing having two or more stacked openings, the curved or bent portion of the contact pins associated with each opening avoid bending of contact pins during insertion into a through-hole, keeps it from bending inside the housing, and keeps the portion outside the housing from bending during insertion into a through-hole of a mounting PCB. Hence, it is possible to make the contact pins longer for female connectors that are stacked vertically together, whereupon the contact pins having the added length will avoid bending during insertion into through-holes of a mounting PCB. 
     Referring to  FIG. 12A , in an example, each contact pin described above can include a proximal end  70  that connects to a corresponding contact of the connector. The connector can also include a distal end  72 , at least a portion of which is intended to be inserted into a through-hole of a substrate, such as mounting PCB  32 . Between proximal end and distal end, the contact pin can include a curved portion ( 50 / 50 ′/ 68 / 68 ′) that includes an upper part  74  connected to proximal end  70  and a lower part  76  connected to distal end  72 . In the example shown in  FIG. 12 , a transition  78  between proximal end and upper part  74  can be curved having a radius of any extent deemed suitable and/or desirable by one of ordinary skill in the art. Similarly, the transition  80  between upper part  74  and lower part  76  can be curved having a radius of any extent deemed suitable and/or desirable by one of ordinary skill in the art. Finally, the transition  82  between lower part  76  and distal end  72  can be curved having a radius of any extent deemed suitable and/or desirable by one of ordinary skill in the art. 
     In the example shown in  FIG. 12A , proximal end  70  and distal end  72  can be aligned along the same axis  84 . However, this is not to be construed in a limiting sense. In this example, first transition  78  bends contact pin away from axis  84  in a first direction while second transition  80  bends said contact pin in a second, opposite direction back toward axis  84 . Finally, transition  82  bends in a manner such that distal end  72  is aligned once again with axis  84 . 
     The alignment of proximal end  70  and distal end  72  after forming transition  78 ,  80 , and  82  is ideal. However, in practice, proximal end  70  and distal end  72  can be misaligned relative to each other by as much as, in an example, ±10°, due to tolerances in the formation of one or more transitions  78 - 82 . Accordingly, the description herein of proximal end  70  and distal end  72  being aligned on axis  84  is not to be construed in a limiting sense. 
     Referring to  FIG. 12B  and with continuing reference to  FIG. 12A , the example contact pin shown in  FIG. 12B  is similar in most respects to the example contact pin shown in  FIG. 12A  with at least the following exceptions: the example contact pin shown in  FIG. 12B  includes transition  78 ′,  80 ′, and  82 ′ which are bent at sharp angles having minimal radiuses versus transition  78 ,  80 , and  82  in  FIG. 12A  having curved transitions with discernible radiuses. Other than this difference, the example contact pins shown in  FIGS. 12A and 12B  are similar. 
     While  FIGS. 12A and 12B  show contact pins including curved and bent portions, this is not to be construed in a limiting sense since it is envisioned that a contact pin can be formed of combinations of curved and bent portions. 
     The examples have been described with reference to the accompanying Figures. Modifications and alterations will occur to others upon reading and understanding the foregoing examples. Accordingly, the foregoing examples are not to be construed as limiting the disclosure.