Patent Publication Number: US-6216338-B1

Title: Header pin pre-load apparatus

Description:
BACKGROUND 
     1. Field of the Invention 
     The present invention relates to electrical connections and, more particularly, to an apparatus for selectively deflecting a pin for use in an electrical connection, and an electrical connection incorporating a deflected pin. 
     2. Description of Related Art 
     Making electrical connections secure and durable, i.e., resistant to mechanical uncoupling (and resultant electrical uncoupling), has been a problem for as long as electrical connections have been made. Joined plug and receptacle elements almost always seem to tend to loosen and separate when exposed to vibration, flexing, pulling, or other mechanical disturbances. 
     A fairly typical electrical connection with multi-pin/receptacle connectors is disclosed in U.S. Pat. No. 4,072,390 (Fox). The connector is for ribbon cable terminals and has two spaced parallel rows of conductor pins which are embedded in a block of insulating material. Each pin has a first end portion and a second end portion, the axes of which are in spaced parallel relationship, and a bent intermediate portion. The bent intermediate portion is embedded within a block of insulating material. Pin/socket connectors of the general type shown in the Fox patent have been used for a long time, and in many industries. They have proliferated in recent years with the rapid growth in the computer, video, audio and communications industries. Despite the increased friction due to the multiple pins and sockets, this type of connection still has a tendency to uncouple, particularly when the cables are long. The Fox patent makes no suggestion about how to alleviate this problem and, in particular, its bent intermediate portions do not address the problem. Further, although Fox makes a reference to dies being used to fashion pins (column 1, line 28-30), no specific pin bending apparatus or method is suggested. 
     There have been many attempts to make the connection between connector elements more secure. People have tried hasp-like latching connectors and screws or threaded collars that bridge between two connector components, but these are expensive, cumbersome and may interfere with easily joining the connectors. In addition, they complicate and slow disconnection because they require unlatching or unscrewing before the two connector components can be separated. Adhesives have been used to join male and female connector elements. While adhesively joined connectors may stay joined, they cannot be easily selectively disconnected once the connection is made. 
     As evidenced by U.S. Pat. No. 5,427,552 (Zielinski et al.) spring elements have been used to make electrical connections more secure. Zielinski et al. disclose an electrical terminal for use in automobiles where a female terminal uses a contact spring to urge an inserted male contact blade into contact with a contact floor. Spring loaded female connectors of the general type represented by the Zielinski et al. patent require a spring member, thereby increasing the complexity of a connector. The Zielinski et al. patent also discloses a method of making the subject female terminal including, with reference to FIG. 8, bending the terminal by using a die to form a socket to receive a male contact; the male contact is not bent. 
     Two other methods for creating a secure electrical connection are disclosed in U.S. Pat. No. 4,427,252 (Lee et al.) and U.S. Pat. No. 4,784,619 (Blanchet). The Lee et al. patent discloses an electrical connector for effecting connection to a banana-type socket, including a connector body having an axially elongated male pin extended from one end. Threaded portions, e.g., a captive, internally threaded collar at the proximate end of the pin, are provided to create a secure connection. The Blanchet electrical connection module provides security by incorporating a locking catch and locking collar arrangement. 
     While the above-noted patents represent advances in the art of electrical connections, there is a need for a simple, inexpensive way to provide for secure electrical connections, particularly connections formed by connectors of the general type disclosed in the Fox patent and of the type used in linking computer and other electronic equipment. 
     SUMMARY 
     In one embodiment, the present invention provides an apparatus and method for deforming a normally straight electrical pin or selected number of pins to provide for a secure electrical connection, for example the connection between a motherboard and cable end connector. 
     While other embodiments are certainly possible, the present invention is well-suited for connecting intelligent drive electronics (“IDE”) and floppy drive cables, which may disconnect from a motherboard during shipping. The present invention can also be used in small computer system interface (“SCSI”) connections for connecting scanners, hard drives and other equipment. Shipment of such equipment with connectors in place may result in the male and female connector elements becoming loose and separating. Also, after shipping and installation, the weight of longer cables can cause pulling, leading to disconnection. The security of the conventional connection between an IDE connector and headers mounted on a motherboard can vary, depending on the type of contact (e.g., dual or single beam) and contact material used, but even in the case of multi-pin dual beam contacts, there is a tendency for the cables to come uncoupled. The present invention attempts to reduce this tendency conveniently and inexpensively. 
     The apparatus may include a frame, a die pivotally coupled to the frame and an operating member pivotally coupled to the frame and the die, whereby moving the operating member moves the die into contact with at least one pin to deflect or bend it. 
     In one embodiment, the support frame is generally vertical, comprising two generally parallel support members, each having a top end and a bottom end. The die is generally flat, rectangular and solid, having two generally parallel flat side surfaces, a first, top edge, a bottom edge generally parallel to the first, top edge, and two generally parallel side edges, each of which is generally perpendicular to the top and bottom edges. The die is supported generally between the two support members, with its two side edges aligned with the support members, and is pivotally coupled to the two support members adjacent to its bottom edge. 
     The operating member is generally congruent with respect to the die, being generally flat, rectangular and solid. Like the die, it has a top edge, a bottom edge generally parallel to the top edge, two generally parallel side edges, each of which is generally perpendicular to the top and bottom edges, and a mid-portion. The operating member is positioned above the die, between the two support members, with its side edges generally aligned with the support members. Thus, the die and operating member are generally co-planar. The operating member is pivotally coupled to the two support members, the pivotal coupling generally at the mid-portion of the operating member and adjacent to the top end of the support members. It is also coupled to the die generally at the bottom edge of the operating member and the first or top edge of the die, whereby moving the operating member moves the die. 
     In one embodiment, the present invention includes an adjustable die travel stop carried by the support frame for selectively controlling the movement of the die. 
     One advantage of the embodiments of the present invention is that equipment/cable and other connections remain more secure during shipping and after installation, even when the cables are very long. Another advantage is that the header or motherboard is not damaged during the operations to implement the embodiments of the inventions, because the deflecting load or force is exerted substantially only on the metal pin connector. While not limited to such uses, the invention is well suited for use on single and dual beam connectors because it enhances connective security by increasing the friction generated by the deflected pin on its receptacle and, further, because it urges the female connector into tighter contact with undeflected pins. The present invention does not require expensive latching connectors on the motherboard, and use of permanent adhesive is avoided. An additional possible advantage is that the deflection in the pin connector is not in the area of single or dual beam contacts, rather, the deflection is spaced away from the base of the pin so the connector, and the connection it is used to form, tend to keep their integrity. The apparatus embodiments of the present invention (which also may be referred to synonymously as a fixture, tool, machine or the like) may be designed to be portable and to occupy a minimum amount of space. The apparatus can be used to retrofit or improve connectors on site, e.g., in the home or office, or during the manufacturing or assembly of electrical components and systems. 
     The preceding and other features and advantages of the present invention will become more apparent with reference to the drawings, the description of the preferred embodiments and the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevational view depicting one side, the front and open side, of one embodiment of the present invention. 
     FIG. 2 is an elevational view, partially in cross-section taken along line  2 — 2  of FIG. 1, depicting another side of the embodiment depicted in FIG.  1 . 
     FIG. 3 depicts a workpiece, i.e., a motherboard header with pin connections. 
     FIG. 4 diagrams one operational flow path for one embodiment of the method of the present invention. 
     FIGS. 5 a-d  diagram making an electrical connection using a male connector element modified by the apparatus and method of one embodiment of the present invention. 
     FIG. 6 depicts an electrical connection in accordance with one embodiment of the present invention. 
    
    
     DESCRIPTION 
     1.0 Introduction 
     FIGS. 1-3 depict the pin deflection apparatus  10 , and features and components thereof. FIG. 4 depicts, in block diagram form, the operational flow of using the apparatus in one embodiment of the pin deflection method of the present invention. FIGS. 5 a-d  depict a method of making an electrical connection  12  using a male element  14  modified in accordance with the method described in FIG.  4 . FIG. 6 depicts another electrical connection  16  made using a header element  18  modified by the method described in FIG.  4 . 
     With regard to means for fastening, mounting, attaching or connecting the components of the pin bending apparatus  10 , unless specifically described as otherwise, such means are intended to encompass conventional fasteners such as screws, complementary snaps, machined connectors, rivets, nuts and bolts, toggles, pins, and the like. Components may be joined adhesively, by means of deformation, or by sonic, chemical or high temperature welding. Conventional wires or cables of a suitable gauge, and typical electrical connection methods (e.g., splices, clamps, soldering, pins, etching, etc.), may be used to operably couple any electrical inputs, outputs and components of the present invention. Materials for making the components of the apparatus  10  are selected from appropriate materials such as metal, metallic alloys, wood, various plastics and vinyls or the like. Appropriate methods of forming the components may include casting, extruding, molding or machining. 
     As used herein, the term “pin” is intended to have its customary meaning, i.e., a piece of material, generally in slender elongated form, used for fastening separate articles together. In the electrical field, particularly to make an electrical connection, a body (e.g., a plug) carrying a pin or a plurality of pins may be received in a complementary female receptacle fitting or connector having a generally tubular receptacle or plurality of receptacles complementary to the pin or pins. Examples of such connective components include, but are not limited to, plugs and receptacles used in the computer industry to couple hard drives and other peripheral equipment to motherboards. 
     As used herein, the term “die” is intended to mean any of various tools or devices for imparting a desired shape, form or finish to a material or object, including those which produce a desired form or shape by application of pressure. 
     Any references herein to front and back, right and left, top and bottom, upper and lower and horizontal and vertical are intended for convenience of description only, not to limit the present invention or its components to any one positional or spatial orientation. 
     2.0 One Embodiment of the Apparatus 
     Referring to FIG. 1, the apparatus  10  for deflecting a pin or a number of pins  20  for use in an electrical connection (see, e.g., FIG. 6) comprises a frame  22 , a die  24  pivotally coupled to the frame  22 , and an operating member  26  pivotally coupled to both the frame  22  and the die  24 , whereby moving the operating member  26  moves the die  24  into contact with a pin, or pins,  20  sufficiently to deflect or bend the pin  20  selectively slightly from its unbent, pre-deflection normal or customary straight configuration. 
     2.1 Frame 
     In one embodiment, as depicted in FIGS.  1  and/or  2 , the support frame  22  is generally vertically positioned relative to the plane of a motherboard  46  that has a number of pins  20  extending perpendicularly through the motherboard plane. The frame  22  includes two upright support members  32 ,  34 , each having a bottom end  36  and a top end  38 . Referring to FIG. 2, a rear side wall  30  connects between the uprights  32 ,  34 . The frame  22  includes a pin-receiving and supporting base  33  extending between the uprights  32 ,  34  at the bottom of the rear wall  30 . The base  33  includes a recess  35  extending substantially for the length of the base  33  for receiving the built-up, pin carrying and supporting straight, double row header portion  44  of a motherboard  46 , and a plurality of pin-receiving bores or holes  37  in a selected pattern for accommodating the pins  20  of a workpiece. In the present embodiment, two parallel, linear arrays or rows of holes  37  are provided, but any suitable array or pattern of holes  37  may be provided. The base  33  and the holes  37  substantially capture and support the motherboard  46 , helping to immobilize it during operation of the apparatus  10 . The base  33  also supports pins  20  which are intended to remain undeflected, and provides a fulcrum edge  39  for facilitating precise deflection of the pins  20  which are intended to be deflected. Generally, the shoulder portion  44  of the motherboard  46  lodges or fits under the base  33  in the recess  35  and between the bottom ends  36  of the uprights  32 ,  34 . Although the recess  35  securely holds the motherboard  46  for deflection operations, each upright  32 ,  34  may be provided with an optional recess  40  (shown in phantom in FIG. 1) for receiving the ends of the shoulder  44  of the motherboard  46 . The two recesses  40  are substantially identical, and are shaped and aligned with each other to supplement the recess  35  by accommodating and gripping the ends of the shoulder  44  of the motherboard  46 . 
     2.2 Die 
     Referring to FIGS.  1  and/or  2 , the die  24  is generally flat, having a first, upper edge  50 , a second lower, working edge  52  generally parallel to the first edge, and two generally parallel side edges  54 ,  56 . Each side edge  54 ,  56  is generally perpendicular to the first and second edges  50 ,  52 . The die  24  is supported generally between the two uprights  32 ,  34 , and pivotally coupled to the uprights  32 ,  34  generally adjacent to the second or working edge  52  of the die. The pivotal connection  58  may be effected in a variety of ways. A hinge-like connection is used in one embodiment and is formed by a bore  60  in each upright  32 ,  34  and in the lower edge  52  of the die  24 , with a cylindrical, elongated pin  62  therethrough. At or adjacent to the first, upper edge  50 , the die  24  is provided with a second bore or channel  64  which may be formed by a curled portion of the die  24  or by a generally tubular member attached at the edge  50  of the die  24 . 
     The die  24  includes a relieved area  66  generally at the middle portion of the lower edge  52 . The relieved area, specifically the length thereof along the lower edge  52 , allows for a selected number of pins  20  to be deflected, because pins in the relieved area are not engaged. It should be appreciated that the relieved area  66  may be varied in size and location to accommodate fewer or more pins  20 , or a selected pattern of pins  20 . In particular, the relieved area  66  may comprise two separate sections, so that pins in the middle of the die  24  as well as at the ends of the die  24  are engaged. 
     2.3 Operating Member 
     The operating member  26  of the present invention is coupled to the die  24  by a hinge-like arrangement  70  with a pin  65  contained within bores  64 , substantially similar to that at the lower, working edge  52  of the die  24 . The operating member  26  is generally flat, and generally congruent with respect to the die  24 . It has a first, upper edge  72 , a second, lower edge  74  generally parallel to the first edge  72  but having two hinge tabs  75 , two parallel side edges  76 ,  78  generally perpendicular to the first and second edges  72 ,  74 , and a relieved central portion  80 . The relieved central portion  80  is provided for receiving the hand or fingers of a user. In a fashion generally similar to the die  24 , the operating member  26  is supported by and positioned generally between the uprights  32 ,  34 . The operating member  26  is pivotally coupled between the two upright support members  32 ,  34 , the pivotal coupling  82  being generally at the middle of the operating member  26  and adjacent to the upper, free ends  38  of the uprights  32 ,  34 . The pinned rotatable connection  82  between the frame  22  and the operating member  26  is substantially similar to the pinned rotatable connection  58  at the lower end of the frame  22  and die  24 , i.e., comprising a bore  84  and pin  86 . The operating member  26  and die  24  are operably coupled along their respective lower edge  74  (with hinge tabs  75 ) and upper edge  50  by the hinge-like connection  70 . The top corners  88  of the operating member  26  may be rounded or cut at an angle as shown in FIGS. 1 and 2. 
     From the preceding description of the coupling arrangement between the frame  22 , the die  24  and the operating lever  26 , it should be appreciated that when the operating member  26  is moved in the direction of the arrow “A” in FIG. 2, the upper portion of the die  24  moves in the opposite direction so that the operating member  26  and die  24  become non-co-planar. Because the lower working edge  52  of the die  24  is fixed relative to the frame  22 , the working surface  90  of the die, a region closely adjacent to the bottom edge  52 , engages the pins  20  of the motherboard  46 , such as the dual beam board  46  depicted in FIG.  3 . The engaged pins are then deflected, with the deflection starting at the point where the pins  20  extend above the edge  41  of the base of the frame  22 . 
     2.4 Adjustable Stop 
     The adjustable stop  92  is carried on an upper region  94  of the rear side wall  30  of the frame  22  and comprises a stop head  96 , a shaft  98  and a nut  100 . The shaft  98  has a threaded portion  102  at the end opposite the stop head  96 . When the stop  92  is mounted as shown in FIG. 2, the shaft  98  extends transversely through an aperture  104  in the rear side wall  30  of die  24 . The position of the shaft  98  relative to the nut  100  (which may be fixed to the rear side wall  30 ) can be varied by turning it clockwise or counterclockwise to thereby limit or control the distance the upper portion  106  of the die  24  can travel. Preferably, the travel should be adjusted so that a pin  20  or a number of pins  20  can be bent at an angle of approximately 2-8 degrees. For the connection of FIGS. 5 a-d , a bend angle of approximately 5 degrees or less is preferred. 
     3.0 Electrical Connection 
     FIG. 6 depicts a representative IDE cable end/motherboard connection incorporating a pin  20  or number of pins  20 ′ bent by the apparatus  10  in accordance with the method of the present invention. 
     3.1 Female Connector 
     Referring to FIG. 6, the female or receptacle electrical connector  110  is typically a cable mounted end unit including an appropriate number of tubular apertures or sockets  112  generally complementary to the position and number of pin connectors  20  on the header of the motherboard  46  (shown in FIGS.  1  and  2 ). 
     3.2 Male Connector 
     The male connector  18  depicted in FIG. 6, e.g., a motherboard or straight dual row header, comprises a generally non-conductive insulating shoulder body  44  having a plurality of pins  20  extending therethrough. The pins  20  are in a selected arrangement and number for being mounted to the motherboard  46  and connected to the female connector  110 . Each pin  20  has a base  21 , a tip  23  and a pin length extending therebetween. Prior to modification by the apparatus  10  and method in accordance with the invention, typical pins  20  have a generally straight pre-deflection configuration including a normal, straight generally central longitudinal axis. The electrical connection  16  depicted in FIG. 6 incorporates at least one pin  20 ′ bent in accordance with the present invention. The deflection or bending of the bent pin  20 ′ is lateral, i.e., generally transverse or perpendicular to the normal longitudinal axis of the pin  20 ′. Referring back to FIG. 1, it should be clear from the configuration of the lower working edge  52  of the die  24  that only a selected row of pins  20  or selected pins  20  of a row will be deflected. When the bent or deflected pins  20 ′ are inserted into the connector  110  as shown in FIG. 6, the pin tip  23  and/or a portion of the length of the pin  20 ′ near its tip  23  contact the inside wall of the socket  112 . This produces a load or force which is asymmetrical within the socket  112  and acts to resist uncoupling by increasing the friction between the bent pin  20 ′ and receiving socket  112 . There is also a spring force between the deflected and undeflected pins that is overcome when the pins  20  are inserted, but also increases frictional forces in the receiving socket  112 . These pre-load forces and resulting friction help ensure that the coupling between the male and female connectors is maintained despite vibration and flexing. 
     4.0 In Use 
     With reference to FIG. 4, which depicts the operational flow or steps in one method embodiment, in using the apparatus or tool  10 , a die  24  is selected, block  400 , according to the number of pins  20  to be bent, i.e., by the size or shape of the relieved region  66  at the working surface  90  of the die  24 . The selected die  24  is installed, block  410 , in the frame  22  by aligning it with the uprights  32 ,  34  and pinning it in place by sliding the hinge pin  62  into the channel  60 . The operating lever  26  is similarly pinned in place and may be connected to the top of the die  24 . As represented at block  420 , the base  33  of the tool  10  is placed over a strip header  44  as shown in FIGS. 1 and 2 with the pins to be deflected to the front of the apparatus  10  generally adjacent to and along the fulcrum edge  39 . To perform pin deflection, the tool operating member  26  may be moved or rotated, block  430 , as shown in FIG. 2 at arrow “A”. Doing so brings the working surface  90  of the die  24  into contact with the selected pins  20  adjacent to the tip  23  of the pins  20 , bending and pre-loading them, block  440 . The deflection takes place at a place along the length of the pin  20 , spaced away from the base  21  or tip  23 . The tool  10  may be removed, block  450 , and set aside, the connector then being ready to form a connection, block  460 . 
     FIGS.  4  and FIGS. 5 a-d  depict the forming of an electrical connection  120  using a male connector  122  with a pin  20 ′ (or pins, only one of which is shown) modified in accordance with the present invention. Referring to block  470  of FIG.  4  and FIG. 5 a , the female cable connector  124  is placed above the pins (or pin set or sets)  20 ′ and  20 ″ (the straight or undeflected pins) of the male connector  122  at a slight angle whereby the complementary generally tubular socket (shown in phantom at  128  in FIG. 5 a ) lines up with the deflected portion of the bent pin  20 ′. Preferably the deflection angle will be at about 5 degrees or less from vertical (i.e., with respect to the normal or pre-deflection longitudinal axis of the pin). Referring to FIG. 4, block  480 , and FIGS. 5 b  and  c , the pin  20 ′ is engaged and the connector  124  is then rotated to a vertical position to bring the appropriate socket  130  into alignment with the unbent pin  20 .″ The connector  124  then can be partially, the fully engaged as shown FIG. 4, block  490  and FIGS. 5 c  and  5   d , respectively. The bent pin  20 ′ (or pins) produce a force tending to resist withdrawal of the receptacle  124  from the male connector  122  by contacting the inside of the tubular socket  128 . Frictional force tending to resist uncoupling is also increased because the bent pin  20 ′ tends to urge the connector  124 , specifically, the inside wall of the receptacle  130 , more tightly against pin  20 ″. 
     5.0 Other Embodiments 
     Although the pin deflection apparatus  10  is well-suited for use on multiple pin connectors such as those commonly used in the computer industry, the pin deflection apparatus  10  could be used to modify connectors having any number of pins, and it could be useful in diverse fields, e.g., communications, manufacturing, recording, video, etc., in which a secure pin/receptacle-type connection or coupling would be desirable. 
     Square or round pins may be treated by the apparatus  10  in accordance with the method of the present invention. The size of the relieved area  66  (shown in FIG. 1) may be varied to bend a selected number of pins  20 , thereby varying the load or force the bent pins produce in a connection. Similarly, the angle and location at which the pins  20  may be deflected or bent may be varied as long as the pins are not weakened and joining the male/female connectors is not adversely affected. The frame  22  may comprise only the two uprights  32 ,  34 , general stability, rigidity and resistance to forces generated by operation being provided by the three transversely extending hinge pins. The rear wall  30  may be omitted, in which case the die stop  92  may be carried on a cross-member (not shown) spanning the distance between and attached to the uprights  32 ,  34 . Also, the rear wall  30  and base  33  may be formed as a unit or may be connected to each other. The die  24  may be reconfigured by eliminating the extended pin  62 , replacing it with short pins extending from the die  24  into the uprights  32 ,  34 , then forming a slot (not shown) cut into the bottom edge  52  of the die  24 . This slot (or set of slots selectively placed) receives the row or set of pins to be deflected, in which case, the pins to be deflected would be received in the die edge  52  prior to being deflected. 
     The generally flat rectangular operating member  26  may be shaped more like a typical lever, i.e., having two ends and a length, one of the ends being a free, handle end and the other attached to the die  24 . The pivotal connections, e.g., connections  58 ,  82 , among operational components may be made by piano type hinges, living hinges and the like. The apparatus  10  may be embodied as a hand-held, hand-operated workstation tool for use on a selected set of pins for custom board or connector designs, or it may be embodied as a pin bending portion of an automated, continuous manufacturing process. 
     Although a description of specific embodiments has been presented, various changes, including those mentioned above, could be made without deviating from the spirit of the present invention. It is desired, therefore, that reference be made to the appended claims rather than to the foregoing description to indicate the scope of the invention.