Patent Publication Number: US-8974251-B2

Title: Electrical connector assembly and method of manufacturing the same

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to an electrical connector assembly, more specifically to an electrical connector assembly for transmitting power and data signal. 
     DESCRIPTION OF PRIOR ART 
     PCT Pat. Pub. No. WO2011150403 published to GOLKO etc. on Nov. 1, 2011 discloses a plug connector. Please refer to FIGS. 20A-22H, the plug connector comprises a tab having a grounding ring, two flex circuit with flex contacts received into the grounding ring, a dielectric overmold formed around the contacts and formed with the metallic housing, an inner jacket formed on a rear end of the tab, a cable bundle electrically connected to a rear end of the two flex circuit and a body formed around the inner jacket. It should be noted that the plug connector has complicated structure and is difficult to manufacture. Please refer to FIG. 21, the manufacturing process of the plug connector comprises many assembling steps and some steps are difficult to achieve. For example, an overmold is difficult to form around the contacts and will overflow to top and bottom surface of the grounding ring result in defective products. Thus, the plug connector will not be used or not be worked in a normal state. 
     An improved electrical connector assembly overcoming shortages of existing technology is needed. 
     SUMMARY OF THE INVENTION 
     Accordingly, an object of the present invention is to provide an electrical connector assembly having a simple structure. 
     In order to achieve the above-mentioned object, an electrical connector assembly comprises: a metallic housing having a receiving space extending along a longitudinal and two openings respectively formed on top and bottom surfaces thereof and communicated with the receiving space; a pair of flexible printed circuit boards (FPCs) received into the receiving space and arranged in a back-to-back manner. Each of the FPC defines a protuberant portion extending into the corresponding opening. And each of the protuberant portion has a plurality of contacts formed on one side thereof and communicated with an exterior. A pair of supporting pieces are received into the receiving space and attached to another side of the protuberant portion. And, a spacer is received into the receiving space and sandwiched between the pair of flexible printed circuit boards and supporting pieces. 
     Accordingly, another object of the present invention is to provide a method of manufacturing the electrical connector assembly with high efficiency and accuracy. 
     In order to achieve the above-mentioned object, a method of manufacturing an electrical connector assembly, comprises the steps of: providing a metallic housing having a receiving space extending forwardly from a rear surface thereof, and two openings formed on a top and bottom surfaces thereof and communicated with the receiving space; providing two reinforcement pieces, each of the reinforcement defining a protruding portion and a through hole throughout top and bottom surfaces of the protruding portion; assembling the two reinforcement pieces to the metallic housing, the two protruding portions respectively extended into the two openings; providing two flexible printed circuit boards (FPCs) arranged in a back-to-back manner, each of the FPC defining a protuberant portion passing through the through hole and extended into the opening, each of protuberant portion defining a plurality of contacts formed thereon; providing two supporting pieces; assembling the two supporting pieces to the two protuberant portions; providing a spacer; and inserting the spacer into the receiving space, the spacer sandwiched between two FPCs and two supporting pieces. 
     Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an electrical connector assembly in accordance with the present invention; 
         FIG. 2  is an exploded, perspective view of  FIG. 1 ; 
         FIG. 3  is an assembled, perspective view of an upper and a lower FPCs in the electrical connector assembly shown in  FIG. 1 ; 
         FIG. 4  is an exploded, perspective view of the upper and a lower FPCs shown in  FIG. 3 ; and 
         FIG. 5  is a cross-section view take along line  5 - 5  of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Reference will now be made to the drawing figures to describe the present invention in detail. 
       FIG. 1  illustrate perspective view of an electrical connector assembly  100  made in accordance with the present invention. Referring to  FIG. 2  and in conjunction with  FIG. 5 , the electrical connector assembly  100  comprises a metallic housing  1  having a receiving space  10  extending forwardly from a rear surface thereof, two flexible printed circuit boards (FPCs)  2  received into the metallic housing  1  along a rear-to-front direction, a cable  7  electrically and mechanically connected to two rear ends of the two FPCs  2  and an insulative cover  6  surrounding a rear end of the metallic housing  1  and a front end of the cable  7  through an overmolding process. 
     Referring to  FIGS. 1 to 2 , the metallic housing  1  is structured in a rectangular shape and defines a top and bottom openings  11 ,  12  respectively formed on a top and bottom surfaces thereof and communicated with the receiving space  10 . 
     Referring to  FIGS. 2 to 5 , the two flexible printed circuit boards (FPCs)  2  comprises an upper FPC  21  and a lower FPC  22  arranged in a back-to-back manner and spaced apart with each other. The upper and lower FPCs  21 ,  22  respectively defines a plurality of contacts  23  integratively formed on a top surface  210 ,  220  thereof. The upper and lower FPCs  21 ,  22  respectively defines a protuberant portion  212 ,  222  extending into the two openings  11 ,  12  and a front portion  216 ,  226  extending forwardly respectively from the protuberant portion  212 ,  222 . Actually, the plurality of contacts  23  are respectively formed on the corresponding protuberant portions  212 ,  222  of the upper and lower FPCs  21 ,  22 . The two front portions  216 ,  226  respectively a vertical free end  214 ,  224  mechanically connected with each other by glue or adhesive tape, not electrically connected with each other. In alternative embodiment, two flexible printed circuit boards  2  also can be formed by a single flexible printed circuit board through bending process. A plurality of cutouts  20  are formed between two vertical free ends  214 ,  224  when the two vertical free ends  214 ,  224  of the two FPCs  21 ,  22  are connected with each other. 
     Referring to  FIG. 2  and in conjunction with  FIG. 5 , the electrical connector assembly  100  further comprises a spacer  3  received into the metallic housing  1  and sandwiched between the upper and lower FPCs  21 ,  22 . The spacer  3  is structured in a flat shape and defines a plurality of protrusions  30  formed on a front end thereof and passed through the corresponding cutouts  20  of the two FPCs  2 . Thus, the spacer  3  and the FPCs  2  are engaged with each other. In should be noted that two receiving rooms (not figured) are formed between two protuberant portions  212 ,  222  and the spacer  3  for receiving two supporting pieces  4 . 
     Referring to  FIG. 2  and in conjunction with  FIG. 5 , the electrical connector assembly  100  further comprises supporting piece  4  sandwiched between the two FPCs  2  and the spacer  3 . The supporting piece  4  comprises an upper supporting piece  41  sandwiched between the protuberant portion  212  of the upper FPC  21  and the spacer  3 , and a lower supporting piece  42  sandwiched between the protuberant portion  222  of the lower FPC  22  and the spacer  3 . 
     Referring to  FIG. 2  and in conjunction with  FIG. 5 , the electrical connector assembly  100  further comprises reinforcement piece  5  sandwiched between the two FPCs  2  and the metallic housing  1 . The reinforcement piece  5  comprises an upper reinforcement piece  51  sandwiched between the upper FPC  21  and the metallic housing  1 , and a lower reinforcement piece  52  sandwiched between the lower FPC  22  and the metallic housing  1 . The upper and lower reinforcement pieces  51 ,  52  respectively defines a protruding portion  510 ,  520  received into the openings  11 ,  12 . The upper and lower reinforcements  51 ,  52  respectively defines a through hole  512 ,  522  throughout top and bottom surfaces thereof for for receiving a portion of the protuberant portion  212 ,  222  of the upper and lower FPCs  21 ,  22 . 
     Referring to  FIGS. 1 to 5 , the manufacturing process of the electrical connector assembly  100  made in according to the present invention starts from assembling the upper and lower FPCs  21 ,  22  together. The two FPCs  21 ,  22  are arranged in a back-to-back manner. Two free ends  214 ,  224  of the two FPCs  21 ,  22  are preliminary engaged with each other by glue or adhesive tape. 
     Then, assemble the two supporting pieces  41 ,  42  respectively to the upper and lower FPCs  21 ,  22 . The upper and lower supporting pieces  41 ,  42  are assembled to a bottom surface of the upper and lower FPCs  21 ,  22 , and respectively preliminary positioned to the upper and lower FPCs  21 ,  22  by glue. 
     Then, insert the two reinforcement pieces  51 ,  52  into the receiving space  10  of the metallic housing  1 . The protruding portions  510 ,  520  of the two reinforcement pieces  51 ,  52  are extended into the two openings  11 ,  12  of the metallic housing  1 . The two reinforcement pieces  51 ,  52  are preliminary positioned with the metallic housing  1  through glue. 
     Then, insert the upper and lower FPCs  21 ,  22  with two supporting pieces  41 ,  42  together to the receiving space  10  of the metallic housing  1 . Thus, a portion with contacts  23  of each of protuberant portions  212 ,  222  respectively extends to an exterior of the metallic housing  1  through the through holes  512 ,  522 . 
     Then, insert the spacer  3  into the metallic housing  1 . The spacer  3  is sandwiched between the upper and lower FPCs  21 ,  22  and the upper and lower supporting pieces  41 ,  42 . The plurality of protrusions  30  of the spacer  3  pass through the corresponding cutouts  20  of a connection area of the upper and lower FPCs  21 ,  22 . 
     Finally, solder the cable  7  to a rear end of the upper and lower FPCs  21 ,  22 . And assemble the cover  6  to a rear end of the housing  1  and a front end of the cable  7 . 
     After the above assembling steps, the entire process of manufacturing of the electrical connector assembly  100  is finished. Actually, the electrical connector assembly  100  has simple structure and is easily to manufacture. Thus, the manufacturing cost of the electrical connector assembly  100  is lower. And, a method of manufacturing the electrical connector assembly  100  with high efficiency and accuracy. 
     It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.