Patent Abstract:
An electrical connector assembly is disclosed that includes a receptacle connector and plug connector. The receptacle connector includes a receptacle housing having a top surface and a bottom surface, a support plate, spacers configured to retain the support plate adjacent to the top surface, and a post retained against the support plate by a spring and a fastener configured to releasable assemble the post and the support plate. The receptacle connector is less complex, lighter, and less expensive than receptacle connectors entirely made of a unitary composite, metal, or metallized composite.

Full Description:
FIELD OF THE INVENTION 
   The present invention relates to electrical connector assemblies. More specifically, the present invention relates to an electrical connector assembly having a receptacle connector with a threaded insert, support plate and spacer. 
   BACKGROUND OF THE INVENTION 
   Electrical connector assemblies typically include a plug connector and a receptacle connector configured to mate with the plug connector. The plug connector generally includes a plug housing containing contacts, and the receptacle connector generally a receptacle housing containing contacts configured to mate with the corresponding plug contacts. When the plug connector and receptacle connector are mated, the corresponding contacts mate to form an electrical connection. 
   In many applications, the receptacle connector utilizes machined components. The machined components can include mounting ears and spacers, which can be complex, heavy, and expensive to manufacture into the connector. 
   Therefore, there is an unmet need to provide an electrical connector assembly having a receptacle connector that is less complex, lighter, less expensive, and less susceptible to receptacle housing breakage than prior connector. 
   SUMMARY OF THE INVENTION 
   In one embodiment, an electrical connector assembly is disclosed that includes a receptacle connector and plug connector. The receptacle connector includes a receptacle housing having a top surface and a bottom surface, a support plate, spacers configured to retain the support plate adjacent to the top surface, and a post retained against the support plate by a spring and a fastener. The spring and fastener are configured to releasably assemble the post and the support plate to the receptacle housing. The receptacle connector is configured to mate with the plug connector by releasably engaging the post of the receptacle connector to the plug connector. 
   In another embodiment, a receptacle connector is disclosed that includes a receptacle housing having a top surface and a bottom surface, a support plate, spacers configured to retain the support plate adjacent to the top surface, and a post retained against the support plate by a spring and a fastener configured to releasably assemble the post and the support plate. 
   Further aspects of the method and system are disclosed herein. The features as discussed above, as well as other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates a perspective view of an exemplary electrical connector assembly according to the disclosure. 
       FIG. 2  illustrates a top perspective view of an exemplary receptacle connector according to the disclosure. 
       FIG. 3  illustrates a bottom perspective view of the receptacle connector of  FIG. 2 . 
       FIG. 4  illustrates an exploded perspective view of the receptacle connector of  FIG. 2 . 
       FIG. 5  illustrates a cross sectional view of the receptacle connector of  FIG. 2  taken along line  5 - 5 . 
       FIG. 6  illustrates a partial cross sectional perspective view of another embodiment of a spacer. 
       FIG. 6A  illustrates an exploded view of the spacer of  FIG. 6 . 
       FIG. 6B  illustrates a partial cross sectional perspective view of yet another embodiment of a spacer. 
       FIG. 7  illustrates another embodiment of a receptacle connector according to the disclosure. 
       FIG. 8  illustrates an exploded view of the receptacle connector of  FIG. 7 . 
       FIG. 9  illustrates a top cross sectional view of the receptacle connector of  FIG. 7  taken along line  9 - 9 . 
       FIG. 10  illustrates a bottom cross sectional view of the receptacle connector of  FIG. 7  taken along line  9 - 9 . 
   

   Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. 
     FIG. 1  shows an exemplary embodiment of an electrical connector assembly  100  according to the disclosure. The electrical connector assembly  100  includes a plug connector  101  and a receptacle connector  102 . The plug connector  101  is configured to mate with the receptacle connector  102 . The plug connector  101  and receptacle connector  102  include corresponding mating terminals (not shown) disposed therewithin, which mate to form an electrical connection upon mating of the plug connector  101  and receptacle connector  102  as would be appreciated by one of ordinary skill in the art. 
     FIGS. 2-5  show an exemplary embodiment of a receptacle connector  102  according to the disclosure. The receptacle connector  102  includes a receptacle housing  104 , a support plate  118 , a post  120 , spacers  122 , a fastener  124 , and a spring  126 . The receptacle connector  102  further includes a plurality of electrical terminals (not shown) disposed therewithin, which have not been shown to simplify the inventive elements of the disclosure. The receptacle connector  102  may be formed of metals, metal alloys, plastics, composites, polymers and any combination thereof. For example, the receptacle connector may be formed of a light weight metal alloy, for example a magnesium-aluminum alloy. The light weight metal alloy may be machined or molded to form the various components. In another example, the receptacle connector  102  may be formed of engineered composites including reinforcing material. For example, the reinforcing material may include carbon, glass, carbon nanotubes, and micro-spheres. 
   The receptacle housing  104  includes a base portion  106  and a receiver shroud portion  108 . The base portion  106  includes a top surface  112 , end surfaces  114  and a bottom surface  116 . The top surface  112  includes a support plate recess  133  configured to receive support plate  118 . The bottom surface  116  includes spacer recesses  117  configured to receive spacers  122 . 
   The receiver shroud portion  108  is configured to receive a portion of a corresponding plug connector (not shown). The receiver portion  108  includes grounding tabs  110  for releasably engaging plug connector  101  ( FIG. 1 ). The grounding tabs  110  include contact portions  111 . In another embodiment, the receiver portion  108  may not include grounding tabs  110 . In this exemplary embodiment, the receiver portion  108  is offset in relationship to the base portion  106 . In another embodiment, the receiver portion  108  may be symmetrically positioned in relationship to the base portion  106 . 
   The support plate  118  includes countersunk through-holes  128 , a slot  130 , and positioning tabs  132 . The support plate  118  is received in a recess  133  in the top surface  112  of the receptacle housing  104 . The recess  133  includes insert holes  134  and a post hole  136  configured to align with the tapered through-holes  128  and slot  130 , respectively, when assembled. The support plate  118  is retained in the recess  133  against the receptacle housing by the spacers  122  as will be discussed in detail below. 
   The post  120  includes an upper portion  138 , a support plate  140 , and a lower portion  142 . The upper portion  138  includes pins  143 . The lower portion  142  includes fastener feature  144 . The support plate  140  is configured to be positioned over and in contact with slot  130  between tabs  132  of support plate  118 , so as to fixedly position the locking post with respect to the support plate  118  and prevent the locking post  120  from rotating within the post hole  136  when the locking post  120  is releasably assembled with the support plate  118  by spring  126  and fastener  124  as shown in  FIG. 3 . The posts  120  are configured to be releasably engaged by the plug connector  101  ( FIG. 1 ) so as to releasably mate the plug connector  101  and the receptacle connector  102 . 
   The spacers  122  include an insertion portion  146  and a spacer portion  148 . In this exemplary embodiment, the spacers  122  are a single unit body including both the insertion portion  146  and the spacer portion  148 . The spacer portion  148  extends away from the bottom surface  162  a predetermined distance D as shown in  FIG. 2 . In this exemplary embodiment, the spacers  122  are a unitary body. The spacers  122  may be formed by molding or other similar forming method. In another embodiment, the spacers  122  may be formed from an insertion portion  146  and a spacer portion  148  that are joined by know methods such as, but not limited to, thermal welding and adhesive bonding. 
   As shown in  FIG. 5 , the spacers  122  further include a through-hole  150  traversing from a top end  152  to a bottom end  154 . The through-hole  150  includes spacer portion through-hole  302  and an insertion portion through-hole  308 . In this exemplary embodiment, as shown in  FIG. 5 , the insertion portion through-hole  308  includes an non-threaded surface  311 , and the spacer portion through-hole  302  includes internal threads  303 . The spacers  122  may be used to attach the receptacle connector  102  at a predetermined distance from a substrate (not shown). In one embodiment, the substrate may be a printed circuit board (PCB). The spacers  122  may be used to attach the receptacle connector  102  to a substrate by receiving a fastener (not shown) in the spacer portion  148 , where the fastener is further attached to the substrate. The fastener may be a screw or other similar threaded fastener. 
   In another embodiment shown in  FIG. 5A , a spacer  122  includes an insertion portion through-hole  308  including internal threads  309 . In this embodiment, the internal threads  309  of the insertion portion through-hole  308  are different than the internal threads  303  of the spacer portion through-hole  302 . The internal threads  309 ,  303  may differ by pitch, count, or other thread feature. In this embodiment, a screw (not shown) may be received in the insertion portion through-hole  146  to further securely assemble the spacers  122 , support plate  118 , and receptacle housing  104 . 
   In yet another embodiment shown in  FIG. 5A , a spacer  122  includes an insertion portion through-hole  308  including a non-threaded surface  309  and a spacer portion through-hole  302  including a non-threaded surface  310 . 
   Referring again to  FIGS. 2-5 , the insertion portion  146  has a generally circular exterior cross-sectional geometry, and the spacer portion  148  has a generally square exterior cross-sectional geometry. In another embodiment, the insertion portion  146  and spacer portion  148  may have other cross-sectional geometry. For example, the insertion portion  146  and spacer portion  148  may have a generally circular or hexagonal exterior cross-section. 
   The spacers  122  are shown including a flare  156  at the top end  152 . The flare  156  is formed on the top end  152  after the insertion portion  146  has been received in insert holes  134  to securely assemble the spacers  122  to the receptacle housing  104 . The flare  156  may be formed by a flaring tool as would be appreciated by one of ordinary skill in the art. The spacer portion  148  of the spacers  122  is received in spacer recesses  117  in the bottom surface  116  of the receptacle housing  104  when the receptacle connector  102  is assembled. 
   The spring  126  is sized to be compressedly disposed in post hole  136  between the support plate  118  and the fastener  124  when the receptacle connector  102  is assembled as shown in  FIG. 2 . The compressibility of the spring  26  is selected to securely retain the post  120  against the support plate  118  and to securely assemble the receptacle connector  102  to the plug connector  101  ( FIG. 1 ). 
   The fastener  124  includes a slot  158  configured to receive fastener feature  144  of post  120 . The fastener  124  further includes a bottom surface  160  having a recess  162  configured to receive fastener feature  144  after the fastener feature has passed through the slot  158  and the fastener  124  has been rotated as shown in  FIG. 1B . The fastener  124  compresses the spring  126  against the support plate  118  when assembled as shown in  FIG. 3B . 
     FIGS. 6 and 6A  show another exemplary embodiment of spacers  122 . In this embodiment, spacers  122  are formed from a separate insertion portion  146  and spacer portion  148 . The insertion portion  146  includes internal threads  309  and external threads  610 . External threads  610  are configured to engage internal threads  314  of the spacer portion. The insertion portion  146  includes flare  156 . In this exemplary embodiment, the flare  156  may be formed prior to assembling the receptacle connector  102  ( FIG. 2 ). In such a manner, the insertion portion  146  may be assembled with the spacer portion  148  having the flare  156  already formed so as to retain the support plate  118  ( FIG. 2 ) when assembled. In another embodiment, the insertion portion  310  is received in insert holes  134  and then the flare  156  is formed. 
   In this exemplary embodiment, the insertion portion  146  is only received for a part of the length of the spacer portion  148 . In other words, the external threads  610  do not extend the entire length of the internal threads  314 . 
   In this exemplary embodiment, the insertion portion  146  has internal threads  309  for substantially the length of the insertion portion  146 . In another embodiment, the insertion portion  146  may have internal threads for only a partial portion of the length of the insertion portion  146 . In still another embodiment, the insertion portion  146  may have no internal threads  309 . For example, the internal threads  309  may be included in the portion of the insertion portion  146  received in the spacer portion  148  or may have internal threads only in the portion of the insertion portion  146  not received in the spacer portion  148 . 
   In another embodiment, not shown, the insertion portion  146  does not include external threads  610  and the spacer portion  148  does not include internal threads  314  in the portion of the spacer portion  148  receiving the insertion portion  146 . The portion of the spacer portion  148  not receiving the insertion portion  146  may or may not be threaded. In this exemplary embodiment, the insertion portion  146  and the spacer portion  148  may be press-fit together to form the spacer  122 . 
     FIG. 6B  shows yet another exemplary embodiment of spacers  122 . In this exemplary embodiment, the spacers  122  are formed from a separate insertion portion  146  and spacer portion  148 , and the spacer portion  148  includes a threaded protrusion  615  configured to engage the internal threads  309  of the insertion portion  146 . In this exemplary embodiment, the flare  156  may be formed before or after the insertion portion  146  is received in insert holes  132 . 
   In the embodiments having the spacer  122  formed by a separate insertion portion  146  and spacer portion  148 , the insertion portion  146  and the spacer portion  148  may be further secured joined by thermal welding, adhesive bonding or other joining methods. 
     FIGS. 7 ,  8 ,  9  and  10  show another exemplary embodiment of the receptacle connector  102 . In this exemplary embodiment, the receptacle connector  102  includes yet another exemplary embodiment of spacers  122 . In this exemplary embodiment, the spacers  122  include an insertion portion  146  and a spacer portion  148 . The spacer portion  148  has a length d′ to position a bottom  181  of the spacer portion  148  (see  FIG. 10 ) approximately parallel with the bottom  116  of the receptacle housing  104 . In this exemplary embodiment, the spacers  122  further include a through hole  150  that includes internal threads  304  covering substantially the length of the through hole  150 . In another embodiment, the internal threads  304  may extend only a partial length of the through hole  150 . In yet another embodiment, the internal threads  304  may be omitted. 
   Furthermore, in this exemplary embodiment, the spacers  122  are a unitary body. In another embodiment, the spacers  122  may include a separate insertion portion  146  and a spacer portion  148  that are joined as discussed above. 
     FIG. 11  shows two other exemplary alternative embodiments of spacers  122 . In a first exemplary alternative embodiment, spacer  122   a  includes an insertion portion  146  that does not include a flare  156  after assembly. The spacer  122   a  includes a through hole  150  having internal threads  152 . In this embodiment, the spacer  122   a  is assembled to the receptacle housing  104  and support plate  118  with a fastener  180  as shown. In this exemplary embodiment, the fastener  180  is a screw, however, other similar fasteners may be used. In another embodiment, the fastener  180  may include a post or a through-hole, which may be threaded. 
   In this exemplary embodiment, the insertion portion  146  and spacer portion  148  are a single component, however, in other embodiments as discussed above, the insertion portion  146  and spacer portion  148  may be separate components. Furthermore, in this exemplary embodiment, the spacer portion  148  has a bottom surface  181  ( FIG. 10 ) that is substantially parallel with the bottom surface  116  ( FIG. 10 ) of the housing  104 . In another embodiment, the spacer  122   a  may include a spacer portion  148  that extends away from the bottom surface  181  of the housing  104  as discussed above. 
     FIG. 11  also shows another exemplary alternative embodiment of a spacer  122   b . In this embodiment, the spacer  122   b  includes an insertion portion  148  having internal threads  309  and a spacer portion  149  having external threads  149   a  configured to engage the internal threads  152  of the insertion portion  146 . As can be seen in  FIG. 11 , the spacer portion  148  does not include a through hole, but is a solid body. In this exemplary embodiment, the insertion portion  146  includes a flare  156  which may be formed prior to or during assembly of the connector  102 . In another embodiment, the spacer  122   b  may include a spacer portion  149  that extends away from the bottom surface  181  of the housing  104  as discussed above. 
   While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

Technology Classification (CPC): 7