Abstract:
A convenience outlet is provided for mounting on a printed circuit board (PCB). The convenience outlet includes a connector housing having an outlet face configured to be mated with an electrical plug, a contact chamber having a contact secured therein, and an open end configured to abut against, and be mounted on, a PCB. The contact includes a beam and a contact blade. The beam is configured to electrically engage an electrical plug and the contact blade is configured to be inserted through a circular via in a PCB. Optionally, the contact may also have a stopping blade adjacent to the contact blade configured to abut against a surface of the PCB when the contact blade is fully inserted into the via. Optionally, the PCB can have multiple vias, and the outlet can have multiple contacts.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    Certain embodiments of the present invention generally relate to electrical contacts and to connector housings for electrical contacts, and more particularly, to electrical convenience outlets mounted onto printed circuit boards (PCBs).  
           [0002]    Convenience outlets have been proposed in the past to be mounted on a printed circuit board (PCB). The convenience outlets are configured to be quickly and easily installed onto PCBs. PCBs are typically formed from one or more layers of non-conductive material, such as plastic. The layers include conductive traces therein or thereon that carry power or data signals. Certain traces electrically join circular “through holes” that are formed through the PCB. The through holes are also referred to as “vias.” Each through hole, or via, includes a passage cut through the non-conductive layers of the PCB. The passage securely receives a conductive tubular-shaped liner that contacts one or more traces. Vias are used to interconnect traces that are located on opposite sides or within different layers of the PCB. Vias are also used to connect electrical components to the PCB. For example, a pattern of vias may be formed to correspond to the pin pattern on a processor, memory chip, a socket and the like. The vias include circular passages therethrough. These passages are circular in shape to correspond to the circular cross-section of pins on the mating component.  
           [0003]    Convenience outlets have been configured to be mountable in the circular passages through the vias. A convenience outlet enables a connection to be made between the PCB and a male plug, such as an electrical cord. The convenience outlet may include a female receptacle on one side having a contact pattern similar to a wall receptacle. The convenience outlet also includes a set of pins arranged in a pin pattern aligning with a corresponding set of vias in the PCB. The pins on the convenience outlet have the same shape as pins on other components and sockets that are mounted on the PCB. The individual pins are circularly shaped and arranged to align with and fit in the vias. The pins are secured to the vias frictionally or through solder. Each pin is inserted into a separate via.  
           [0004]    However, convenience outlets are expensive to manufacture due, in part, to the circular shape of the pins. Additionally, convenience outlets offer a limited power carrying capability as they exhibit undesirably high resistance and a less than ideal connection with the PCB. The connection between each pin and PCB may be enhanced with solder. However, the solder rests on top of the PCB and does not enter the vias in the PCB. Hence, the connection between the pins and PCB is through surface contact along the pins and vias and through solder (if present) at the top of the vias surrounding a small portion of each pin.  
           [0005]    A need remains for an improved PCB mount convenience outlet.  
         BRIEF SUMMARY OF THE INVENTION  
         [0006]    An embodiment of the present invention provides a convenience outlet for mounting on a printed circuit board. The convenience outlet includes a connector housing and a contact. The housing includes an outlet face configured to be mated with an electrical plug, a contact chamber having the contact secured therein, and an open end configured to abut against, and be mounted on, a printed circuit board (PCB). The contact includes a beam and a contact blade. The beam is configured to electrically engage an electrical plug, and the contact blade is configured to be inserted through a circular via in the PCB. Optionally, the contact may have two or more beams extending adjacent to each other. The contact blade has a width that is substantially greater than a thickness of the contact blade. The contact blade also has a thickness that is substantially smaller than a diameter of the via and a width slightly less than the diameter of the via. The contact blade includes two opposed planar surfaces.  
           [0007]    The contact blade may contain a chamfered outer end and may be stamped from a singe piece of material, in order that the contact blade and the beam are integrally formed with one another.  
           [0008]    An advantage of certain embodiments of the present invention is that the convenience outlet can be manufactured cheaply since the contact can be stamped from a single piece of material.  
           [0009]    A second advantage of certain embodiments of the present invention is that the contact provides the capability of carrying high power. The sufficient power carrying capability of the contact is enhanced, in part, because the contact blade and the beam are integrally formed with one another. The contact blade configuration enables solder to enter the via and provide a superior connection along the length of the contact blade with the via.  
           [0010]    These and other features and embodiments of the present invention are discussed or apparent in the following detailed description of certain embodiments of the present invention. 
       
    
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 illustrates a top front perspective view of a convenience outlet connector housing formed in accordance with an embodiment of the present invention.  
         [0012]    [0012]FIG. 2 illustrates a bottom rear perspective view of the convenience outlet connector housing of FIG. 1.  
         [0013]    [0013]FIG. 3 illustrates a bottom front perspective view of an active contact formed in accordance with an embodiment of the present invention.  
         [0014]    [0014]FIG. 4 illustrates a top rear perspective view of an active contact formed in accordance with an embodiment of the present invention.  
         [0015]    [0015]FIG. 5 illustrates a bottom front perspective view of a neutral contact formed in accordance with an embodiment of the present invention.  
         [0016]    [0016]FIG. 6 illustrates a top plan view of a neutral contact formed in accordance with an embodiment of the present invention.  
         [0017]    [0017]FIG. 7 illustrates a bottom front perspective view of a ground contact formed in accordance with an embodiment of the present invention.  
         [0018]    [0018]FIG. 8 illustrates a top rear perspective view of a ground contact formed in accordance with an embodiment of the present invention.  
         [0019]    [0019]FIG. 9 illustrates bottom rear perspective view of a connector housing with installed contacts formed in accordance with an embodiment of the present invention.  
         [0020]    [0020]FIG. 10 illustrates top front perspective view of a printed circuit board formed in accordance with an embodiment of the present invention.  
         [0021]    [0021]FIG. 11 illustrates a bottom perspective view of a connector housing with installed contacts mounted on a printed circuit board formed in accordance with an embodiment of the present invention. 
     
    
       [0022]    The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentality shown in the attached drawings.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0023]    [0023]FIG. 1 illustrates a convenience outlet connector housing  100  formed in accordance with an embodiment of the present invention. The connector housing  100  includes an outlet face  102  configured to receive a mating electrical plug (not shown). The outlet face  102  includes neutral, ground and active slots  104 - 106  for receiving respective neutral, ground and active blades of an electrical plug. The connector housing  100  includes a ledge  108  that is located a step  110  down from the outlet face  102  and is aligned parallel to the outlet face  102 . The ledge  108  is configured for securing the connector housing  100  within a larger structure, but is not necessarily used in all applications. The connector housing  100  includes sidewalls  112 ,  114 ,  212 ,  214  (FIGS. 1 &amp; 2). Sidewall  112  includes a bottom edge  116  that may include heat dissipation notches  118  cut or formed therein. Sidewall  114  includes a bottom edge  120  that may include a heat dissipation notch  122  cut or formed therein. The sidewall  114  may also include a heat dissipation slit  124  cut or formed therein. The heat dissipation notch  122  extends vertically from the bottom edge  120  by a short distance, while the heat dissipation slit  124  extends vertically upward from the bottom edge  120  to an underside  201  (FIG. 2) of the ledge  108 .  
         [0024]    [0024]FIG. 2 illustrates a rear view of the connector housing  100 . The sidewalls  112 ,  114 ,  212 ,  214  may include gussets  216  for supporting the ledge  108 . The sidewall  212  includes a bottom edge  218 . The bottom edge  218  may include heat dissipation notches  220 . The sidewall  212  may include a heat dissipation slit  222 , extending vertically from the bottom edge  218  of the sidewall  212  to the underside  201  of the ledge  108 . The sidewall  214  includes a bottom edge  224  that may include a heat dissipation notch  226 . The sidewall  214  may include a heat dissipation slit  228 , extending vertically from the bottom edge  224  of the sidewall  214  to the underside  201  of the ledge  108 . Optionally, different configurations, combinations and numbers of heat dissipation slits and heat dissipation notches may be used.  
         [0025]    The sidewalls  112 ,  114 ,  212 ,  214  define a contact chamber  230 . The contact chamber  230  includes an open end  232  of rectangular shape that is defined by the bottom edges  116 ,  120 ,  218 ,  224  of the sidewalls  112 ,  114 ,  212 ,  214 , respectively. While FIG. 2 illustrates the open end  232  to be located on the bottom of the connector housing  100  and opposite to the outlet face  102 , optionally the open end  232  may be formed in one the sidewalls  112 ,  114 ,  212 ,  214  to form a right-angle convenience outlet. The open end  232  is configured to receive, and the contact chamber is configured to retain, contacts  300 ,  500 ,  700  (FIGS. 3, 5, and  7 ). The open end  232  firmly engages a surface of a PCB  1000  (FIG. 10).  
         [0026]    The connector housing  100  includes an inner wall  233  having stabilizing projections  234 ,  236 . The stabilizing projections  234 ,  236  include bottom surfaces  238 ,  240  for stabilizing the connector housing  100  on the PCB  1000  (FIG. 10).  
         [0027]    [0027]FIGS. 3 and 4 illustrate front and rear views of an active contact  300  formed in accordance with an embodiment of the present invention. The active contact  300  extends along a longitudinal axis  302  and includes a rectangular-shaped body section  304 . The body section  304  includes two side edges  306 ,  308 . Each side edge  306 ,  308  may include triangular retention bulges  310 , extending outward from the body section  304 . The retention bulges  310  retain the active contact  300  in the connector housing  100  when installed. The body section  304  includes an upper edge  312  that is formed with a blade-receiving section  314 , extending upward from the body section  304 . The blade-receiving section  314  includes a pair of beams  316  and  318 , extending upward in a direction parallel to the longitudinal axis  302 . Outer ends  320  and  322  of the beams  316  and  318  bend outward away from one another. The outer ends  320  and  322  may be separated by a gap  324 . The beam  318  includes a base portion  326  spaced apart from the beam  316  and bent at a corner  328  inward toward the beam  316 . The beam  318  extends upward at an angle toward the beam  316 . The beams  316  and  318  are configured to frictionally receive a blade contact on an electrical plug mated with the connector housing  100 .  
         [0028]    The body section  304  includes a bottom edge  330  that is formed with a contact blade  332 , extending downward along the longitudinal axis  302 . The contact blade  332  is of a generally rectangular shape and has a chamfered outer end  334 . The contact blade  332  includes two planar surfaces  336 ,  436  (FIGS. 3 &amp; 4) that are parallel to one another. The contact blade  332  has a thickness  402 , a width  404 , and a length  406 . The thickness  402  is substantially less than the width  404 .  
         [0029]    The contact may also include a stopping blade  338  extending from the bottom edge  330  of the body section  304 . The stopping blade  338  is of the same general width and thickness as the contact blade  332 , but is shorter in length. The stopping blade  338  includes two planar surfaces  340 ,  440  (FIGS. 3 &amp; 4) that are parallel to one another and a flat bottom surface  342 . The contact blade  332  is configured to be inserted into a via in the PCB  1000 , until the stopping blade  338  abuts against a surface of the PCB  1000 .  
         [0030]    [0030]FIGS. 5 and 6 illustrate a neutral contact  500 . The neutral contact  500  extends along a longitudinal axis  502  and includes a rectangular-shaped body section  504 . The body section  504  includes two side edges  506 ,  508 . Each side edge  506 ,  508  may include triangular retention bulges  510 , extending outward from the body section  504 . The retention bulges  510  retain the neutral contact  500  in the connector housing  100  when installed. The body section  504  includes an upper edge  512  that is formed with a blade-receiving section  514 , extending upward from the body section  504 . The blade-receiving section  514  includes beams  516 - 518 , extending upward in a direction parallel to the longitudinal axis  502  and a direction perpendicular to the upper edge  512  of the body section  504 .  
         [0031]    Outer ends  520  and  522  of the beams  516  and  518  bend away from one another. The outer ends  520  and  522  may be separated by a gap  602 . The beams  516  and  518  include respective base portions  524  and  526  spaced apart from one another. The base portions  524 ,  526  are bent inward toward one another at corners  528 ,  530 . The beams  516  and  518  extend upward at angles toward one another. The beam  517  includes a base portion  534  that adjoins the base portions  524 ,  526  and is aligned perpendicular to the base portions  524 ,  526 . The base portion  534  is bent at corner  536  inward toward beams  516  and  518 . The beam  517  extends upward at an angle toward the beams  516  and  518 . Outer end  532  of the beam  517  bends outward and away from the outer ends  520  and  522 . The outer end  532  may be separated from the outer ends  520  and  522  by a gap  604 .  
         [0032]    The body section  504  includes a bottom edge  538  that is formed with a contact blade  540 , extending downward along the longitudinal axis  502 . The contact blade  540  is of a generally rectangular shape and has a chamfered outer end  542 . The contact blade  540  has a thickness  541 , a width  543 , and a length  545 . The thickness  541  is substantially less than the width  543 .  
         [0033]    The bottom edge  538  of the body section  504  may also include a stopping blade  544 . The stopping blade  544  is of the same general width and thickness as the contact blade  540 , but is shorter in length. The stopping blade  544  includes a flat bottom surface  546 . The contact blade  544  is configured to be inserted into a via in the PCB  1000 , until the stopping blade  544  abuts against a surface of the PCB  1000 .  
         [0034]    [0034]FIGS. 7 and 8 illustrate front and rear views of a ground contact  700  formed in accordance with an embodiment of the present invention. The ground contact  700  extends along a longitudinal axis  702  and includes a rectangular-shaped body section  704 . The body section  704  includes two side edges  706 ,  708 . Each side edge  706 ,  708  may include triangular retention bulges  710 , extending outward from the body section  704 . The retention bulges  710  retain the ground contact  700  in the connector housing  100  when installed. The body section  704  includes an upper edge  712  that is formed with a blade-receiving section  714 , extending upward from the body section  704 . The blade-receiving section  714  includes a pair of beams  716  and  718 , extending upward in a direction parallel to the longitudinal axis  702  and perpendicular to the upper edge  712  of the body section  704 . Outer ends  720  and  722  of the beams  716  and  718  bend away from one another. The outer ends  720  and  722  may be separated by a gap  723 . The beam  718  includes a base portion  724  spaced apart from the beam  716  and bent at a corner  726  inward toward the beam  716 . The beams  716  and  718  are configured to frictionally receive a blade contact on an electrical plug mated with the connector housing  100 .  
         [0035]    The body section  704  includes a bottom edge  728  that is formed with a contact blade  730 , extending downward along the longitudinal axis  702 . The contact blade  730  is of a generally rectangular shape and has a chamfered outer end  732 . The contact blade  730  includes two planar surfaces  734 ,  834  (FIGS. 7 &amp; 8) that are parallel to one another. The contact blade  730  has a thickness  802 , a width,  804 , and a length  806 . The thickness  802  is substantially less than the width  804 .  
         [0036]    The bottom edge  728  of the body section  704  may also include a stopping blade  736 . The stopping blade  736  is of the same general width and thickness as the contact blade  730 , but is shorter in length. The stopping blade  736  includes two planar surfaces  738 ,  838  (FIGS. 7 &amp; 8) that are parallel to one another and a flat bottom surface  740 . The contact blade  730  is configured to be inserted into a via in the PCB  1000 , until the stopping blade  736  abuts against a surface of the PCB  1000 .  
         [0037]    [0037]FIG. 9 illustrates a rear view of the connector housing  100  with the contacts  300 ,  500 ,  700  installed. The bottom edges  116 ,  120 ,  218 ,  224  of the sidewalls  112 ,  114 ,  212 ,  214 , the bottom surfaces  238 ,  240  of the stabilizing projections  234 ,  236  and the bottom surfaces  342 ,  546 ,  740  of the stopping blades  338 ,  544 ,  736  are aligned in substantially the same plane.  
         [0038]    [0038]FIG. 10 illustrates a PCB  1000  that includes a plurality of vias or holes  1002 - 1004  that are circular in shape. The holes  1002 - 1004  are configured to receive the contact blades  332 ,  540 ,  730  on the active contact  300 , the neutral contact  500  and the ground contact  700 , respectively. The holes include conductive tubular-shaped liners  1006  therein.  
         [0039]    [0039]FIG. 11 illustrates a bottom view of the connector housing  100  with the active, neutral and ground contacts  300 ,  500 ,  700  mounted on the PCB  1000 . The chamfered outer ends  334 ,  542  and  732  of the contact blades  332 ,  540 ,  730  protrude through the PCB  1000  beyond a bottom surface  1102  thereof. Because the holes  1002 - 1004  have circular shapes and the contact blades  332 ,  540 ,  730  have rectangular cross sections, the holes  1002 - 1004  include gaps  1106  therein between the conductive tubular-shaped liners  1006  and the contact blades  332 ,  540 ,  730 . Optionally, the gaps  1106  can be filled with solder.  
         [0040]    While certain embodiments of the present invention employ the connector housing having three contacts, other embodiments may include the connector housing having one contact, two contacts, or more than three contacts.  
         [0041]    While certain embodiments of the present invention employ the outlet faces configured to receive  15  amperes and  20  amperes electrical plugs, the outlet faces are in no way limited to the outlet faces having configurations for receiving  15  amperes and  20  amperes electrical plugs.  
         [0042]    While certain embodiments of the present invention employ the contacts having the stopping beam, other embodiments may include contacts without the stopping beam.  
         [0043]    While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted 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 its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.