Patent Document

CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of and is a continuation of U.S. application Ser. No. 13/713,987, filed on Dec. 13, 2012, which application is a non-provisional application claiming priority from U.S. Provisional Application Ser. No. 61/570,506, filed Dec. 14, 2011, entitled “Electrical Connectors for Use with Printed Circuit Boards” each of which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    The present description relates generally to electrical connectors and more particularly to electrical connectors for use with printed circuit boards. 
       BACKGROUND OF RELATED ART 
       [0003]    Connectors and more particularly, connectors capable of electrically connecting printed circuit boards (“PCBs”) to one another are generally known in the art. For example, U.S. Pat. No. 7,462,036, entitled “Printed Circuit Board Connector for Back Light Unit and Chassis Using the Same,” describes a connector for electrically connecting PCBs on which are mounted a plurality of light emitting diodes (“LEDs”). The described connector includes a horizontal supporter, a vertical supporter that divides the horizontal supporter into first and second areas, and at least one connecting terminal formed on the horizontal supporter which is partially exposed in each of the first and second areas of the horizontal supporter. The connecting terminal functions to electrically connect PCBs each having one end placed on the first and second areas, respectively. 
         [0004]    U.S. Pat. No. 7,892,022, entitled “Jumper Connector for a Lighting Assembly,” also describes a connector for electrically connecting PCBs on which are mounted a plurality of LEDs. The described connector includes a connector body having a mating surface configured to engage more than one PCB. The connector body is configured to be secured to a substrate by a fastener. The connector body additionally includes a conductor and the conductor is configured to be electrically connected to the PCBs during the same step in which the connector body is secured to the substrate. In this manner, the connector body engages the outer surface of the PCBs and simultaneously forces the inner surface of the PCBs into thermal contact with the substrate. 
         [0005]    U.S. Published Application No. 2011/0207372, entitled “Electrical Connector With Push-in Termination,” describes an edge connector having a first portion adapted to receive an edge of a PCB and a second portion adapted to receive a least one conductor of a stripped end of a wire. The first portion includes at least one terminal assembly and the terminal assembly includes a retention member adapted to engage the conductor via a push-in wire termination. The second portion includes include a terminal portion adapted to releasably engage a contact on a PCB. 
         [0006]    While the connectors described in each of these publications, which are incorporated herein by reference in their entirety, generally work for their intended purpose, the following describes improved connectors for use with PCBs. By way of non-limiting example, the improved connectors provide a low profile to reduce or eliminate shadowing of light from any LEDs mounted on the PCBs, allow PCBs to mount directly onto the mounting surface, allow PCBs to be placed adjacent to one another without breaks for continuous lighting, allow for easy replacement of PCBs, eliminate the need to solder together PCBs and connectors, allow wires to be routed from behind a mounting surface such that the wires will not obstruct light from any LEDs mounted on the PCBs, prevent incorrect placement of PCBs within assemblies, etc. 
       SUMMARY 
       [0007]    Described hereinafter are improved connectors for use with PCBs. 
         [0008]    More particularly, a connector for electrically connecting a first printed circuit board (PCB) with a second PCB is described wherein the connector includes a housing having a keyed feature that is adapted to mate with a correspondingly keyed feature provided to each of the first and second PCBs and at least one connecting terminal carried by the housing having at least partially exposed opposed ends each of which electrically engages a contact pad formed on an underside of the respective PCBs. 
         [0009]    Also described is a connector for electrically connecting a first PCB with a second PCB directly on a mounting surface having a hole, recess, channel, cavity, and/or the like defined therein. The connector includes a housing adapted to be mounted within the cavity of the mounting surface such that the housing does not extend above the mounting surface, and includes at least one connecting terminal carried by the housing having at least partially exposed opposed ends, each of which electrically engages a contact pad formed on an underside of each of the first and second PCBs. 
         [0010]    Also described is a connector for electrically connecting a first PCB with a second PCB wherein the connector includes a housing and at least one connecting terminal carried by the housing having at least partially exposed opposed ends each of which electrically engages a contact pad formed on an underside of the respective PCBs and wherein the connector is adapted to allow the edges of the PCBs to be placed into direct contact. 
         [0011]    Yet further is described a connector for electrically connecting a first PCB with a second PCB wherein the connector includes a housing and at least one connecting terminal carried by the housing having at least partially exposed opposed ends each of which electrically engages a contact pad formed on an underside or a top side of the respective PCBs and wherein the connecting terminal is arranged to accept a conductor and to thereby electrically couple the conductor to the first and second PCBs. 
         [0012]    Still further is described a connector for electrically connecting a PCB with a conductor wherein the connector has a housing having a keyed feature adapted to mate with a correspondingly keyed feature provided to the PCB and at least one connecting terminal carried by the housing having an at least partially exposed opposed end which electrically engages a contact pad formed on an underside or a top side of the PCB wherein an opposite end of the connecting terminal is arranged to cooperate with an interior surface of the housing to engage a conductor inserted therebetween. 
         [0013]    Yet further is described a connector for electrically connecting a PCB with a conductor wherein the connector includes a housing and at least one connecting terminal carried by the housing having an at least partially exposed opposed end which electrically engages a contact pad formed on a top side of the PCB and which functions to urge the PCB upon a mounting surface and wherein an opposite end of the connecting terminal is arranged to cooperate with an interior surface of the housing to engage a conductor inserted therebetween. 
         [0014]    While the foregoing provides a general description of the subject assemblies for holding a source of LED light and some advantages thereof, a better understanding of the objects, advantages, features, properties, and relationships of the subject assemblies will be obtained from the following detailed description and accompanying drawings which set forth illustrative embodiments and which are indicative of the various ways in which the principles of the invention may be employed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    For a better understanding of the hereinafter described connectors for use with PCBs, reference may be had to the following drawings. 
           [0016]      FIG. 1  illustrates an example printed circuit board having contact pads on a top surface thereof. 
           [0017]      FIG. 2  illustrates an example printed circuit board having contact pads on a bottom surface thereof. 
           [0018]      FIG. 3  illustrates an end view of the example printed circuit board of  FIG. 1 . 
           [0019]      FIG. 4  illustrates an example center bridge for electrically connecting underside located contact pads of a plurality of printed circuit boards of  FIG. 2 . 
           [0020]      FIG. 5  is an assembly view of the example of  FIG. 4 . 
           [0021]      FIG. 6  is an example center bridge for use with the assembly of  FIG. 4 . 
           [0022]      FIG. 7  illustrates the example center bridge of  FIG. 6  showing a single printed circuit board connected to the bridge. 
           [0023]      FIG. 8  is an exploded view of the center bridge of  FIG. 6 . 
           [0024]      FIG. 9  illustrates an example center bridge having at least one wire insertion port for electrically connecting a wire to underside located contact pads of plural printed circuit boards. 
           [0025]      FIG. 10  is an assembly view of the example of  FIG. 9 . 
           [0026]      FIG. 11  is an example center bridge for use with the assembly of  FIG. 9 . 
           [0027]      FIG. 12  illustrates the example center bridge of  FIG. 11  showing insertion of a wire therein. 
           [0028]      FIG. 13  is an exploded view of the center bridge of  FIG. 11 . 
           [0029]      FIG. 14  illustrates the example center bridge of  FIG. 9  as installed with a plurality of printed circuit boards. 
           [0030]      FIGS. 15-17  illustrate a still further exemplary center bridge having at least one wire insertion port for electrically connecting a wire to top side located contact pads of plural printed circuit boards; 
           [0031]      FIGS. 18-23  illustrate an exemplary edge connector having an underside located wire insertion port for electrically connecting to a wire to an underside contact pad of a printed circuit board; 
           [0032]      FIGS. 24-28  illustrate an exemplary edge connector having a side located wire insertion port for electrically connecting a wire to an underside or top side contact pad of a printed circuit board; and 
           [0033]      FIGS. 29-33  illustrate an exemplary edge connector having an underside located wire insertion port for electrically connecting a wire to a top side contact pad of a printed circuit board. 
       
    
    
     DETAILED DESCRIPTION 
       [0034]    The following description of example methods and apparatus is not intended to limit the scope of the description to the precise form or forms detailed herein. Instead the following description is intended to be illustrative so that others may follow its teachings. 
         [0035]    Turning now to the Figures, wherein like elements are referenced using common identifiers, illustrated are various connectors for use with printed circuit boards (“PCBs”). By way of non-limiting example, a PCB  10  may have mounted thereon one or more light emitting diodes (“LEDs”) which LEDs are, in turn, electrically coupled to one or more contact pads  12  formed on a top side and/or a bottom side of the PCB  10  as illustrated in  FIGS. 1-3 . For purposes that will be discussed in greater detail below, ends of the PCB  10  may additionally include one or more keyed features  14 . In the illustrated example, the keyed feature  14  comprises a shaped recess formed in the edge of the PCB  10 . It will be understood, however, that the shape and positioning of the keyed feature  14  as illustrated in the figures is not intended to be limiting. Rather, it will be understood that keyed feature  14  may be provided with any shape and/or be arranged on the PCB  10  in any manner as needed to meet the objectives described hereinafter. For example, the keyed feature may include a hole defined in the PCB  10  and a corresponding post formed on the connector. 
         [0036]    For providing an electrical connection between two PCBs  10 , a center bridge connector  16  is illustrated in  FIGS. 4-8 . The center bridge connector includes a housing  18  formed using an electrically insulating material, such as plastic. The housing  18  carries one or more connecting terminals  17 . Opposite ends of the connecting terminals  17  are arranged to engage contact pads  12  provided on the underside of a PCB  10 . For example, as illustrated in  FIGS. 4 and 5 , the center bridge connector  16  may be mounted in a cavity of a mounting surface  20 , e.g., a heat sink, with the PCBs  10  then being mounted to the mounting surface  20  such that an end of each of the PCBs  10  is positioned over a one of the respective, opposite sides of the housing  18  as particularly shown in  FIG. 7 . Preferably, the connecting terminals  17  have elasticity to thereby facilitate engagement with the contact pads  12  of the PCBs  10 , e.g., the ends  17 A of the contacting terminals  17  that are exposed in the housing  18  may be curved and arranged over a hole, slot, recess, cavity, or the like as shown in  FIG. 8  so that the curved portion of the connecting terminal  17  is elastically moveable. As noted above, the center bridge connector  16  may be positioned in a recess, cavity, or the like formed in the mounting surface  20  to thereby allow the center bridge connector  16  to be positioned generally below the mounting surface to allow the PCBs  10  to lay directly on the mounting surface. As illustrated, the center bridge connector  16  and the PCBs  10  may be mounted to the mounting surface  20  via use of screws, snap-fit, or the like. 
         [0037]    To facilitate proper alignment of the PCBs  10  with the connector  16 , the housing  18  may optionally carry a keyed feature  22  (an example of which is illustrated in  FIGS. 6-8 ) which is complementary to the keyed feature  14  which may be optionally provided to the PCB  10 . In this regard, it is preferred that the keyed features  22  and  18  are arranged to ensure that an edge of a PCB  10  is not incorrectly placed from a given side of the connector  16 . It is also preferred that the keyed feature  22  have a low-profile, i.e., a thickness that is no greater than the thickness provided to the PCB  10 , to thereby prevent the keyed feature  22  from blocking a path of light emitted from any LEDs mounted on the PCB  10 . It will be additionally appreciated that the keyed feature may be used to prevent a PCB  10  with an incorrect rating from being inserted into a lighting fixture. As noted previously, the keyed features  22  and  14  may have any desired cooperable locations and/or shapes without limitation. For example, the keyed feature  14  of the PCBs  10  need not be in the form of one or more slots positioned at an edge of the PCBs  10  but may be in the form of one or more holes provided to a PCB  10  where the holes are arranged and configured to accept a complimentary post or connector provided to the housing  18 . 
         [0038]    Turning to  FIGS. 9-14 , a further center bridge connector  30  having one or more conductor insertion ports  32  is illustrated. In the illustrated example, a conductor, e.g., stripped end of wire, it to be inserted into the conductor insertion port  32  whereupon the conductor will be placed into electrical connection with contact pads  12  formed on the underside of PCBs  10  via connecting terminals  19  and  21 . More particularly, as illustrated in  FIG. 14 , the connecting terminals  19  and  21  are arranged to provide wire insertion port  32  with a push-in type electrical connector. To this end, a first end  19 B of connecting terminal  19  is provided with a resilient, spring-like member that is arranged to electrically engage a conductor inserted into the conductor insertion port  32  and to thereby drive the inserted conductor into electrical engagement with a first end  21 B of the other connecting terminal  21  as shown in  FIGS. 13 and 14 . As previously described, the second end  19 A of the connecting terminal  19  and the second end  21 A of the connecting terminal  21 , which are exposed from the plastic housing  18  of the center bridge connector  30 , are preferably provided with curves to thereby facilitate engagement with the contact pads  12  of the PCBs  10  when the PCBs  10  are positioned over the center bridge connector  30  in the manner shown in  FIGS. 9 ,  10 , and  14 . When a conductor is not inserted into the wire insertion port  32 , the first end  19 B of the connecting terminal  19  and the second end  21 B of the connecting terminal  21  are preferably electrically engaged—owing to the spring force note previously—to thereby allow the center bridge connector  30  to place the contact pads of the PCBs  10  into electrical communication with one another via the connecting terminals  19  and  21 . As before, the housing  18  of the center bridge connector  30  may be provided with low-profile, keyed features  22  and the center bridge connector  30  may be positioned in a recess, cavity, or the like formed in the mounting surface  20  to thereby allow the center bridge connector  30  to be positioned generally below the PCBs  10 . While the example illustrated in  FIGS. 9-14  disclose a center bridge connector  30  in which the wire insertion port  32  is vertically oriented and located on a side of the center bridge connector  30  that would be opposite of the PCBs  10 , it will be appreciated that the described components may be rearranged as needed to facilitate other locations for and/or orientations of the wire insertion port  32  as needed to meet any given connection requirements. 
         [0039]    Turning now to  FIGS. 15-17 , a still further center bridge connector  30 ′ having one or more conductor insertion ports  32  is illustrated. In the illustrated example, a conductor, e.g., stripped end of wire, it to be inserted into the conductor insertion port  32  whereupon the conductor will be placed into electrical connection with contact pads  12  formed on the top side of PCBs  10  via connecting terminals  19 ′ and  21 ′. As with center bridge connector  30 , the connecting terminals  19 ′ and  21 ′ are preferably arranged to provide wire insertion port  32  with a push-in type electrical connector. To this end, a first end  19 B′ of connecting terminal  19 ′ is provided with a resilient, spring-like member that is arranged to electrically engage a conductor inserted into the conductor insertion port  32  and to thereby drive the inserted conductor into electrical engagement with a first end  21 B′ of the other connecting terminal  21 ′ as shown in  FIG. 17 . The second end  19 A′ of the connecting terminal  19 ′ and the second end  21 A′ of the connecting terminal  21 ′, which are exposed from the plastic housing  18  of the center bridge connector  30 ′, are preferably provided with downward curves to thereby facilitate engagement with the contact pads  12  located on the top side of the PCBs  10  when the PCBs  10  are positioned within PCB accepting slots  31  formed in the housing  18 . As additionally illustrated, the PCB accepting slots  31  are preferably covered by housing section  33  to thereby prevent an inadvertent touching of energized parts such as the top mounted contact pads  12  or connecting terminals  19 ′ and  21 ′ when the PCB  10  is inserted into the center bridge connector  30 ′ as well as the connecting terminals  19 ′ and  21 ′ when the PCB  10  is removed from the PCB accepting slot  31 . When a conductor is not inserted into the wire insertion port  32 , the first end  19 B′ of the connecting terminal  19 ′ and the second end  21 B′ of the connecting terminal  21 ′ are preferably electrically engaged—owing to the spring force note previously—to thereby allow the center bridge connector  30 ′ to place the contact pads of the PCBs  10  into electrical communication with one another via the connecting terminals  19 ′ and  21 ′. As before, the housing  18  of the center bridge connector  30 ′ may be provided with keyed features  22  (not illustrated). While the example illustrated in  FIGS. 15-17  disclose a center bridge connector  30 ′ in which the wire insertion port  32  is vertically oriented and located on a side of the center bridge connector  30 ′ that would be opposite to the PCBs  10 , it will be appreciated that the described components may be rearranged as needed to facilitate other locations for and/or orientations of the wire insertion port  32  as needed to meet any given connection requirements. 
         [0040]    Turning now to  FIGS. 18-23 , an edge connector  40  having one or more conductor insertion ports  32  is illustrated. In the illustrated example, a conductor, e.g., stripped end of wire, it to be inserted into the conductor insertion port  32  whereupon the conductor will be placed into electrical connection with a contact pad  12  formed on the underside of a PCB  10  via a connecting terminal  42 . More particularly, as illustrated in  FIG. 23 , the connecting terminal  42  is arranged to cooperate with an interior side of the housing of the edge connector  40  to provide wire insertion port  32  with a push-in type electrical connector. To this end, a first end  42 B of the connecting terminal  42  is provided with a resilient, spring-like member that is arranged to electrically engage a conductor inserted into the conductor insertion port  32  and to thereby trap the inserted conductor between the first end  42 B of the connecting terminal  42  and the interior side of the housing  18  of the edge connector  40 . As previously described, the second end  42 A of the connecting terminal  42 , which is exposed from the plastic housing  18  of the edge connector  40 , is preferably provided with curves to thereby facilitate engagement with the contact pad  12  of the PCB  10  when the PCB  10  is positioned over the edge connector  40  in the manner shown in  FIGS. 4 ,  21 , and  23 . Similarly, the housing  18  of the edge connector  40  may be provided with low-profile, keyed feature  22  as described above for cooperating with keyed feature  14  provided to the PCB  10 . 
         [0041]    While the example illustrated in  FIGS. 18-23  disclose an edge connector  40  in which the wire insertion port  32  is vertically oriented and located to allow for wire insertions from the underside of the PCB  10 ,  FIGS. 24-28  illustrate an edge connector  40 ′ in which the wire insertion port  32  is horizontally oriented and located to allow for wire insertions from a side of the PCB  10 . The edge connector  40 ′ includes the same components as those described above with respect to edge connector  40  with the components being oriented and arranged to accommodate wire insertion from the side of the PCB  10 . The edge connector  40 ′ can be used to engage contact pads  12  located on the top side or the underside of a PCB  10 . In the illustrated embodiment, the housing of the edge connector  40 ′ includes a housing section  55  to thereby prevent an inadvertent touching of energized parts such as the top mounted contact pads  12  or connecting terminal  42 ′ when the PCB  10  is inserted under the connecting terminal  42 ′ as well as the connecting terminal  42 ′ when the PCB  10  is removed therefrom. It will also be appreciated that the curves provided to the connecting terminal  42 ′ may function to urge the PCB  10  into engagement with the mounting surface  20  when used to engage a top side contact pad  12  of a PCB  10 . Similarly, when used to engage a top side contact pad  12  of a PCB  10 , the top portion of the edge connector  40 ′ is desired to have a height that will minimize the blocking of light emitted from any LEDs mounted on the PCB  10 . 
         [0042]    Turning now to  FIGS. 29-33 , a further edge connector  50  having one or more conductor insertion ports  32  is illustrated. In the illustrated example, a conductor, e.g., stripped end of wire, it to be inserted into the conductor insertion port  32  whereupon the conductor will be placed into electrical connection with a contact pad  12  formed on the upper side of a PCB  10  via a connecting terminal  52 . More particularly, as illustrated in  FIG. 29 , the connecting terminal  52  is arranged to cooperate with an interior side of the housing of the edge connector  50  to provide wire insertion port  32  with a push-in type electrical connector. To this end, a first end  52 B of the connecting terminal  52  is provided with a resilient, spring-like member that is arranged to electrically engage a conductor inserted into the conductor insertion port  32  and to thereby trap the inserted conductor between the first end  52 B of the connecting terminal  52  and the interior side of the housing  18  of the edge connector  50 . As previously described, the second end  52 A of the connecting terminal  52 , which is exposed from the plastic housing  18  of the edge connector  50 , is preferably provided with downward curves to thereby facilitate engagement with the contact pad  12  of the PCB  10  when the PCB  10  is positioned within insertion opening  54  as particularly illustrated in  FIGS. 29 and 33 . In this regard, the PCB insertion opening  54  is preferably covered by housing section  55  to thereby prevent an inadvertent touching of energized parts such as the top mounted contact pads  12  or connecting terminal  52  when the PCB  10  is inserted into the edge connector  50  as well as the connecting terminal  52  when the PCB  10  is removed therefrom. It will also be appreciated that the curves provided to the connecting terminal  52  may function to urge the PCB  10  into engagement with the mounting surface  20 , i.e., the lower surface of the PCB insertion slot  54  would be lower than the top of the PCB  10 . Preferably, the top portion of the edge connector  50  is provided with a height to minimize the blocking of light emitted from any LEDs mounted on the PCB  10 . The insertion opening  54  may also be provided with keyed features (not shown) for the purposes described previously. 
         [0043]    While specific embodiments of the subject invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of this disclosure. For example, it is to be appreciated that features described with respect to the various embodiments are not to be limited to any particular embodiment but may be freely used across embodiments where applicable. Yet further, while discussed with respect to examples involving PCBs carrying LEDs, it will be understood that the disclosed electrical connectors could be incorporated into other electrical apparatus and systems. Still further, it will be appreciated that the size, shape, arrangement, and/or number of components illustrated and described can be changed as necessary to meet a given need. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any equivalents thereof.

Technology Category: 2