CA2347604A1 - Electrical connector capable of exerting a selectively variable contact force - Google Patents
Electrical connector capable of exerting a selectively variable contact force Download PDFInfo
- Publication number
- CA2347604A1 CA2347604A1 CA002347604A CA2347604A CA2347604A1 CA 2347604 A1 CA2347604 A1 CA 2347604A1 CA 002347604 A CA002347604 A CA 002347604A CA 2347604 A CA2347604 A CA 2347604A CA 2347604 A1 CA2347604 A1 CA 2347604A1
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- CA
- Canada
- Prior art keywords
- contact
- electrical connector
- housing
- connector
- contact beam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/10—Sockets for co-operation with pins or blades
- H01R13/11—Resilient sockets
- H01R13/112—Resilient sockets forked sockets having two legs
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/502—Bases; Cases composed of different pieces
- H01R13/506—Bases; Cases composed of different pieces assembled by snap action of the parts
Landscapes
- Details Of Connecting Devices For Male And Female Coupling (AREA)
- Coupling Device And Connection With Printed Circuit (AREA)
Abstract
An electrical connector for mating with a male contact of a mating connector is capable of exerting a selectively variable contact force. The electrical connector includes a conducing member having a lead and a contact beam electrically coupled to the lead. The contact beam is adapted to resiliently engage the male contact. The electrical connector further comprises a contact housing. At least a portion of the lead is disposed within the contact housing. At least a portion of the contact beam is disposed within the contact housing so that the contact beam is urged into and restrained by the contact housing when the contact beam resiliently engages the male contact. A contact force is thereby generated between the contact beam and the contact pin. The contact housing is capable of being selectively positioned in relation to the contact beam so that a point of restraint on the contact beam is selectively variable. The contact force between the contact beam and the male contact can thereby be varied on a selective basis.
Description
IaERG2515/C2448 PATENT
ELECTRICAL CONNECTOR CAPABLE OF EXERTING A SELECTIVELY
VARIABLE CONTACT FORCE
',Field of the Invention The present invention relates generally to electrical connectors. More particularly, the :invention relates to an electrical connector that is capable of exerting a contact force that can 'be selectively varied.
Background of the Invention Electrical connectors typically incorporate one or more conductive contacts.
The contacts are typically mated to the contacts of another connector to establish an electrical path between the connectors. For example, a common receptacle-type connector may incorporate one or more contact beams that slidably engage a male contact of a mating connector, thereby forming a conductive path between the connectors.
Mating first and second electrical contact gives rise a contact force between the respective contacts. Establishing an appropriate contact force between the contact pair is critical to the proper operation of the connectors. For example, the contact force must be large enough to ensure that the contacts tightly engage. Insufficient engagement can result in poor electrical conductivity (and high signal losses). Excessive contact force, however, can lead to several problems. For example, high contact forces can make it difficult to mate the connectors, and can damage the contacas. High contact forces can also inhibit the removal of S the male contact from the mating connector. This problem is particularly troublesome in unmating connectors that incorporate large numbers of contacts, as the contact forces ~~ssociated with each individual contact can combine to generate excessive insertion and removal forces.
Furthermore, high contact forces can produce excessive wiping action during insertion and removal of the male contact. Excc;ssive wiping action can result in premature wear of the contacts. Excessive wiping action can also erode the various coatings that are commonly applied to contacts, e.g., gold plating.
Hence, the contact force generated by a given connector pair must be considered when deciding whether the connector pair is appropriate for a particular application. For example, certain applications may require very llow signal losses. A connector pair that generates a relatively large contact force may be appropriate for such applications, particularly where lFrequent insertion and removal of the male contact is not anticipated.
Conversely, a connector pair that generates a relatively low contact force may be appropriate where frequent iinsertion and removal of the male contact will occur, and where minimal signal losses are not ~~n absolute necessity.
Conventional connectors produce a fixed, i.e., non-variable, contact force.
Hence, .different types of connectors must be utilized in applications that require different contact forces. A connector manufacturer must therefore produce a different type of connector for each application that requires a differc;nt contact force. This is true even where all of the other requirements for the connector acre identical, e.g., overall size, number and type of individual contacts, etc.
The above discussion illustrates the current need for a connector that is capable of exerting a contact force that can be varied among different values. Such a connector could be used in a variety of different applications that each require different amounts of contact force, thereby eliminating the need to produce different types of connectors for each of the various applications.
Utilizing a single connector configuration in a variety of different applications can lead to potentially significant cost savings. For example, manufacturing costs can be lowered by reducing the number of different hardware configurations that need to be produced for a given number of applications. Savings in inventory, packaging, and marketing-related c;xpenses can also be realized by using; a single type of connector in place of multiple connector types. Also, the use of a connector that is capable of exerting a variable contact iEorce can allow the contact force to be more closely tailored to an optimal value than may otherwise be possible.
;Summary of the Invention An object of the present invention is to provide an electrical connector that is capable ~of exerting a contact force that can be selectively varied. In accordance with this object, a ;presently-preferred embodiment of the invention provides an electrical connector for mating with a male contact of a mating connector. The connector module comprises a conducting member including a lead and a contact beam electrically coupled to the lead.
The contact beam is adapted to resiliently engage the male contact. The connector module further comprises a contact housing. At least: a portion of the lead is disposed within the contact housing. At least a portion of the contact beam is disposed within the contact housing so that the contact beam is urged into and restxained by the contact housing when the contact beam resiliently engages the male contact. A contact force is thereby generated between the contact beam and the contact pin.
The contact housing in one particular preferred embodiment is capable of being selectively positioned in relation to tree contact beam so that a point of restraint on the contact beam is selectively variable. The contact force between the contact beam and the male contact can thereby be varied on a selective basis.
Further in accordance with the above-noted object, another presently-preferred embodiment of the invention provides an electrical connector for mating with a male contact of a mating connector. The electrical) connector comprises a conducting element having a lead. The conducting element also includes a contact beam having a first end that is fixedly coupled to the lead. The contact beam also has a second free-standing end for resiliently q HERG-2515/C2448 -4- PATENT
engaging the male contact so that the contact beam deflects when the contact beam engages tike male contact.
The electrical connector further comprises a housing that is adapted to inhibit the dleflection of the contact beam by restraining the contact beam at a point of restraint located between the first and the second ends of the contact beam, whereby a contact force is generated between the contact beam and the male contact and the contact force is dependent upon the location of the point of restraint on the contact beam.
A further object of the present :invention is to provide a method of adjusting a spring rate of a contact in an electrical connector. In accordance with this object, a presently-yreferred method of adjusting a spring rate of a contact in an electrical connector before the connector engages a mating connector comprises the step of providing an electrical connector with a housing and a deflectable contact, the housing being positionable relative to the contact at a plurality of positions. The: preferred method further comprises the step of positioning the housing at a predetermined one of the plurality of positions, wherein the predetermined position of the housing determines the spring rate of the contact.
A further object of the present invention is to provide a kit for making an electrical connector. In accordance with this object, a presently-preferred embodiment of the invention provides a kit for making an electrical connector having a contact with a predetermined spring rate. The kit comprises a plurality of housings and a deflectable contact mountable to ~~ny one of the plurality of housings to form an electrical connector, wherein the housings can engage the contact to provide a predetermined spring rate to the contact, and each one of the :housings provides a different predetermined spring rate.
Brief Description of the Drawings The foregoing summary, as well as the following detailed description of a presently-preferred embodiment, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, the drawings show an embodiment that is presently preferred. The invention is not limited, however, to the specific instrumentalities disclosed in the drawings. In the drawings:
_ _..... _ Fig. 1 is a side view of an electrical connector in accordance with the present invention;
~tERG2515/C2448 -5- PATENT
Fig. 2 is an exploded perspective view of a connector module of the electrical connector shown in Fig.l;
Fig. 3 is another exploded perspective view of the connector module shown in Fig. 2;
Fig. 4 is a top perspective view of a contact portion of the connector module shown in Figs. 2 and 3;
Fig. 5 is a top perspective view of a forward portion of a contact housing of the connector module shown in Figs. 2 and 3;
Fig. 6A is a forward-side view of the contact housing shown in Fig. 5 located in a rearward position on the electrical connector shown in Fig. 1;
Fig. 6B is a forward-side view of the contact housing shown in Figs. 5 and 6A
v~rith the contact housing located in an intermediate position on the electrical connector shown in Fig. l;
Fig. 6C is a forward-side view of the contact housing shown in Figs. 5, 6A, 1 S and 6B with the contact housing located in a forward position on the electrical connector shown in Fig. 1;
Fig. 7A is a side view of the contact portion shown in Fig. 4 and a cam surface of the contact housing shown in Figs. _'> and 6A-6C, with the contact housing positioned as depicted in Fig. 6A;
Fig. 7F is a side view of the contact portion shown in Figs. 4 and 7A and a cam surface of the contact housing shown in Figs. 5 and 6A-6C, with the contact housing positioned as depicted in Fig. 6B;
Fig. 7C is a side view of the contact portion shown in Figs. 4, 7A, and 7B and a~ cam surface of the contact housing shown in Figs. 5 and 6A-6C, with the contact housing ~ positioned as depicted in Fig. 6C;
Fig. 8 is a side view of the contact portion shown in Figs. 5 and 7A- 7C
engaging a male contact;
Fig. 9 is a top perspective view of an alternative embodiment of the electrical connector shown in Figure 1;
_ _ _-.- - _ Fig. l0A is rear perspective view of an outer contact housing of another alternative embodiment of the electrical connector shown in Figure 1;
)BtERG2515/C2448 -6- PATENT
Fig. l OB is a side view of the outer contact housing shown in Fig. 10A;
Fig. 11 A is a side view of the outer contact housing shown in Figs. l0A and l OB about to engage a contact housing.;
Fig. 11B is a side view of the outer contact housing shown in Figs. 10A, 10B, and 11 A partially engaging the contact housing shown Fig. 11 A; and Fig. 11 C is a side view of the outer contact housing shown in Figs. 10A, l OB, 11 A, and 11 B fully engaging the contact housing shown in Figs. 11 A and 11 B.
Tlescription of Preferred Embodiments A presently-preferred embodiment of the invention is illustrated in Figures 1 through 8. The figures are each referenced to a. common coordinate system 10 shown in each illustration. The invention provides an electrical connector 11 formed by a plurality of connector modules 12. The electrical connector 11 is adapted to mate with one or more male contacts of a mating connector. The electrical connector 11 also comprises an electrically insulative main housing 13. The connector modules 12 are at least partially disposed within the main housing 13, as explained in detail below.
Each of the connector modules 12 comprises a contact housing 15, an overmold 18, a 1>lurality of conducting members 20, and a ground assembly 22 (see Figures 2 and 3). The conducting member 20 is formed fromi an electrically-conductive material. The conducting member 20 comprises a contact portion 24 (see Figure 4). The contact portion 24 includes a ride contact beam 24a, a lower contact beam 24b, and a rearward portion 24c.
Preferably, the contact beam 24a, the lower contact beam 24b, and the rearward portion 24c are unitarily formed. The rearward portion 24c ha;. a substantially L-shaped cross section.
The contact beams 24a and 24b extend from the rearward portion 24c, and are disposed in substantially parallel orientations.
The side contact beam 24a includes a contact tab 24d (see Figure 4). The lower .contact beam 24b likewise includes a contact tab 24e. The contact tabs 24d and 24e form the forward ends of the respective contact: beams 24a and 24b. (The "forward" and "rearward"
directions correspond respectively to the y+ and y directions denoted on the coordinate .,.._. -system 10.) A cam surface 24f is formed on an upper edge 24g of the rearward portion 24c.
E~ cam surface 24h is likewise formed on a side edge 24i of the rearward portion 24c. The significance of the cam surfaces 24h and 24j is discussed below.
The contact member 20 further comprises a signal lead 26 and a contact pin 28 (see Figures 2 and 3). A first end of the signal lead 26 is mechanically coupled to the contact pin 2;8. An opposing second end of the signal lead 26 is mechanically coupled to the rearward portion 24c of the contact portion 24. This arrangement forms an electrical path between the contact pin 28 and the contact portion 24. Each signal lead 26 includes one or more bends that cause the contact portions 24 and the contact pins 28 to extend in substantially perpendicular directions.
The ground assembly 22 is fonned from an electrically-conductive material. The l;round assembly 22 includes a plurality of ground leads 30 (see Figures 2 and 3). Each l;round lead 30 adjoins one or more adjacent ground leads 30. A first end of each ground lead :30 is mechanically coupled to a contact pin 32. An opposing second end of each ground lead :30 is mechanically coupled to a first ground contact 34a and a second ground contact 34b.
'Chis arrangement electrically couples the contact pin 32 and the ground contacts 34a and 34b.
Mach ground leads 30 includes one or more bends that cause the ground contacts 34a and 34b lie substantially perpendicular to the contact pins 32.
The overmold 18 is formed from an electrically insulative material such as plastic.
'The overmold 18 has a forward face 18a and a lower face 18b (see Figures 2 and 3). 'The :forward face 18a and the lower face 18b are disposed in substantially perpendicular orientations. The overmold 18 is molded around the signal leads 26 of the contact member :20. More particularly, the overmold 18 partially encloses the signal leads 26 so that a portion ~of each signal lead 26 and the corresponding contact portion 24 extend away from the forward face 18a and the contact pins 28 extend away from the lower face 18b.
The overmold 18 includes a plurality of grooves 18c (see Figure 3). The grooves 18c extend between the forward face 18a .and the lower face 18b. Each ground lead 30 of the ground assembly 22 is partially disposed within a corresponding groove 18c. A
portion of each ground lead 30 and the corresponding ground contacts 34a and 34b extend away from the forward face 18a of the overmold 18 when the ground leads 30 are partially disposed _.,.". _ within the grooves 18c. In addition, the contact pins 32 of the ground assembly 22 extend away from the lower face 18b of the overmold 18 when the ground leads 30 are so disposed.
~tERG2515/C2448 -8- PATENT
Each overmold 18 can accommodate six conducting members 20 and six ground assemblies 22. Alternative embodiments of the overmolds 18 may accommodate any desired number of conducting members 20 andl ground assemblies 22. The contact portions 24 of the conducting members 20 in each connector module 12 are substantially vertically aligned (see Figures 2, 3 and 6A-6C). The contacts 34a and 34b of the ground assemblies 22 in each connector module 12 are likewise substantially vertically aligned. The connector module 12 is shown in a single-ended arrangement. Alterative embodiments of the connector module 12 nnay comprise two columns of ground contacts 34a, 34b and two columns of contact portions 2;4 for a differential-pair arrangement.
The exemplary electrical connector 11 includes thirteen of the connector modules 12 disposed in a side-by-side arrangement. In other words, the connector modules 12 are positioned so that the forward faces 18a of the overmolds 18 are substantially co-planar, and the lower faces 18a of the overmolds 18 are also substantially co-planar. The modules 12 are then inserted into the larger main housing 13 to fonm the electrical connector 11. The main housing 13 of the exemplary embodirr~ent encloses a portion of the connector modules 12. In particular, the main housing 13 does not enclose the portions of the connector modules 12 l:orward of the ovenmolds 18 (see Figure 1 ). The remaining portions of the connector modules 12 are substantially enclosed by the main housing 13. Alternative embodiments of the main housing 13 may be sized so that the main housing 13 encloses a substantial entirety of the connector modules 12. Further variants of the main housing 13 are discussed in detail 'below.
Structural details relating to the contact housing 15 are as follows. Figures 1, 3 and 6A-6C show the contact housing 1 S installed on the connector module 12. The contact housing 15 is also depicted in Figure 2.
A plurality of passages 38 are formed within the contact housing 15 (see Figures 2, 3, and 6A-6C). Figure 5 is a detailed diagrammatical illustration showing one of the passages 38. Each passage 38 is defined by a top wall 38a, an opposing bottom wall 38b, a first side wall 38c, and a second side wall 38d that opposes the first side wall 38c. A
cam surface 38e is fonmed on the bottom wall 38b (see Figure 5). The significance of this feature is discussed in detail below. Each passage 38 extends between (and through) a forward edge 15a and a rearward edge 1 Sb of the contact housing 15. The passages 38 are arranged so that the vertical spacing between the individual passages 38 substantially matches the vertical spacing t>etween the contact portions 24 of the contact members 20. The function of the passages 38 is explained below.
The contact housing 15 defines a plurality of troughs 39 (see Figures 2, 3, and 6A-fiC). The troughs 39 are positioned between the passages 38. Each trough 39 extends between (and through) the forward anti rearward edges 15a and 15b of the contact housing l~ 5. The function of the troughs 39 is discussed in detail below.
The contact housing 15 engages the contact portions 24 of the conducting member 20.
l:n accordance with the present invention, the contact housing 15 can be variably positioned in relation to the contact beams 24a and 24b. This feature permits the contact force between each lower contact beam 24b and a corresponding male contact of a mating connector to be ;selectively varied, as explained in det<~il below.
The contact housing 15 is engaged with the contact portions 24 by aligning each of the passages 38 with one of the contact portions 24 of the conducting members 20. An insertion force is subsequently applied to the contact housing in the rearward (y) direction.
The insertion force causes the contact portions 24 to become disposed within the passages 38.
In addition, the ground contacts 34a and 34b become disposed within the troughs 39.
The passages 38 are sized so that the cam surface 24f of each side contact beam 24a slidably engages the top wall 38a of a. respective passage 38 as the contact housing 15 is mated to the contact portions 24. In addition, the cam surface 24h of each lower contact beam 24b slidably engages the side wall 38c of a respective passage 38 as the contact housing 15 is mated to the contact portions 24. Frictional forces between the cam surfaces 24g and 24h and the respective passage walls 38a and 38c cause the contact housing 15 to remain in position once the insertion force is removed. Alternatively, the passages 38 may be equipped with detents that engage the cam surfaces and thereby lock the contact housing into one of a limited number of possible positions.
The cam surface 38e on the bottom wall 38b of each passage 38 slidably engages a corresponding lower contact beam 24b as the contact housing 1 S is mated to the contact portions 24. More particularly, each cam surface 38e slidably engages a lower surface 24j of .,_. -the corresponding lower contact beam 24b (see Figures 7A-7C and 8).
>EtERG-2515/C2448 -10. PATENT
The cam surface 38e contacts the lower surface 24j at a point of contact 43.
The point o~f contact 43 is dependent upon the relative positions of the contact housing 15 and the contact portions 24. For example, the contact housing 15 can be placed in a forward position as shown in Figure 6C. Positioning the contact housing 15 in this manner causes the point of contact 43 to be located at its forward-most position along the lower contact beam 24b, as shown in Figure 7C. In other words, the point of contact 43 is located in relatively close proximity to the contact tab 24e of the lower contact beam 24 when the contact housing 1 S is placed in its forward position.
The contact housing 15 can also be placed in an intermediate position as shown in Figure 6B. Moving the contact housing 15 from its forward position to an intermediate position increases the distance between the point of contact 43 and the contact tab 24e, as shown in Figure 7B. The contact housing 15 can also be placed in a rearward position (see Figure 6A). Positioning the contact housing 15 in this manner causes the point of contact 43 t~ be located at its rearward-most position along the lower contact beam 24b, as shown in Figure 7A. In other words, the point of contact 43 is located at its farthest position from the contact tab 24e when the contact housing 1 S is placed in its rearward position. The significance of variably positioning the point of contact 43 in this manner is explained in detail below.
The contact portions 24 of the contact members 20 are adapted to engage a male contact of a mating connector, as noted previously. Figure 8 depicts one of the contact portions 24 mated to a male contact 40 of a mating connector. The contact portion 24 and the male contact 40 are mated by sliding the male contact 40 rearward, in the direction denoted by the arrow 46 in Figure 8. The rearward movement of the male contact 40 causes the contact tab 24e (and the adjacent portion of the lower contact beam 24b) to deflect downward, in the direction denoted by the arrow 48.
The deflection of the lower contact beam 24b is restrained by the cam surface 38e on l:he bottom wall 38b of the passage 38. The restraining effect of the cam surface 38e, in conjunction with the resilience of the lower contact beam 24b, causes a contact force to develop between the male contact 40 and the lower contact beam 24b (this force is commonly referred to as the "spring rate" of the contact 40). A contact force also develops between the :male contact 40 and the side contact beam 24a. A detailed discussion of this contact force is not necessary to an understanding of the invention. Hence, the contact force between the side contact beam 24a and the male contact 40 will not be discussed in detail.
The contact force between the lower contact beam 24b and the male contact 40 is dependent upon the location of the point of contact 43 between the lower contact beam 24b and the cam surface 38. More particularly, the downward deflection of the lower contact beam 24b, in conjunction with the restraining effect of the cam surface 38e, causes the contact tab 24e to pivot about the cam surface 38e (and the point of contact 43). The resistance of the contact beam 24b to such rotation is inversely proportional to the moment arm between the location of the applied force (the contact tab 24e) and the point of rotation I',the point of contact 43). Hence, the resistance of the contact beam 24b (and the resulting contact force between the male contact 40 and the lower contact beam 24b) can be varied by ;altering the distance between the contact tab 24e and the point of contact 43. In other words, 'the effective beam length of the lower contact beam 24b can be altered by varying the location of the point of contact 43.
The distance between the contact tab 24e and the point of contact 43 can be varied through the selective placement of the; contact housing 1 S, as explained above. For example, placing the contact housing 15 in its fbrward position minimizes the distance between the contact tab 24e and the point of contact 43 (see Figures 6C and 7C). Thus, the length of the moment arm between the contact tab 24e and the point of contact 43 is at a minimum when the contact housing 15 is so positioned. The relatively small moment arm causes the lower contact beam 24b to exert a relatively large amount of resistance when the contact tab 24e is deflected downward by the male contact 40. Hence, the contact force between the lower contact beam 24b and the male contact 40 is relatively high when the contact housing 15 is located in its forward position.
Conversely, placing the contact housing 15 in its rearward position maximizes the distance between the contact tab 24e and the point of contact 43, and thereby maximizes the length of the moment arm between the contact tab 24e and the point of contact 43 (see Figures 6A and 7A). The relatively large moment arm causes the contact tab 24e to rotate about the point of contact 43 with a relatively low amount of resistance_when the contact tab 24e is deflected downward by the male contact 40. 'Thus, the contact force between the contact beams 24 and the male contact 40 is relatively low when the contact housing 15 is positioned in this manner. Placing the contact housing 15 in an intermediate position causes the length of the moment arm to lie between its maximum and minimum values.
Hence, the contact force lies between its maximum and minimum values when the contact housing 15 is located in an intermediate position. The contact housing 15 remains at a fixed position relative to the contact 24 once the connector is assembled, thereby producing a uniform spring rate. In other words, the spring rate does not vary after the connector is assembled.
The invention thus permits the contact force between an array of male contacts such ~~s the contacts 40 and an electrical cormector such as the electrical connector 11 to be varied within a range of values using a common hardware configuration. This feature permits a :jingle type of electrical connector to be used in various applications that each require a different amount of contact force. Utilizing a common electrical connector in a variety of different applications offers substantial benefits. For example, the use of a common electrical connector reduces the number of different components that the connector manufacturer must produce. Such reductions can lead to substantially lower production costs.
1 S In addition, inventory-related c;xpenses to both the manufacturer and the user of the common electrical connector can be lowered by reducing the number of different types of connector modules that need to be tracked and stored prior to use. Also, the costs associated with packaging and marketing a multitude of different connector types can be lowered by the use of the common electrical connector.
Furthermore, the ability to vary the contact force of the electrical connector can allow the contact force to be more closely tailored to a desired value than may otherwise be feasible. More particularly, an electrical connector that produces a desired amount of contact force may be unavailable for a particular application, thereby necessitating the use of an electrical connector that produces a less-than-optimal amount of contact force. The use of an electrical connector such as the connector 11 permits the contact force to be set within a range of values, as noted above. This feature provides the user of the electrical connector with greater flexibility in choosing the actual contact force, and thereby increases the potential for the contact force to be set at or near ita optimal value.
It is to be understood that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of the parts, within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims aJ-e expressed.
For example, the contact force between the side contact beam 24a and the .corresponding male contact 40 is not variable in the exemplary electrical connector 11.
Alternative embodiments of the invention may incorporate features that permit the contact force between the side contact beam 2;4a and the male contact 40 to be varied.
Another possible variant of the invention forgoes the use of the contact housings 1 S.
The contact force between the contact: beams 24a and 24b and the respective male contacts 40 of this embodiment is determined by 'the overall length (x dimension) of each overmold 18.
More particularly, each overmold 18 is formed in a manner that causes the contact beams 24a and 24b to extend through the forward face 18a, i.e., the forward face 18a is formed around the rearward portions of the contact beams 24a and 24b. The forward face 18a thereby restrains the contact beams 24a and 24b when the contact beams 24a and 24b are deflected by the respective male contacts 40. The length of the overmold 18 determines the location of the forward face 18a in relation to the contact beams 24a and 24b. Hence, the length of the overmold 18 determines the points of restraint of the contact beams 24a and 24b and, thus, the respective contact forces between. the contact beams 24a and 24b and the male contacts 40.
Figure 9 shows another possible variant of the present invention. Figure 9 depicts an electrical connector l la having a main housing 13a a fixed outer contact housing 49. The electrical connector 11 a is otherwise substantially identical to the electrical connector 11.
Structure on the electrical connector 11 a that is substantially identical to corresponding structure on the electrical connector 11 is described herein using like reference numerals.
The fixed outer contact housing 49 is positioned over the contact housings 1 S
and the contact portions 24 of the conducting members 20 after the contact housings 1 S have been placed in their desired positions relative to the contact portions 24. The outer contact housing 49 is fixed to the main housing 13a by way of an interlocking latch 13b on the main housing 13a _that engages a projection 49a on the outer contact housing 49.
Penetrations 49b are formed in a forward edge 49c of the fixed outer contact housing 49 to facilitate access to the contact portions 24 by the male conl:acts 40.
A further alternative embodiment is shown in Figures l0A through 11C. Figures l0A
~;hrough 11C depict a portion of an electrical connector l lb having a movable outer contact housing 50 and contact housings 15c. Each contact housing 1 Sc includes a fin 15d located along an upper surface of the contact lousing 15c (see Figures 11A-11C). The electrical connector l lc is otherwise substantially identical to the electrical connector 11. Structure on l:he electrical connector 11 c that is substantially identical to corresponding structure on the electrical connector 11 is described herein using like reference numerals.
The movable outer contact housing SO is adapted to enclose the contact housings 1 Sc.
'The outer contact housing 50 is selectively positionable along with the contact housings 15c.
'The outer contact housing SO is placed over the contact housings 15c by sliding the outer contact housing 50 in a rearward direction over the contact housings 15c (the rearward direction is denoted by an arrow 52 shown in Figures 1 lA and 11B). Grooves SOa defined by .an upper inner surface SOb of the outer contact housing 50 slidably engage the fins 15d on the .contact housings 15c as the housing 50 is slid rearward.
The rearward movement of the outer contact housing SO eventually causes a forward .edge 15e of each fin 15d to abut a forward edge SOc of the corresponding groove SOa (see Figure 11 C). Continued rearward movement of the housing 50 causes the outer contact housing SO to drive the contact housings lSc rearward, thereby exposing the contact portions 24 of the conducting members 20. The relative positions of the contact housings 15c and the contact portions 24 can thereby be adjusted by way of selecting the lengths of the grooves SOa in the outer contact housing 50. Hence, the contact farce between the contact beams 24b of the contact portions 24 and the male contacts 40 of a mating connector can be controlled by way of the outer contact housing S0.
A projection (not shown) on the outer contact cover 50 can engage latches on the main housing 13 to retain the contact housings 15c together, as in the previously-described embodiment. Penetrations SOd are formed in a forward edge SOe of the outer contact housing 50 to facilitate access to the contact portions 24 by the male contacts 40.
ELECTRICAL CONNECTOR CAPABLE OF EXERTING A SELECTIVELY
VARIABLE CONTACT FORCE
',Field of the Invention The present invention relates generally to electrical connectors. More particularly, the :invention relates to an electrical connector that is capable of exerting a contact force that can 'be selectively varied.
Background of the Invention Electrical connectors typically incorporate one or more conductive contacts.
The contacts are typically mated to the contacts of another connector to establish an electrical path between the connectors. For example, a common receptacle-type connector may incorporate one or more contact beams that slidably engage a male contact of a mating connector, thereby forming a conductive path between the connectors.
Mating first and second electrical contact gives rise a contact force between the respective contacts. Establishing an appropriate contact force between the contact pair is critical to the proper operation of the connectors. For example, the contact force must be large enough to ensure that the contacts tightly engage. Insufficient engagement can result in poor electrical conductivity (and high signal losses). Excessive contact force, however, can lead to several problems. For example, high contact forces can make it difficult to mate the connectors, and can damage the contacas. High contact forces can also inhibit the removal of S the male contact from the mating connector. This problem is particularly troublesome in unmating connectors that incorporate large numbers of contacts, as the contact forces ~~ssociated with each individual contact can combine to generate excessive insertion and removal forces.
Furthermore, high contact forces can produce excessive wiping action during insertion and removal of the male contact. Excc;ssive wiping action can result in premature wear of the contacts. Excessive wiping action can also erode the various coatings that are commonly applied to contacts, e.g., gold plating.
Hence, the contact force generated by a given connector pair must be considered when deciding whether the connector pair is appropriate for a particular application. For example, certain applications may require very llow signal losses. A connector pair that generates a relatively large contact force may be appropriate for such applications, particularly where lFrequent insertion and removal of the male contact is not anticipated.
Conversely, a connector pair that generates a relatively low contact force may be appropriate where frequent iinsertion and removal of the male contact will occur, and where minimal signal losses are not ~~n absolute necessity.
Conventional connectors produce a fixed, i.e., non-variable, contact force.
Hence, .different types of connectors must be utilized in applications that require different contact forces. A connector manufacturer must therefore produce a different type of connector for each application that requires a differc;nt contact force. This is true even where all of the other requirements for the connector acre identical, e.g., overall size, number and type of individual contacts, etc.
The above discussion illustrates the current need for a connector that is capable of exerting a contact force that can be varied among different values. Such a connector could be used in a variety of different applications that each require different amounts of contact force, thereby eliminating the need to produce different types of connectors for each of the various applications.
Utilizing a single connector configuration in a variety of different applications can lead to potentially significant cost savings. For example, manufacturing costs can be lowered by reducing the number of different hardware configurations that need to be produced for a given number of applications. Savings in inventory, packaging, and marketing-related c;xpenses can also be realized by using; a single type of connector in place of multiple connector types. Also, the use of a connector that is capable of exerting a variable contact iEorce can allow the contact force to be more closely tailored to an optimal value than may otherwise be possible.
;Summary of the Invention An object of the present invention is to provide an electrical connector that is capable ~of exerting a contact force that can be selectively varied. In accordance with this object, a ;presently-preferred embodiment of the invention provides an electrical connector for mating with a male contact of a mating connector. The connector module comprises a conducting member including a lead and a contact beam electrically coupled to the lead.
The contact beam is adapted to resiliently engage the male contact. The connector module further comprises a contact housing. At least: a portion of the lead is disposed within the contact housing. At least a portion of the contact beam is disposed within the contact housing so that the contact beam is urged into and restxained by the contact housing when the contact beam resiliently engages the male contact. A contact force is thereby generated between the contact beam and the contact pin.
The contact housing in one particular preferred embodiment is capable of being selectively positioned in relation to tree contact beam so that a point of restraint on the contact beam is selectively variable. The contact force between the contact beam and the male contact can thereby be varied on a selective basis.
Further in accordance with the above-noted object, another presently-preferred embodiment of the invention provides an electrical connector for mating with a male contact of a mating connector. The electrical) connector comprises a conducting element having a lead. The conducting element also includes a contact beam having a first end that is fixedly coupled to the lead. The contact beam also has a second free-standing end for resiliently q HERG-2515/C2448 -4- PATENT
engaging the male contact so that the contact beam deflects when the contact beam engages tike male contact.
The electrical connector further comprises a housing that is adapted to inhibit the dleflection of the contact beam by restraining the contact beam at a point of restraint located between the first and the second ends of the contact beam, whereby a contact force is generated between the contact beam and the male contact and the contact force is dependent upon the location of the point of restraint on the contact beam.
A further object of the present :invention is to provide a method of adjusting a spring rate of a contact in an electrical connector. In accordance with this object, a presently-yreferred method of adjusting a spring rate of a contact in an electrical connector before the connector engages a mating connector comprises the step of providing an electrical connector with a housing and a deflectable contact, the housing being positionable relative to the contact at a plurality of positions. The: preferred method further comprises the step of positioning the housing at a predetermined one of the plurality of positions, wherein the predetermined position of the housing determines the spring rate of the contact.
A further object of the present invention is to provide a kit for making an electrical connector. In accordance with this object, a presently-preferred embodiment of the invention provides a kit for making an electrical connector having a contact with a predetermined spring rate. The kit comprises a plurality of housings and a deflectable contact mountable to ~~ny one of the plurality of housings to form an electrical connector, wherein the housings can engage the contact to provide a predetermined spring rate to the contact, and each one of the :housings provides a different predetermined spring rate.
Brief Description of the Drawings The foregoing summary, as well as the following detailed description of a presently-preferred embodiment, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, the drawings show an embodiment that is presently preferred. The invention is not limited, however, to the specific instrumentalities disclosed in the drawings. In the drawings:
_ _..... _ Fig. 1 is a side view of an electrical connector in accordance with the present invention;
~tERG2515/C2448 -5- PATENT
Fig. 2 is an exploded perspective view of a connector module of the electrical connector shown in Fig.l;
Fig. 3 is another exploded perspective view of the connector module shown in Fig. 2;
Fig. 4 is a top perspective view of a contact portion of the connector module shown in Figs. 2 and 3;
Fig. 5 is a top perspective view of a forward portion of a contact housing of the connector module shown in Figs. 2 and 3;
Fig. 6A is a forward-side view of the contact housing shown in Fig. 5 located in a rearward position on the electrical connector shown in Fig. 1;
Fig. 6B is a forward-side view of the contact housing shown in Figs. 5 and 6A
v~rith the contact housing located in an intermediate position on the electrical connector shown in Fig. l;
Fig. 6C is a forward-side view of the contact housing shown in Figs. 5, 6A, 1 S and 6B with the contact housing located in a forward position on the electrical connector shown in Fig. 1;
Fig. 7A is a side view of the contact portion shown in Fig. 4 and a cam surface of the contact housing shown in Figs. _'> and 6A-6C, with the contact housing positioned as depicted in Fig. 6A;
Fig. 7F is a side view of the contact portion shown in Figs. 4 and 7A and a cam surface of the contact housing shown in Figs. 5 and 6A-6C, with the contact housing positioned as depicted in Fig. 6B;
Fig. 7C is a side view of the contact portion shown in Figs. 4, 7A, and 7B and a~ cam surface of the contact housing shown in Figs. 5 and 6A-6C, with the contact housing ~ positioned as depicted in Fig. 6C;
Fig. 8 is a side view of the contact portion shown in Figs. 5 and 7A- 7C
engaging a male contact;
Fig. 9 is a top perspective view of an alternative embodiment of the electrical connector shown in Figure 1;
_ _ _-.- - _ Fig. l0A is rear perspective view of an outer contact housing of another alternative embodiment of the electrical connector shown in Figure 1;
)BtERG2515/C2448 -6- PATENT
Fig. l OB is a side view of the outer contact housing shown in Fig. 10A;
Fig. 11 A is a side view of the outer contact housing shown in Figs. l0A and l OB about to engage a contact housing.;
Fig. 11B is a side view of the outer contact housing shown in Figs. 10A, 10B, and 11 A partially engaging the contact housing shown Fig. 11 A; and Fig. 11 C is a side view of the outer contact housing shown in Figs. 10A, l OB, 11 A, and 11 B fully engaging the contact housing shown in Figs. 11 A and 11 B.
Tlescription of Preferred Embodiments A presently-preferred embodiment of the invention is illustrated in Figures 1 through 8. The figures are each referenced to a. common coordinate system 10 shown in each illustration. The invention provides an electrical connector 11 formed by a plurality of connector modules 12. The electrical connector 11 is adapted to mate with one or more male contacts of a mating connector. The electrical connector 11 also comprises an electrically insulative main housing 13. The connector modules 12 are at least partially disposed within the main housing 13, as explained in detail below.
Each of the connector modules 12 comprises a contact housing 15, an overmold 18, a 1>lurality of conducting members 20, and a ground assembly 22 (see Figures 2 and 3). The conducting member 20 is formed fromi an electrically-conductive material. The conducting member 20 comprises a contact portion 24 (see Figure 4). The contact portion 24 includes a ride contact beam 24a, a lower contact beam 24b, and a rearward portion 24c.
Preferably, the contact beam 24a, the lower contact beam 24b, and the rearward portion 24c are unitarily formed. The rearward portion 24c ha;. a substantially L-shaped cross section.
The contact beams 24a and 24b extend from the rearward portion 24c, and are disposed in substantially parallel orientations.
The side contact beam 24a includes a contact tab 24d (see Figure 4). The lower .contact beam 24b likewise includes a contact tab 24e. The contact tabs 24d and 24e form the forward ends of the respective contact: beams 24a and 24b. (The "forward" and "rearward"
directions correspond respectively to the y+ and y directions denoted on the coordinate .,.._. -system 10.) A cam surface 24f is formed on an upper edge 24g of the rearward portion 24c.
E~ cam surface 24h is likewise formed on a side edge 24i of the rearward portion 24c. The significance of the cam surfaces 24h and 24j is discussed below.
The contact member 20 further comprises a signal lead 26 and a contact pin 28 (see Figures 2 and 3). A first end of the signal lead 26 is mechanically coupled to the contact pin 2;8. An opposing second end of the signal lead 26 is mechanically coupled to the rearward portion 24c of the contact portion 24. This arrangement forms an electrical path between the contact pin 28 and the contact portion 24. Each signal lead 26 includes one or more bends that cause the contact portions 24 and the contact pins 28 to extend in substantially perpendicular directions.
The ground assembly 22 is fonned from an electrically-conductive material. The l;round assembly 22 includes a plurality of ground leads 30 (see Figures 2 and 3). Each l;round lead 30 adjoins one or more adjacent ground leads 30. A first end of each ground lead :30 is mechanically coupled to a contact pin 32. An opposing second end of each ground lead :30 is mechanically coupled to a first ground contact 34a and a second ground contact 34b.
'Chis arrangement electrically couples the contact pin 32 and the ground contacts 34a and 34b.
Mach ground leads 30 includes one or more bends that cause the ground contacts 34a and 34b lie substantially perpendicular to the contact pins 32.
The overmold 18 is formed from an electrically insulative material such as plastic.
'The overmold 18 has a forward face 18a and a lower face 18b (see Figures 2 and 3). 'The :forward face 18a and the lower face 18b are disposed in substantially perpendicular orientations. The overmold 18 is molded around the signal leads 26 of the contact member :20. More particularly, the overmold 18 partially encloses the signal leads 26 so that a portion ~of each signal lead 26 and the corresponding contact portion 24 extend away from the forward face 18a and the contact pins 28 extend away from the lower face 18b.
The overmold 18 includes a plurality of grooves 18c (see Figure 3). The grooves 18c extend between the forward face 18a .and the lower face 18b. Each ground lead 30 of the ground assembly 22 is partially disposed within a corresponding groove 18c. A
portion of each ground lead 30 and the corresponding ground contacts 34a and 34b extend away from the forward face 18a of the overmold 18 when the ground leads 30 are partially disposed _.,.". _ within the grooves 18c. In addition, the contact pins 32 of the ground assembly 22 extend away from the lower face 18b of the overmold 18 when the ground leads 30 are so disposed.
~tERG2515/C2448 -8- PATENT
Each overmold 18 can accommodate six conducting members 20 and six ground assemblies 22. Alternative embodiments of the overmolds 18 may accommodate any desired number of conducting members 20 andl ground assemblies 22. The contact portions 24 of the conducting members 20 in each connector module 12 are substantially vertically aligned (see Figures 2, 3 and 6A-6C). The contacts 34a and 34b of the ground assemblies 22 in each connector module 12 are likewise substantially vertically aligned. The connector module 12 is shown in a single-ended arrangement. Alterative embodiments of the connector module 12 nnay comprise two columns of ground contacts 34a, 34b and two columns of contact portions 2;4 for a differential-pair arrangement.
The exemplary electrical connector 11 includes thirteen of the connector modules 12 disposed in a side-by-side arrangement. In other words, the connector modules 12 are positioned so that the forward faces 18a of the overmolds 18 are substantially co-planar, and the lower faces 18a of the overmolds 18 are also substantially co-planar. The modules 12 are then inserted into the larger main housing 13 to fonm the electrical connector 11. The main housing 13 of the exemplary embodirr~ent encloses a portion of the connector modules 12. In particular, the main housing 13 does not enclose the portions of the connector modules 12 l:orward of the ovenmolds 18 (see Figure 1 ). The remaining portions of the connector modules 12 are substantially enclosed by the main housing 13. Alternative embodiments of the main housing 13 may be sized so that the main housing 13 encloses a substantial entirety of the connector modules 12. Further variants of the main housing 13 are discussed in detail 'below.
Structural details relating to the contact housing 15 are as follows. Figures 1, 3 and 6A-6C show the contact housing 1 S installed on the connector module 12. The contact housing 15 is also depicted in Figure 2.
A plurality of passages 38 are formed within the contact housing 15 (see Figures 2, 3, and 6A-6C). Figure 5 is a detailed diagrammatical illustration showing one of the passages 38. Each passage 38 is defined by a top wall 38a, an opposing bottom wall 38b, a first side wall 38c, and a second side wall 38d that opposes the first side wall 38c. A
cam surface 38e is fonmed on the bottom wall 38b (see Figure 5). The significance of this feature is discussed in detail below. Each passage 38 extends between (and through) a forward edge 15a and a rearward edge 1 Sb of the contact housing 15. The passages 38 are arranged so that the vertical spacing between the individual passages 38 substantially matches the vertical spacing t>etween the contact portions 24 of the contact members 20. The function of the passages 38 is explained below.
The contact housing 15 defines a plurality of troughs 39 (see Figures 2, 3, and 6A-fiC). The troughs 39 are positioned between the passages 38. Each trough 39 extends between (and through) the forward anti rearward edges 15a and 15b of the contact housing l~ 5. The function of the troughs 39 is discussed in detail below.
The contact housing 15 engages the contact portions 24 of the conducting member 20.
l:n accordance with the present invention, the contact housing 15 can be variably positioned in relation to the contact beams 24a and 24b. This feature permits the contact force between each lower contact beam 24b and a corresponding male contact of a mating connector to be ;selectively varied, as explained in det<~il below.
The contact housing 15 is engaged with the contact portions 24 by aligning each of the passages 38 with one of the contact portions 24 of the conducting members 20. An insertion force is subsequently applied to the contact housing in the rearward (y) direction.
The insertion force causes the contact portions 24 to become disposed within the passages 38.
In addition, the ground contacts 34a and 34b become disposed within the troughs 39.
The passages 38 are sized so that the cam surface 24f of each side contact beam 24a slidably engages the top wall 38a of a. respective passage 38 as the contact housing 15 is mated to the contact portions 24. In addition, the cam surface 24h of each lower contact beam 24b slidably engages the side wall 38c of a respective passage 38 as the contact housing 15 is mated to the contact portions 24. Frictional forces between the cam surfaces 24g and 24h and the respective passage walls 38a and 38c cause the contact housing 15 to remain in position once the insertion force is removed. Alternatively, the passages 38 may be equipped with detents that engage the cam surfaces and thereby lock the contact housing into one of a limited number of possible positions.
The cam surface 38e on the bottom wall 38b of each passage 38 slidably engages a corresponding lower contact beam 24b as the contact housing 1 S is mated to the contact portions 24. More particularly, each cam surface 38e slidably engages a lower surface 24j of .,_. -the corresponding lower contact beam 24b (see Figures 7A-7C and 8).
>EtERG-2515/C2448 -10. PATENT
The cam surface 38e contacts the lower surface 24j at a point of contact 43.
The point o~f contact 43 is dependent upon the relative positions of the contact housing 15 and the contact portions 24. For example, the contact housing 15 can be placed in a forward position as shown in Figure 6C. Positioning the contact housing 15 in this manner causes the point of contact 43 to be located at its forward-most position along the lower contact beam 24b, as shown in Figure 7C. In other words, the point of contact 43 is located in relatively close proximity to the contact tab 24e of the lower contact beam 24 when the contact housing 1 S is placed in its forward position.
The contact housing 15 can also be placed in an intermediate position as shown in Figure 6B. Moving the contact housing 15 from its forward position to an intermediate position increases the distance between the point of contact 43 and the contact tab 24e, as shown in Figure 7B. The contact housing 15 can also be placed in a rearward position (see Figure 6A). Positioning the contact housing 15 in this manner causes the point of contact 43 t~ be located at its rearward-most position along the lower contact beam 24b, as shown in Figure 7A. In other words, the point of contact 43 is located at its farthest position from the contact tab 24e when the contact housing 1 S is placed in its rearward position. The significance of variably positioning the point of contact 43 in this manner is explained in detail below.
The contact portions 24 of the contact members 20 are adapted to engage a male contact of a mating connector, as noted previously. Figure 8 depicts one of the contact portions 24 mated to a male contact 40 of a mating connector. The contact portion 24 and the male contact 40 are mated by sliding the male contact 40 rearward, in the direction denoted by the arrow 46 in Figure 8. The rearward movement of the male contact 40 causes the contact tab 24e (and the adjacent portion of the lower contact beam 24b) to deflect downward, in the direction denoted by the arrow 48.
The deflection of the lower contact beam 24b is restrained by the cam surface 38e on l:he bottom wall 38b of the passage 38. The restraining effect of the cam surface 38e, in conjunction with the resilience of the lower contact beam 24b, causes a contact force to develop between the male contact 40 and the lower contact beam 24b (this force is commonly referred to as the "spring rate" of the contact 40). A contact force also develops between the :male contact 40 and the side contact beam 24a. A detailed discussion of this contact force is not necessary to an understanding of the invention. Hence, the contact force between the side contact beam 24a and the male contact 40 will not be discussed in detail.
The contact force between the lower contact beam 24b and the male contact 40 is dependent upon the location of the point of contact 43 between the lower contact beam 24b and the cam surface 38. More particularly, the downward deflection of the lower contact beam 24b, in conjunction with the restraining effect of the cam surface 38e, causes the contact tab 24e to pivot about the cam surface 38e (and the point of contact 43). The resistance of the contact beam 24b to such rotation is inversely proportional to the moment arm between the location of the applied force (the contact tab 24e) and the point of rotation I',the point of contact 43). Hence, the resistance of the contact beam 24b (and the resulting contact force between the male contact 40 and the lower contact beam 24b) can be varied by ;altering the distance between the contact tab 24e and the point of contact 43. In other words, 'the effective beam length of the lower contact beam 24b can be altered by varying the location of the point of contact 43.
The distance between the contact tab 24e and the point of contact 43 can be varied through the selective placement of the; contact housing 1 S, as explained above. For example, placing the contact housing 15 in its fbrward position minimizes the distance between the contact tab 24e and the point of contact 43 (see Figures 6C and 7C). Thus, the length of the moment arm between the contact tab 24e and the point of contact 43 is at a minimum when the contact housing 15 is so positioned. The relatively small moment arm causes the lower contact beam 24b to exert a relatively large amount of resistance when the contact tab 24e is deflected downward by the male contact 40. Hence, the contact force between the lower contact beam 24b and the male contact 40 is relatively high when the contact housing 15 is located in its forward position.
Conversely, placing the contact housing 15 in its rearward position maximizes the distance between the contact tab 24e and the point of contact 43, and thereby maximizes the length of the moment arm between the contact tab 24e and the point of contact 43 (see Figures 6A and 7A). The relatively large moment arm causes the contact tab 24e to rotate about the point of contact 43 with a relatively low amount of resistance_when the contact tab 24e is deflected downward by the male contact 40. 'Thus, the contact force between the contact beams 24 and the male contact 40 is relatively low when the contact housing 15 is positioned in this manner. Placing the contact housing 15 in an intermediate position causes the length of the moment arm to lie between its maximum and minimum values.
Hence, the contact force lies between its maximum and minimum values when the contact housing 15 is located in an intermediate position. The contact housing 15 remains at a fixed position relative to the contact 24 once the connector is assembled, thereby producing a uniform spring rate. In other words, the spring rate does not vary after the connector is assembled.
The invention thus permits the contact force between an array of male contacts such ~~s the contacts 40 and an electrical cormector such as the electrical connector 11 to be varied within a range of values using a common hardware configuration. This feature permits a :jingle type of electrical connector to be used in various applications that each require a different amount of contact force. Utilizing a common electrical connector in a variety of different applications offers substantial benefits. For example, the use of a common electrical connector reduces the number of different components that the connector manufacturer must produce. Such reductions can lead to substantially lower production costs.
1 S In addition, inventory-related c;xpenses to both the manufacturer and the user of the common electrical connector can be lowered by reducing the number of different types of connector modules that need to be tracked and stored prior to use. Also, the costs associated with packaging and marketing a multitude of different connector types can be lowered by the use of the common electrical connector.
Furthermore, the ability to vary the contact force of the electrical connector can allow the contact force to be more closely tailored to a desired value than may otherwise be feasible. More particularly, an electrical connector that produces a desired amount of contact force may be unavailable for a particular application, thereby necessitating the use of an electrical connector that produces a less-than-optimal amount of contact force. The use of an electrical connector such as the connector 11 permits the contact force to be set within a range of values, as noted above. This feature provides the user of the electrical connector with greater flexibility in choosing the actual contact force, and thereby increases the potential for the contact force to be set at or near ita optimal value.
It is to be understood that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of the parts, within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims aJ-e expressed.
For example, the contact force between the side contact beam 24a and the .corresponding male contact 40 is not variable in the exemplary electrical connector 11.
Alternative embodiments of the invention may incorporate features that permit the contact force between the side contact beam 2;4a and the male contact 40 to be varied.
Another possible variant of the invention forgoes the use of the contact housings 1 S.
The contact force between the contact: beams 24a and 24b and the respective male contacts 40 of this embodiment is determined by 'the overall length (x dimension) of each overmold 18.
More particularly, each overmold 18 is formed in a manner that causes the contact beams 24a and 24b to extend through the forward face 18a, i.e., the forward face 18a is formed around the rearward portions of the contact beams 24a and 24b. The forward face 18a thereby restrains the contact beams 24a and 24b when the contact beams 24a and 24b are deflected by the respective male contacts 40. The length of the overmold 18 determines the location of the forward face 18a in relation to the contact beams 24a and 24b. Hence, the length of the overmold 18 determines the points of restraint of the contact beams 24a and 24b and, thus, the respective contact forces between. the contact beams 24a and 24b and the male contacts 40.
Figure 9 shows another possible variant of the present invention. Figure 9 depicts an electrical connector l la having a main housing 13a a fixed outer contact housing 49. The electrical connector 11 a is otherwise substantially identical to the electrical connector 11.
Structure on the electrical connector 11 a that is substantially identical to corresponding structure on the electrical connector 11 is described herein using like reference numerals.
The fixed outer contact housing 49 is positioned over the contact housings 1 S
and the contact portions 24 of the conducting members 20 after the contact housings 1 S have been placed in their desired positions relative to the contact portions 24. The outer contact housing 49 is fixed to the main housing 13a by way of an interlocking latch 13b on the main housing 13a _that engages a projection 49a on the outer contact housing 49.
Penetrations 49b are formed in a forward edge 49c of the fixed outer contact housing 49 to facilitate access to the contact portions 24 by the male conl:acts 40.
A further alternative embodiment is shown in Figures l0A through 11C. Figures l0A
~;hrough 11C depict a portion of an electrical connector l lb having a movable outer contact housing 50 and contact housings 15c. Each contact housing 1 Sc includes a fin 15d located along an upper surface of the contact lousing 15c (see Figures 11A-11C). The electrical connector l lc is otherwise substantially identical to the electrical connector 11. Structure on l:he electrical connector 11 c that is substantially identical to corresponding structure on the electrical connector 11 is described herein using like reference numerals.
The movable outer contact housing SO is adapted to enclose the contact housings 1 Sc.
'The outer contact housing 50 is selectively positionable along with the contact housings 15c.
'The outer contact housing SO is placed over the contact housings 15c by sliding the outer contact housing 50 in a rearward direction over the contact housings 15c (the rearward direction is denoted by an arrow 52 shown in Figures 1 lA and 11B). Grooves SOa defined by .an upper inner surface SOb of the outer contact housing 50 slidably engage the fins 15d on the .contact housings 15c as the housing 50 is slid rearward.
The rearward movement of the outer contact housing SO eventually causes a forward .edge 15e of each fin 15d to abut a forward edge SOc of the corresponding groove SOa (see Figure 11 C). Continued rearward movement of the housing 50 causes the outer contact housing SO to drive the contact housings lSc rearward, thereby exposing the contact portions 24 of the conducting members 20. The relative positions of the contact housings 15c and the contact portions 24 can thereby be adjusted by way of selecting the lengths of the grooves SOa in the outer contact housing 50. Hence, the contact farce between the contact beams 24b of the contact portions 24 and the male contacts 40 of a mating connector can be controlled by way of the outer contact housing S0.
A projection (not shown) on the outer contact cover 50 can engage latches on the main housing 13 to retain the contact housings 15c together, as in the previously-described embodiment. Penetrations SOd are formed in a forward edge SOe of the outer contact housing 50 to facilitate access to the contact portions 24 by the male contacts 40.
Claims (30)
1. An electrical connector fir mating with a male contact of a mating connector, comprising:
a conducting member including a lead and a contact beam electrically coupled to the lead, the contact beam being adapted to resiliently engage the male contact; and a contact housing, at least a portion of the contact beam being disposed within the contact housing so that the contact beam is urged into and restrained by the contact housing when the contact beam resiliently engages the male contact, whereby a contact force is generated between the contact beam and the contact pin.
a conducting member including a lead and a contact beam electrically coupled to the lead, the contact beam being adapted to resiliently engage the male contact; and a contact housing, at least a portion of the contact beam being disposed within the contact housing so that the contact beam is urged into and restrained by the contact housing when the contact beam resiliently engages the male contact, whereby a contact force is generated between the contact beam and the contact pin.
2. The electrical connector of claim 1, wherein the contact housing is capable of being selectively positioned in relation to the contact beam so that a point of restraint on the contact beam is selectively variable, whereby the contact force between the contact beam and the male contact is capable of being varied on a selective basis.
3. The electrical connector of claim 2, wherein the contact housing is capable of being positioned in a rearward position, a forward position, and an intermediate position.
4. The electrical connector of claim 1, wherein the contact housing has a cam surface and the contact beam is urged into and restrained by the cam surface when the contact beam resiliently engages the male contact.
5. The electrical connector of claim 1, wherein the contact beam includes a contact tab for engaging the male contact.
6. The electrical connector of claim 1, further comprising a connector module comprising the conducting member, an overmold enclosing at least a portion of the conducting member, and the contact housing.
7. The electrical connector of claim 6, further comprising a main housing enclosing at least a portion of the connector module.
8. The electrical connector of claim 6, wherein the lead is a signal lead and the connector module further includes a ground assembly having a lead portion.
9. The electrical connector of claim 1, wherein the conducting member further includes a contact pin electrically coupled to the lead, the contact pin and the contact beam being mechanically coupled to opposing ends of the lead.
10. The electrical connector of claim 9, wherein a longitudinal axis of the contact pin is substantially perpendicular to a longitudinal axis of the contact beam.
11. The electrical connector of claim 6, wherein the connector module includes a plurality of the conducting members and at least a portion of the conducting members are substantially vertically aligned.
12. The electrical connector of claim 11, further comprising a plurality of the connector modules positioned substantially side-by-side.
13. The electrical connector of claim 1, wherein the conducting member includes two of the contact beams.
14. The electrical connector of claim 4, wherein the contact housing defines a passage for receiving at least a portion of the contact beam and the cam surface is disposed within the passage.
15. The electrical connector of claim 14, wherein the conducting member includes a cam surface for engaging a wall of the passage so that the portion of the contact beam is retained within the passage.
16. The electrical connector of claim 8, wherein the contact housing defines a trough for receiving the lead portion of the ground assembly.
17. The electrical connector of claim 8, wherein the ground assembly includes a contact pin coupled to a first end of the lead portion and a ground contact coupled to a second end of the lead portion.
18. An electrical connector for mating with a male contact of a mating connector, comprising:
a conducting element having a lead and a contact beam having a first end fixedly coupled to the lead and a second free-standing end for resiliently engaging the male contact so that the contact beam deflects when the contact beam engages the male contact;
and a housing adapted to inhibit the deflection of the contact beam by restraining the contact beam at a point of restraint located between the first and the second ends of the contact beam, whereby a contact force is generated between the contact beam and the male contact and the contact force is dependent upon the location of the point of restraint on the contact beam.
a conducting element having a lead and a contact beam having a first end fixedly coupled to the lead and a second free-standing end for resiliently engaging the male contact so that the contact beam deflects when the contact beam engages the male contact;
and a housing adapted to inhibit the deflection of the contact beam by restraining the contact beam at a point of restraint located between the first and the second ends of the contact beam, whereby a contact force is generated between the contact beam and the male contact and the contact force is dependent upon the location of the point of restraint on the contact beam.
19. The electrical connector of claim 18, wherein the housing is capable of being selectively positioned in relation to the contact beam so that the point of restraint on the contact beam is selectively variable.
20. The electrical connector of claim 19, wherein the housing is capable of being positioned in (i) a rearward position so that the point of restraint on the contact beam is located proximate the first end of the contact beam and the contact force between the contact beam and male contact has a minimum value, (ii) a forward position so that the point of restraint on the contact beam is located proximate the second end of the contact beam and the contact force between the contact beam and male contact has a maximum value, and (iii) an intermediate position so that the point of restraint on the contact beam is located proximate a center of the contact beam and the contact force between the contact beam and male contact is greater than the minimum value and less than the maximum value.
21. The electrical connector of claim 18, wherein the housing includes a cam surface for restraining the contact beam.
22. The electrical connector of claim 18, further comprising a connector module, the connector module comprising the conducting member and an overmold enclosing at least a portion of the conducting member.
23. The electrical connector of claim 22, wherein the lead is a signal lead and the connector module further includes a ground assembly having a lead portion.
24. The electrical connector of claim 21, wherein the housing defines a passage for receiving at least a portion of the contact beam, the cam surface being disposed within the passage.
25. The electrical connector of claim 24, wherein the housing defines a trough for receiving the lead portion of the ground assembly.
26. A method of adjusting a spring rate of a contact in an electrical connector before the connector engages a mating connector, comprising the steps of providing an electrical connector with a housing and a deflectable contact, the housing being positionable relative to the contact at a plurality of positions; and positioning the housing at a predetermined one of the plurality of positions;
wherein the predetermined position of the housing determines the spring rate of the contact.
wherein the predetermined position of the housing determines the spring rate of the contact.
27. The method as recited in 26, further comprising the step of maintaining the predetermined position while the electrical connector engages the mating connector.
28. A kit for making an electrical connector having a contact with a predetermined spring rate, comprising:
a plurality of housings; and a deflectable contact mountable to any one of the plurality of housings to form an electrical connector;
wherein the housings can engage the contact to provide a predetermined spring rate to the contact, each one of the housings providing a different predetermined spring rate.
a plurality of housings; and a deflectable contact mountable to any one of the plurality of housings to form an electrical connector;
wherein the housings can engage the contact to provide a predetermined spring rate to the contact, each one of the housings providing a different predetermined spring rate.
29. The kit as recited in claim 28, wherein the plurality of housings are generally similar and the different predetermined spring rates are achieved by selective positioning of the plurality of housings relative to the contact.
30. The kit as recited in claim 28, wherein each housing is different than the other of the housings.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US57864800A | 2000-05-25 | 2000-05-25 | |
| US09/578,648 | 2000-05-25 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2347604A1 true CA2347604A1 (en) | 2001-11-25 |
Family
ID=24313717
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002347604A Abandoned CA2347604A1 (en) | 2000-05-25 | 2001-05-15 | Electrical connector capable of exerting a selectively variable contact force |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP1158619A3 (en) |
| JP (1) | JP2002008790A (en) |
| CA (1) | CA2347604A1 (en) |
Families Citing this family (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4333715B2 (en) * | 2006-09-07 | 2009-09-16 | 日立工機株式会社 | Battery pack, charger, and power tool |
| US8366485B2 (en) | 2009-03-19 | 2013-02-05 | Fci Americas Technology Llc | Electrical connector having ribbed ground plate |
| WO2012138519A2 (en) | 2011-04-04 | 2012-10-11 | Fci | Electrical connector |
| EP2624034A1 (en) | 2012-01-31 | 2013-08-07 | Fci | Dismountable optical coupling device |
| US9257778B2 (en) | 2012-04-13 | 2016-02-09 | Fci Americas Technology | High speed electrical connector |
| USD727852S1 (en) | 2012-04-13 | 2015-04-28 | Fci Americas Technology Llc | Ground shield for a right angle electrical connector |
| US8944831B2 (en) | 2012-04-13 | 2015-02-03 | Fci Americas Technology Llc | Electrical connector having ribbed ground plate with engagement members |
| USD718253S1 (en) | 2012-04-13 | 2014-11-25 | Fci Americas Technology Llc | Electrical cable connector |
| USD727268S1 (en) | 2012-04-13 | 2015-04-21 | Fci Americas Technology Llc | Vertical electrical connector |
| US9543703B2 (en) | 2012-07-11 | 2017-01-10 | Fci Americas Technology Llc | Electrical connector with reduced stack height |
| USD751507S1 (en) | 2012-07-11 | 2016-03-15 | Fci Americas Technology Llc | Electrical connector |
| USD745852S1 (en) | 2013-01-25 | 2015-12-22 | Fci Americas Technology Llc | Electrical connector |
| USD720698S1 (en) | 2013-03-15 | 2015-01-06 | Fci Americas Technology Llc | Electrical cable connector |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4402563A (en) * | 1981-05-26 | 1983-09-06 | Aries Electronics, Inc. | Zero insertion force connector |
| JP3161642B2 (en) * | 1992-12-18 | 2001-04-25 | 富士通株式会社 | Connector and method of assembling the same |
| JP3379747B2 (en) * | 1997-05-20 | 2003-02-24 | 矢崎総業株式会社 | Low insertion force terminal |
-
2001
- 2001-05-15 CA CA002347604A patent/CA2347604A1/en not_active Abandoned
- 2001-05-18 EP EP01111933A patent/EP1158619A3/en not_active Withdrawn
- 2001-05-23 JP JP2001153709A patent/JP2002008790A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| JP2002008790A (en) | 2002-01-11 |
| EP1158619A2 (en) | 2001-11-28 |
| EP1158619A3 (en) | 2002-07-03 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued | ||
| FZDE | Discontinued |
Effective date: 20040517 |