GB2445380A

GB2445380A - Electrical contact having deflectable portion

Info

Publication number: GB2445380A
Application number: GB0700119A
Authority: GB
Inventors: Michael Astanovsky; Eli Margalit; Ariel Rotman
Original assignee: Motorola Inc
Current assignee: Motorola Solutions Inc
Priority date: 2007-01-04
Filing date: 2007-01-04
Publication date: 2008-07-09
Anticipated expiration: 2027-01-04
Also published as: GB2445380B; GB0700119D0

Abstract

A connector 205 suitable for making an electrical connection between first and second electrical components of an electronic device (100, fig.1), the connector comprising a conducting strip including: a first section including a deflectable member 209 and a support member 211 supporting the deflectable member 209, the deflectable member 209 being adapted to be contacted and deflected about the support member by a conductor (111, fig.5) of the first component; and a second section 401, 405, 403, 409 adapted to provide a spring loading of the first section when the first section is contacted and deflected by the conductor of the first component, the second section being adapted to contact a conductor of the second component. The connector is preferably in the form of a resilient S-shape which avoids excessive contact force. Also described is a connector module (109, fig.2) including at least one of the connectors, the module may be used to electrically connect the terminals of a battery to a mobile phone.

Description

1

2445380

TITLE: ELECTRICAL CONNECTOR AND CONNECTOR MODULE FIELD OF THE INVENTION

5 The present invention relates to an electrical connector for connecting electrically operated components and a connector module incorporating at least one connector.

10 BACKGROUND OF THE INVENTION

In a device employing electrically operated components in which one of the components, e.g. a battery, is removable by an operator or user, a 15 connector module is often employed. The module makes electrical connection between the removable component and another component or components fixed in the device, such as at least one printed circuit board of the operational circuitry of the device. An example of such 20 a device is a handset providing a mobile communications unit. The connector module is itself normally fixed in the device in contact with the fixed component. The connector module normally includes one or more individual connectors which make contact with conductors 25 on the removable component and the fixed component.

Examples of known modules and connectors for them are described in US-A-5487674 and US-A-5655913.

Often the performance of a connector module may not be ideal. A contact force has to be maintained between 30 the removable component and each connector of the module so that a good electrical connection is made between

2

them. However, there is a series of design tolerances required to be allowed in each of the contacts made by each of the connectors of the module. These tolerances are additive and their application can cause an 5 excessive force to be produced. The excessive force can lead to undesirable plastic deformation of the connectors and other contact parts which can produce impaired performance or failure of the circuitry of the device. Another problem which may be experienced with 10 connectors in connector modules of the kind which have been described is fretting corrosion of the connector and/or a corresponding conductor of the removable component. Fretting corrosion is a form of corrosion that can occur on a load bearing contact surface between 15 mating metal parts, especially where the parts are made of dissimilar metals. It is caused by a combination of corrosion which produces a debris of corrosion products and abrasive effects on the debris produced by relative movement between the mating parts. Other problems 20 induced by fretting corrosion include surface pitting, seizing and galling of mating surfaces. Reduced fatigue life is obtained as a result of stress concentrations produced on the mating surfaces.

25 SUMMARY OF THE INVENTION

According to the present invention in a first aspect there is provided a connector as defined in claim 1 of the accompanying claims.

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According to the present invention in a second aspect there is provided a connector module as defined in claim 18 of the accompanying claims.

According to the present invention in a third 5 aspect there is provided an electrical device as defined in claim 26 of the accompanying claims.

Further features of the invention are as defined in the accompanying dependent claims and in the embodiments of the invention to be described.

10 Embodiments of the present invention will now be described by way of example with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

15

The accompanying drawings, in which like reference numerals refer to identical or functionally similar elements throughout the separate views and which, together with the accompanying description below, serve 20 to further illustrate various embodiments and to explain various principles and advantages of the present invention.

In the accompanying drawings:

FIG. 1 is a plan view of a rear of an illustrative 25 mobile communications handset which may be adapted in accordance with an embodiment of the invention, with components removed from the handset.

FIG. 2 is a side perspective view of an illustrative connector module embodying the invention 30 for employment in the handset shown in FIG. 1.

4

FIG. 3 is a plan view of the connector module shown in FIG. 2.

FIG. 4 is a side view of a connector of the connector modules shown in FIGS. 2 and 3.

5 FIGS. 5 to 7 are side views of the connector of

FIG. 4 showing the shape of the connector during different stages of application of a force against the connector at the top of the connector.

FIG. 8 is an end perspective view of an alternative 10 illustrative connector module embodying the invention employed in the handset shown in FIG. 1.

FIG. 9 is a side perspective view of a connector fitted in a part of a module shown in FIG. 8.

FIGS. 10 to 12 are side views of the connector 15 shown in FIG. 9 showing the shape of the connector during different stages of application of a force against the connector at the top of the connector.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

20

In embodiments of the invention to be described, there is provided an improved connector for use in a connector module, e.g. for electrically connecting a first component which may be removable to a second 25 component which may be fixed in an electrically operated device, for example a mobile communications handset. The improved connector comprises a conducting strip including: (i) a first section including a deflectable member and a support member supporting the deflectable 30 member, the deflectable member being adapted to be contacted and deflected about the support member by a

5

conductor of the first component; and (ii) a second section adapted to provide a spring loading of the first section when the first member is contacted and deflected by the conductor of the first component, the second 5 section being adapted to contact a conductor of the second component.

The improved connector beneficially allows a constant contact force to be obtained between the connector and a conductor of the first component, even 10 if a force greater than the constant force is applied to the connector. The improved connector, together with an improved connector module to be described herein, also allows minimal relative movement between the connector and the conductor.

15 FIG. 1 shows a plan view of a rear of an illustrative mobile communications handset 100 having a casing 101 together with components which have been removed. In the following description and accompanying drawings, it is assumed that the handset 100 is laid on 20 a horizontal surface, so the handset 101 seen in FIG. 1 is generally horizontal. Of course, use of the handset 100 is not limited to this orientation. The components which have been removed from the handset 100 are a rear cover 103, which when replaced forms part of the casing 25 101, and a battery 107. When the rear cover 103 has been removed, as shown in FIG. 1, an enclosure 105 is seen in which the battery 107 is normally fitted. When the battery 107 has been removed as shown in FIG. 1, a connector module 109 is seen fitted in the handset 100 30 in the enclosure 105. The battery 107 has substantially flat conductors 111 on its outer surface adjacent to one

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end of the battery 107. The conductors 111 make electrical contact with internal parts of the battery 107 in a known manner. The battery 107 has lugs 113 which facilitate fitting of the battery 107 in the 5 handset 100 in a known manner.

When the battery 107 is fitted in the handset 100 shown in FIG. 1, the conductors 111 make contact with connectors of the connector module 109 to be described in more detail below.

10 In an alternative example of a handset (not shown)

or other device which may be adapted in accordance with an embodiment of the invention, the removable items, namely the battery and cover, may be combined in a common removable part.

15 FIG. 2 is a side perspective view and FIG. 3 is a plan view of the connector module 109 which is an illustrative improved connector module embodying the invention. The module 109 comprises an electrically insulating body 201, e.g. made from a moulded organic 20 polymeric material such as a tough resilient plastics material. Parallel enclosures 203 are formed in the body 201. Each enclosure 203 has an elongate rectangular shape of uniform cross-section in which the length of the shape (measured vertically in the plane shown in 25 FIG. 3) is greater than the height of the shape

(measured vertically in FIG. 2), and the height of the shape is greater than the width of the shape (measured horizontally in FIG. 3). Each enclosure 203 incorporates one of a plurality of identical improved connectors 205. 30 Each of the connectors 205 includes an upper portion 211 above the body 201 of the module 109. An incomplete or

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three sided cut 207 is made in the upper portion 211 of each connector 205 to form a projecting portion 209 which is obtained by making the cut 207. The upper portion 211 and the projecting portion 209 together 5 correspond to the first section of the improved connector referred to earlier, and the upper portion 211 and the projecting portion 20 9 correspond respectively to the support member and the deflectable member referred to earlier. The cut 207 formed in each upper 10 portion 211 forms an aperture through which the corresponding portion 209 may be deflected when a force is applied in a downward vertical direction against the portion 209. Each connector 205 and its operation are described in more detail later with reference to FIGS. 4 15 to 7.

Each connector 205 makes electrical contact, e.g. by soldering through the base of each of the recesses 203, with a corresponding conductor (not shown) of a component (corresponding to the second component 20 referred to earlier) fixed inside the handset 101. The fixed component may for example be a printed circuit board of operational circuitry of the handset 100.

In use, the battery 107, which is an example of the first component referred to earlier, is fitted to lie 25 substantially parallel to a plane representing the top of the connector module 201 as illustrated by the plane of FIG. 3. The conductors 111 of the battery 107 are pushed against corresponding connectors 205 of the module 109 at their portions 209 by the action of 30 fitting of the battery 107 in the handset 100. The conductors 111 of the battery 107 thereby make and

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maintain electrical contact with each of the connectors 205. Operation of the connectors 205 is described in more detail later with reference to FIGS. 5 to 7. The cover 103 is fitted to the casing 101 after the battery 5 107 has been fitted.

FIG. 4 is a side view of one of the connectors 205 as seen in a vertical plane perpendicular to the horizontal plane of FIG. 3. The connector 205 is a strip of conducting material which has been bent in the course 10 of manufacture into the shape shown in FIG. 4, which will provide the strip with properties of a spring. The connector 205 may be made of a suitable workable spring metal such as stainless steel, beryllium copper,

phosphor bronze, tempered spring steel or the like. The 15 connector 205 has the shape shown in FIG. 4 before fitting of the battery 107. As shown in FIG. 4, the shape of the connector 205 approximates to an S shape. The upper portion 211 in which the cut 207 (FIGS. 2 and 3), which provides a support member for the projecting 20 portion 20 9 already seen in FIGS. 2 and 3, is formed is arranged to lie horizontally. The projecting portion 209 is joined to the upper portion 211 where the cut 207 is incomplete. The connector 205 includes, beneath the upper portion 211, portions 401 and 403 joined by a U-25 bend 405. The portions 211 and 401 may be substantially parallel horizontal portions as shown in FIG. 4. The portion 403 may also be parallel with the portions 211 and 401 as shown in FIG. 4, although this is not essential. The portions 403 and 211 are joined by a U-30 bend 409. The portions 401 and 403 and the U-bends 405 and 409 together correspond to the second section of the

9

improved connector referred to earlier. The portion 401 is a base portion of the connector 205 and in use makes electrical contact with a conductor of a fixed component (referred to earlier as the second component) inside the 5 handset 100 beneath the module 109. The portion 401 may be supported in position by a base of the enclosure 203 of the module 109 (FIG. 2) in which the connector 205 is incorporated. It may be fixed in that position.

As noted earlier, the projecting portion 209 is 10 joined to the upper portion 211 of the connector 205 in a region where the cut 207 is not completed and is deflectable about that join. The projecting portion 209 is bent from the horizontal upper portion 211 to include, joined to the upper portion 211, a part 411 15 which projects upwardly from the upper portion 211 at an acute angle of between about 10 degrees to about 30 degrees to the upper portion 211. The portion 209 also includes a bend 413 leading to a further part 415 having a free end. The part 415, which may have a slight 20 curvature, points downwardly at an acute angle, e.g. of between about 10 degrees and about 45 degrees, relative to the horizontal upper portion 211. The projecting portion 209 thus provides a deflectable member which is deflectable about the support member provided by the 25 upper portion 211.

FIGS. 5 to 7 illustrate how the shape of each connector 205 changes when the battery 107 is pushed against the connector 205 in use. The surface of the corresponding conductor 111 is disposed in a horizontal 30 plane perpendicular to the vertical plane of FIGS. 5 to

10

7 so its horizontal edge is represented by reference numeral 111 in FIGS. 5 to 7.

FIG. 5 illustrates the situation when the conductor 111 first contacts its corresponding connector 205 but 5 does not exert any substantial force upon the connector 205. The conductor 111 contacts the connector 205 at its uppermost point which is at the bend 413 of the projecting portion 209. The portions 401, 403 and 211 of the connector 205 are all horizontal.

10 FIG. 6 illustrates the situation when a moderate force is applied by the conductor 111 of the battery 107 against the connector 205. The projecting portion 209 is deflected downwardly by the applied force as illustrated in FIG. 6 by the conductor 111 being closer to the upper 15 portion 211 of the connector 205. The position of the projecting portion 209 shown in FIG. 6 represents a maximum deflection of the portion 209 first being reached. Thus, the contact force between the conductors 111 and the portions 209 will not be changed any more, 20 although further force from the battery 107 may still be applied to the connector 205 (as illustrated in FIG. 7). The portion 403 of the connector 205 as shown in FIG. 6 is still in the same horizontal position as in FIG. 5.

FIG. 7 illustrates the situation when a force is 25 applied by the battery 107 to each of the connectors 205 which is greater than that applied in the situation illustrated in FIG. 6. For example, FIG. 7 illustrates the situation when fitting of the battery 107 in the handset 100 has been completed. At this stage, no 30 further deflection of the projecting portion 209 is possible beyond the position of the portion shown in

11

FIG. 6. Thus, the force applied at the join between the portions 211 and 209 now remains constant. All further force from the battery 107 to each connectors 205 beyond the force applied in the situation illustrated in FIG. 6 5 is applied to the upper surface of the upper portion 211 and not to the portion 209. The battery 107 may include one or more surfaces which begin to contact each of the upper portions 211 when the maximum deflection of each projecting portion 209 is reached. In practice, these 10 surfaces may be provided by an outer casing of the battery 107 which may be made of a tough, resilient material such as a plastics material or metal/plastics laminated material. The further force applied by the battery 107 pushes the portion 211 toward the base 15 portion 401 which may be fixed in position in a base of the enclosure 203 (FIG. 3) in which the connector 205 is incorporated. Each of the portions 209 travels vertically downward together with its corresponding portion 211 but is not further deflected. The further 20 downward force applied by the battery 107 is resisted by the connector 205 acting as a spring causing the portion 403 of the connector 205 to be deflected from its horizontal position shown in FIGS. 5 and 6 to a position which is upwardly slanting from the U-bend 409 to the U-25 bend 405 as shown in FIG. 7.

Thus, as the force applied to the connector 205 by fitting of the battery 107 increases two effects occur generally in sequence. Firstly, a contact force between the portion 209 of each connector 205 and its 30 corresponding conductor 111 of the battery 107 is established to provide a suitable electrical connection

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between the two. Secondly, when that contact force has reached a constant value required to produce a maximum deflection of the portion 209, further applied force is taken up by the spring action of the connector 205.

5 These two effects combine to provide improved performance of the connector 205. In particular, since the force required to provide contact between the conductor 111 and the projecting portion 209 is maintained at a constant value (when the maximum 10 deflection of the projecting portion 209 has been achieved) independent of the force acting upon other parts of the connector 205, a given contact force providing optimal electrical connection and minimal mechanical deformation may be selected by an engineering 15 designer. The force may be one which is lower than is necessary to compensate for engineering tolerances between contacting parts by use of the module 201 thereby reducing the risk of plastic deformation of the material of the connector 205 and consequent 20 deterioration or failure of the connector 205 and the circuitry of the handset 100.

The movement of the projecting portion 20 9 at the join between the portion 209 and the upper portion 211 is very small, so the risk of plastic deformation of the 25 connector 205 in the region of that join is minimal. In any event, the upper portion 211 provides a supporting surface which receives a lower surface of the battery 107 when the portion 209 reaches its maximum deflection and thereby prevents future deformation of the 30 projecting portion 209 and changing of the contact force applied at the join between portions 209 and 211.

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Furthermore, each connector 205 and its incorporation in its enclosure 203 minimises relative movement, especially lateral movement between each conductor 111 and its corresponding connector 205, e.g.

5 caused by mechanical shock, e.g. caused by dropping, or thermal shock, thereby reducing the risk of failure due to fretting corrosion.

An alternative illustrative connector module 800 embodying the invention for use in the handset 100, and 10 an alternative illustrative connector 900 embodying the invention for use in the module 800, will now be described with reference FIGS. 8 to 12. FIG. 8 shows an end perspective view of the module 800. The module 800 includes a vertical external side wall 801, a vertical 15 external side wall 803 and internal walls 805, 807 and 809 each of which is between the external side walls 801 and 803 and parallel with the side walls 801 and 803. Enclosures 811, 813, 815 and 817 are formed respectively between the walls 801 and 805, the walls 805 and 807, 20 the walls 807 and 809 and the walls 809 and 803. Each of the enclosures 811, 813, 815 and 817 is adapted to receive its own identical connector 900 in a manner described below with reference to FIGS. 9 and 10. A horizontal bar 819 in the form of a bridge having an 25 upper surface level with upper horizontal edges of the walls 801, 805, 807 and 809 and 803 is formed between the wall 801 and the wall 805. Similarly, a horizontal bar 821 in the form of a bridge level with the bar 819 is formed between the wall 805 and the wall 807. 30 Similarly, a horizontal bar 823 in the form of a bridge level with the bars 819 and 821 is formed between the

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wall 807 and the wall 809. Similarly, a horizontal bar 825 in the form of a bridge level with the bars 819, 821 and 823 is formed between the wall 809 and the wall 803. The bars 819, 821, 823 and 825 have a rectangular cross-5 sectional shape on a common horizontal axis (not shown).

A horizontal joint portion 827 having a lower surface level with lower edges of the walls 801, 805, 807 and 80 9 is formed between the wall 801 and the wall 805 at one end of the enclosure 811. Similarly, a 10 horizontal joint portion 829 level with the joint portion 827 is formed between the walls 805 and 807 at one end of a base of the enclosure 813. Similarly, a horizontal joint portion 831 level with the joint portions 827 and 829 is formed between the walls 807 and 15 809 at one end of a base of the enclosure 815.

Similarly, a horizontal joint portion 833 level with joint portions 827, 829 and 831 is formed between the walls 803 and 809 at one end of a base of the enclosure 817. The joint portions 827, 829, 831 and 833 have a 20 common cross-sectional shape (shown in FIG. 9) on a horizontal common axis (not shown).

Stepped portions 835, 837, 839 and 841 each having a lower surface level with lower edges of the walls 801, 805, 807 and 809 are formed respectively in a base of 25 the enclosures 811, 813, 815 and 817 respectively between the wall 801 and the wall 805, the wall 805 and the wall 807, the wall 807 and the wall 809 and the wall 803 and the wall 809.

The walls 801, 805, 807, 809 and 803 providing the 30 enclosures 811, 813, 815 and 817 separate and prevent contact between individual connectors 900 (FIG. 9) to be

15

fitted in the module 800 and with other metal parts (not shown). The enclosures 811, 813, 815 and 817 are cut away, i.e. have no walls at their ends, to facilitate fitting of connectors 900 therein. The walls 801, 805, 5 807, 809 and 803 have at one end, i.e. the end at which the joint portions 827, 829, 831 and 833 are located, downward sloping edges or chamfers 843, 845, 847, 849 and 851 to provide more space to access the connectors 900 when in the module 800 and to facilitate easy 10 vertical movement of each connector 900 in its enclosure (in a manner to be described later with reference to FIGS. 10 to 12).

The module 800 may be produced as an integral structure, e.g. by moulding using one of the materials 15 referred to earlier for producing the module 109.

FIG. 9 is a side perspective view, in the direction indicated by arrow 9 in FIG. 8, of a connector 900 fitted in the enclosure 817 of the module 800. Parts of the module 800 including the side wall 803 and parts 20 behind the sloping edge 84 9 have been cut away for clarity. FIG. 10 shows a side view, in a direction indicated by arrow 10 in FIG. 8, of the connector 900 fitted in the module 800.

FIG. 9 shows a cross-sectional shape of the joint 25 portion 833 and of the stepped portion 841 in the base of the module 800 (the shape being shown in FIG. 9 by the front surfaces of the joint portion 833 and the stepped portion 841). The joint portion 833 of the module 800 is seen to have a ramped or wedge shape in 30 cross-section. The stepped portion 841 of the module 800 includes an upper part 918 projecting upwardly from a

16

base part 917. The base part 917 includes a horizontal slot 916 formed in its underside surface and a part 915, which is ramped or wedge shaped, formed at an end of the base portion 917 remote from the joint portion 833.

5 As shown in FIGS. 9 and 10, the connector 900

includes an upper horizontal portion 901, having a function similar to the upper portion 211 of the connector 205 described earlier, and a projecting portion 903 having a function similar to the projecting 10 portion 209 of the connector 205. The portions 901 and 902 are above the module 800. The projecting portion 903 is shown cut from a region at a side of the upper portion 901 rather than from a region along the middle of the portion 901 (similar to the case of the connector 15 205), although the projecting portion 903 could alternatively be cut from a region along the middle of the portion 901. The connector 900 includes an extension portion 902 joined to the upper portion 901. The extension portion 902 is bent in an inverted C-shape and 20 has a lower part 904 which hooks an underside face of the bar 82 5. The purpose of this arrangement is to limit the extent of vertical travel of the connector 900. The bar 825 keeps the connector 900 in a pre-defined vertical position when the connector 900 is first fitted 25 in the enclosure 817.

The connector 900 further includes a straight portion 905, having a function similar to the portion 403 of the connector 205, extending between U-bends 907 and 909. The U-bend 907 joins the portions 905 and 901. 30 The U-bend 909 joins the portion 905 to a base portion 911 of the connector 900. The base portion 911 includes

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a bifurcation 912 which produces a part 913 and a part

914. The part 913 is flat and extends into the slot 916 beneath the stepped portion 841 of the module 800. The part 913 has a width which increases in the slot 916.

5 The part 913 emerges from the slot 916 beyond the stepped portion 841 to form a widened part 919. The part 919 beyond the stepped portion 841 is bent to follow an upper ramped surface of the joint portion 833 of the module 800 eventually becoming horizontal in a part 921 10 on an upper surface of the joint portion 833. The horizontal part 921 abuts against a rim 923 on an upper surface of the joint portion 833. The part 914 of the base portion 911 extending from the bifurcation 912 is also bent to follow an upper ramped surface of the part 15 915 of the stepped portion 841 eventually becoming horizontal in a part 920 on an upper surface of the part

915. The part 920 abuts against a vertical side wall of the upper part 918 to limit travel of the part 920 when the connector 900 is fitted in the enclosure 817 (by

20 moving the connector 900 from right to left as shown in FIG. 10).

The upper part 918 has an upper surface which is parallel with a lower surface of the straight portion 905 of the connector when the portion 905 is moved 25 toward the upper part 918 as described later with reference to FIG. 12.

The construction of the base portion 911 which has been described with reference to FIGS. 9 and 10 facilitates fitting and anchoring of the base portion 30 911 with respect to the stepped portion 841 and the joint portion 833 of the module 800. The construction

18

also provides a fixed supported base of the connector 900 when the connector 900 is employed as a spring to receive an applied force as described below with reference to FIG. 12.

5 In particular, the bends provided on the parts 914

and 919 facilitate fitting and locking of the connector 900 in position in the enclosure 817 of the module 800. The base portion 911 of the connector 900 becomes closed from each side by features provided in the module 900, 10 particularly in the stepped portion 841, namely the vertical wall of the upper part 918 and a wall of the slot 916. Furthermore, downward vertical movement of the base portion 911 is prevented by the joining portion 833 and the lower part 915 of the stepped portion 841, and 15 upward vertical movement is prevented by the portion 919 being trapped beneath the stepped portion 841 in the slot 916.

The joint portions 827, 829 and 831 have a cross-sectional shape which is similar to that of the joint 20 portion 833 shown in FIG. 9. Similarly, the stepped portions 835, 837 and 839 have a cross-sectional shape which is similar to that of the stepped portion 841 shown in FIG. 9. Further individual connectors 900 (not shown) which are the same as the connector 900 shown in 25 FIG. 9 are fitted in each of the enclosures 811, 813 and 815 in a manner similar to that employed for the connector 900 shown in FIG. 9. Thus, in each case, a base portion of the connector 900 is adapted to be engaged by the corresponding stepped portion (835, 837 30 or 839) and bent over the corresponding joint portion

(827, 829 or 831) in the same manner as employed for the

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base portion 911 shown in FIG. 9. In addition, an extension part 902 of each connector 900 is adapted to be bent around the corresponding bar (819, 821 or 823) in the same manner as employed for the extension part 5 902 and the bar 825 as shown in FIG. 9.

The module 800 incorporating a plurality of the connectors 900 may be employed in the same manner as the connector 205 in the handset 100 to receive the battery 103 as described earlier. FIGS. 10 to 12 illustrate how 10 the shape of each connector 900 changes when the corresponding conductor 111 of the battery 107 is pushed against the connector 900 in use. The edge of the conductor 111 is again represented by reference numeral 111 in FIGS. 10 to 12.

15 FIG. 10 illustrates the situation when the conductor 111 first contacts the connector 900 but does not exert any substantial force upon the connector 900. The conductor 111 contacts the connector 900 at the uppermost point of the projecting portion 903. The upper 20 portion 902 is substantially horizontal and parallel to the connector 111. The portion 905 is slightly offset from horizontal so that it is slightly higher at its end which joins the U-bend 909 than at its end which joins the U-bend 907. The parts 920 and 921 (where straight) 25 and 919 are in a substantially horizontal position. The extension part 902 is bent around a side face of the bar 825 (on the right side of the bar 825 as shown) so that the part 904 touches a bottom face of the bar 825.

FIG. 11 illustrates the situation when a moderate 30 force is applied by the battery 107 against the connector 900. The projecting portion 903 is deflected

20

downwardly by the connector 111 as illustrated in FIG.

II by the conductor 111 being closer to the upper portion 901 of the connector 900. The position of the projecting portion 903 shown in FIG. 11 represents a

5 maximum deflection of the portion 903 first being reached. Thus, the contact force between the conductor

III and the portion 903 will not be changed any more, although pushing of the connector 900 by the battery 107 may still take place (as described below with reference

10 to FIG. 12). The portion 905, the extension part 902 and the parts 921, 919 and 920 (where straight) of the connector 900 are in the same horizontal position as in FIG. 5.

FIG. 12 illustrates the situation when a force is 15 applied which is greater than that applied in the situation illustrated in FIG. 11. For example, FIG. 12 illustrates the situation when fitting of the battery 107 in the handset 100 has been completed. At this stage, the projecting portion 903 is not able to be 20 deflected any further than as shown in FIG. 11. All further force by the battery 107 beyond that applied in the situation illustrated in FIG. 5 is applied to the upper surface of the upper portion 901 and not to the portion 903 of the connector 900. This causes the force 25 applied at the join between the portions 901 and 903 to remain constant. As described earlier, the base portion 911 is fixed in position in the enclosure 817. Thus, the parts 921, 919 and 920 of the base portion 911 remain in the same position as shown in FIGS. 10 and 11. The 30 further force applied by the battery 107 is able to push the portion 901, and the portion 903 with it, toward the

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base portion 911. In practice, this further force may again be applied from the battery 107 by an outer casing of the battery which may be made of a resilient material such as a plastics material or metal/plastics laminated 5 material. This force is resisted by the connector 900 acting as a spring causing the portion 905 of the connector 900 to be deflected from its almost horizontal position shown in FIGS. 10 and 11 to a position in which it has a greater upward slant from the U-bend 907 to the 10 U-bend 909 as shown in FIG. 12.

The stepped portion 841 of the module 800 serves as a mechanical reinforcement of the module 800. The upper part 918 of the stepped portion 841 also serves as a stop to limit downward travel of the portion 905. In 15 addition, in the situation illustrated in FIG. 12, the extension part 902 is pushed downward relative to the bar 825. The bar 825 limits the amount of downward travel that may be experienced by the upper portion 901.

Thus, as the force applied to the connector 90 0 by 20 fitting of the battery 107 increases, the two effects that occur with the connector 205 as described earlier, again occur generally in sequence. Firstly, a contact force between the projecting portion 903 of the connector 900 and the conductor 111 of the battery 107 25 is established to provide a suitable electrical connection between the two. Secondly, when that contact force has reached a constant value required to produce a maximum deflection of the portion 903, further applied force is taken up by the spring action of the connector 30 900.

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Identical connectors 900 (not shown) in each of the other enclosures (811, 813 and 815) of the module 800 operate in a similar manner to that which has been described with reference to FIGS. 10 to 12. Normally, all of the connectors 900 experience the same force and go through the stages illustrated in FIGS. 10 to 12 together.

Although the improved connector (205 or 900) and connector module (109 or 800) embodying the invention have been described above with reference to application in a mobile communications handset, the connector and the module may be used in any electrically operated device requiring electrical connection between a fixed component and a removable component, especially where the components include printed circuit boards that need to be connected together. Other examples of applications for the improved connector and connector module include a host electrical unit and a charger and a host electrical unit and a vehicle mounted receiver cradle.

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Claims

1. A connector suitable for making an electrical connection between first and second electrical

5 components, the connector comprising a conducting strip including: (i) a first section including a deflectable member and a support member supporting the deflectable member, the deflectable member being adapted to be contacted and deflected about the support member by a 10 conductor of the first component; and (ii) a second section adapted to provide a spring loading of the first section when the first member is contacted and deflected by the conductor of the first component, the second section being adapted to contact a conductor of the 15 second component.

2. A connector according to claim 1 wherein the conducting strip includes a bend between the first section and the second section.

3. A connector according to claim 1 or claim 2 wherein 20 the deflectable member is a projection joined to and extending from the support member.

4. A connector according to claim 3 wherein the support member is substantially flat and the deflectable member is bent.

25 5. A connector according to claim 4 wherein the deflectable member includes a first part projecting from the support member at an acute angle to the support member and a second part projecting toward the support member at an acute member to the support member, the 30 deflectable member having a between its first and second

24

parts a bend which is adapted to be contacted by the conductor of the first member.

7. A connector according to any one of claims 4 to 6 wherein the support member is adapted to be parallel to

5 a surface of the conductor of the first component when the conductor contacts and deflects the deflectable member.

8. A connector according to any one of claims 3 to 7 wherein the deflectable member is a member which has

10 been cut from the support member.

9. A connector according to claim 8 wherein the deflectable member is deflectable through an aperture in the support member from which it has been cut.

10. A connector according to any one of the preceding 15 claims wherein the second section is adapted to be compressed when the deflectable member reaches a maximum deflection.

11. A connector according to any one of the preceding claims wherein the second section comprises a straight

20 portion joined by a bend to the support member of the first section and a base portion joined by a bend to the straight portion.

12. A connector according to claim 11 wherein at least one of the straight portion and the base portion

25 includes at least a part which is substantially parallel with the support member of the first section.

13. A connector according to any one of the preceding claims wherein the strip has a shape which approximates to an S shape.

30 14. A connector according to any one of claims including an extension portion attached to a free end of

25

the support member, the extension portion being adapted to engage a member of a module in which the connector is incorporated to limit travel of the support member.

15. A connector according to any one of the preceding

5 claims including a base portion adapted to engage one or more base members of a module to lock the base portion in position in an enclosure of the module.

16. A connector according to claim 15 including a base portion including at least one part which is bent to fit

10 on a ramped surface of at least one base member of a connector module.

17. A connector according to claim 15 or claim 16 including a base portion including a bifurcation in the base portion to provide (i) a first part which is bent

15 to fit on a ramped surface of a base member of a module and (ii) a second part which extends in a slot beneath the base member of the module.

18. A connector module including an electrically insulating body having an enclosure and, held in the

20 enclosure, a connector according to any one of the preceding claims.

19. A connector module according to claim 18 wherein the first section of the connector is above the insulating body.

25 20. A connector module according to claim 18 or claim 19 including a plurality of enclosures and a plurality of connectors each of which is held in one of the enclosures, wherein each of the connectors is a connector according to any one of the preceding claims 1 30 to 17.

26

21. A connector module according to any one of claims 18 to 2 0 wherein the module is adapted to receive the first component pushed against each connector in the module.

5 22. A connector module according to any one of claims 18 to 21 including in each of the enclosures a member adapted to be engaged by a portion of the connector in that enclosure to limit travel of the support member of the connector.

10 23. A connector module according to claims 18 to 22 including in each of the enclosures at least one base member having a ramped surface to receive on the ramped surface a bent part of a base portion of the connector.

24. A connector module according to claims 18 to 23 15 including in each of the enclosures at least one base member serving as a stop to limit movement of a straight portion of the connector in that enclosure.

25. A connector module according to any one of claims 18 to 24 including in each of the enclosures at least

20 one member serving to fix a base portion of the connector in that enclosure to at least one base member of the enclosure.

26. An electrical device including a first component removable from the device, a second component fixed in

25 the device and connector module according to any one of claims 18 to 25 electrically connecting the first component and the second component, the first component being pushed against the module with the or each connector of the module contacted by a corresponding 30 conductor of the first component.

27

27. An electrical device according to claim 2 6 wherein the first component is a battery.

28. An electrical device according to claim 18 or claim 19 wherein the device is a mobile communications

5 handset.

29. A connector according to any one of claims 1 to 17 and substantially as herein described with reference to any one or more of the accompanying drawings.

30. A connector module according to any one of claims 10 18 to 25 and substantially as herein described with reference to any one or more of the accompanying drawings.