WO2010038105A1

WO2010038105A1 - Electrical connector assembly

Info

Publication number: WO2010038105A1
Application number: PCT/IB2008/055629
Authority: WO
Inventors: Michel Fonteneau; Ludwig Lange
Original assignee: Fci
Priority date: 2008-09-30
Filing date: 2008-09-30
Publication date: 2010-04-08

Abstract

A connector assembly comprising a first electrical connector (1 ) for mating with a respective second electrical connector (2). The first electrical connector (1 ) comprises an electrically-conductive element (6) formed out of a metal sheet and arranged at least partially around the dielectric body (3). A keying feature (15) is punched out of, and is integral to, the electrically-conductive element (6).

Description

Electrical connector assembly

FIELD OF THE INVENTION

The present invention relates to electrical connector assemblies, and in particular to electrically-conductive elements for such connector assemblies.

The present invention also relates to a method for manufacturing an electrically-conductive element.

DESCRIPTION OF THE RELATED ART

An electrically-conductive element may for example be a shield member fitted to an electrical connector.

Shield members are fitted to electrical connectors for reducing the electromagnetic radiations which may emanate from the connector to the surrounding equipment, as well as protecting the signal transmitting terminals of the connector from electromagnetic radiation which may radiate in its environment. Electromagnetic radiations are due to the transmission of high- frequency electrical signals through the connector, and it creates Electromagnetic Interference (EMI), which may interrupt or degrade the effective performance of surrounding electrical signals. Likewise, high- frequency signals from the environment may interfere with the effective performance of the connector itself.

As a way of preventing mating between incompatible connectors and ensuring correct orientation of complementary mating connectors, there exists connectors having asymmetrical shielding housing (such as D-type connectors). Such geometries or features are designed to receive a mating plug exhibiting only a specific complementary shape adapted for cooperating with such geometries or features.

A further aspect of such geometries or features is to ensure correct mating of complementary connectors when the signals being transmitted require a particular mating orientation of the connectors. The present invention seeks a low-cost and flexible alternative keying (i.e foolproofing or polarization) means capable of not only ensuring that only compatible connectors can mate (coding function) but also that such connectors mate only in a predetermined orientation (polarization function).

SUMMARY OF THE INVENTION

Therefore, according to the invention, there is provided a connector assembly according to claim 1 , wherein an electromagnetic shield, i. e. an electrically-conductive element is made provided with a keying tab.

With these features, because the keying feature is integral with the metal plate, a connector may be produced with fewer or simpler independent parts, leading to less assembling and simpler logistics, thereby reducing the overall costs thereof.

Furthermore, such connectors may easily be provided with a greater number of different shapes and geometries leading to more flexible end-user solutions.

According to a further aspect of the present invention, a shielded electrical connector according to claim 2 is provided.

According to yet a further aspect of the present invention, an electrically-conductive element according to claim 3 is provided.

According to yet a further aspect of the present invention, a method for manufacturing an electrically-conductive element, as recited in claim 9 or 10, is provided.

In various embodiments of the invention, one may also find one or more of the features as recited in the dependant claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Other characteristics and advantages of the invention will readily appear from the following description of various embodiments, provided as non-limiting examples, and of the accompanying drawings.

On the drawings: Figures 1 a and 1 b show respective perspectives view of a socket and a plug assembly according to an aspect of the present invention;

Figure 2 shows a cross sectional view of the socket taken along M-Il in figure 1a;

Figure 3 shows a perspective view of the electrically-conductive element of the socket of figure 1 ;

Figures 4a and 4b show two variants of the keying feature of the socket, taken in a cross-sectional view of the shielding member taken along IV-IV in figure 1 b;

Figure 5a shows a variant of the plug of figure 1 ;

Figure 5b shows a electrically-conductive element for a plug of any one of figures 1 a, 1 b, and 5a;

Figure 6 shows a further variant of the electrically-conductive element of figure 3.

On the different figures, the same reference signs designate like or similar elements.

DETAILED DESCRIPTION

Figures 1a and 1 b show respective perspective views of an assembly of compatible mating connectors, consisting of a shielded socket 1 adapted to mate with a plug 2 along a given relative longitudinal direction X. For the purpose of this description, each connector 1 , 2 has a mating direction M which corresponds respectively to the forward direction.

For the purpose of the following description, the following directions are also used:

- "Y" direction, being substantially vertical and perpendicular to X direction;

- "Z" direction, being substantially lateral and perpendicular to both X and Y directions.

Figure 2 shows a longitudinal cross-section of the socket 1 along a X-Y plane, along M-Il on figure 1 a. The socket 1 comprises a dielectric body 3 and an electrically-conductive element 6 (i.e. an electromagnetic shield also called "shielding member" below).

The dielectric body 3 is made of an insulating material, and is provided with a plurality of independent passageways for receiving a number of electrically-conductive contacts 4 arranged in a predetermined manner.

In the present example, sixteen contacts 4 are arranged in four staggered columns of four contacts.

Each one of the contacts 4 extends through a first aperture of the dielectric body 3 from a first end portion 4a, on the front face 3a of the dielectric body 3, to a second end portion 4b, on the bottom face 3b of the dielectric body 3. Each one of the first end portions 4a is aligned along the longitudinal X direction and is adapted to provide electrical connection with the plug 2. Each one of the second end portions 4b is aligned along the vertical Y direction and is adapted to connect to a support structure 5, such as through appropriate holes 5a of the printed circuit board (PCB) 5 to be soldered to tracks of an electrical circuit.

In a variant, the contacts 4 may simply be connected to a freestanding cable structure rather than to a PCB.

The dielectric body 3 is retained mechanically to the printed circuit board 5 by the shielding member 6, which surrounds at least partly the dielectric body 3. The shielding member 6 is illustrated in further detail on figure 3.

The shielding member 6 is made of electrically conductive material to provide for electromagnetic shielding and is preferably manufactured out of metal sheet which may be stamped and bent into shape. The shielding member 6 comprises a horizontal upper wall 6a, and two lateral walls 6b spaced apart in a lateral direction Z, the walls 6a, 6b extending from a rearmost edge 6r to a forward-most edge 6f along mating direction M. A back wall 6d (see Fig. 2) may be provided at the rear edge 6r to join the upper and lateral walls 6a, 6b.

A forward portion of the shielding member 6 may be further provided with a lower wall 6c joining the two lower extremities of the lateral walls 6b. The forward portion of the shielding member 6 and the lower wall 6c define a front volume 7 positioned flush with the front edge 6f; a rear volume 8 is partially defined by the shielding member 6 behind the front volume 7, and extending back to the rear edge 6r.

The rear volume 8 of the shielding member 6 is adapted for receiving the dielectric body 3 such that its front wall 3a is substantially aligned with the imaginary surface demarcating the front and rear volumes 7, 8. Thus, the first end portion 4a of the contacts 4 extends into the front volume 7 of the shielding member 6.

The front volume 7 of the shielding member 6 is adapted for receiving, along the longitudinal direction X, a portion of the plug 2 during the mating action.

The bottom extremities of each lateral wall 6b and the back wall 6d along the rear volume 8 may be provided with a series of cutouts 10 thereby forming support posts 10a between the respective cutouts 10. The cutouts 10 allow for heat evacuation to take place, while the support posts 10a maintains the shielding member 6 on the printed circuit board 5. The supports posts 10a are illustrated anchored into the PCB 5 (see in particular figure 1 b). Advantageously, the support posts 10a can be electrically connected to the ground of the PCB 5, so as to provide a grounding path.

Retention features 13 may be provided on the shielding member 6 for supporting the dielectric body 3, for mechanically fixing the shielding member 6 to the printed circuit board 5, and/or for providing an electrical "ground" connection to the PCB 5.

According to the illustrated embodiment, three retention features 13 are provided on the interior longitudinal edge 6e of the lower wall 6c of the shielding member 6. Each retention feature 13 is provided with a first portion 13a extending vertically along a predetermined height (see also figure 2) according to the desired vertical position of the dielectric body 3. The first portion 13a is extended by a second horizontal portion 13b adapted to come into contact and to provide support to the dielectric body 3. An end portion 13c extends vertically downwards and is adapted to traverse through holes provided on the printed circuit board 5 to provided mechanical fixation, and/or electrical grounding for the shielding member 6. The retention feature 13 may further be adapted as a positioning guide against the PCB 5, in such a way that when the shielding member 6 is appropriately placed, the forward edge of the PCB abuts the first portion 13a of the retention feature 13.

Furthermore, the lateral faces 6b and the upper face 6a may be provided with resilient pressure tabs 11 partially punched out of the surrounding metal and adapted for protruding into the rear volume 8 such that each pressure tab 11 comes into contact with the dielectric body 3, thus minimizing movement between the dielectric body 3 and the shielding member 6.

Similarly, the forward portion of the shielding member 6 along the front volume 7 (i.e. the upper face 6a, the lower face 6c, and each lateral face 6b) may be provided with a number of similar resilient pressure tabs 12 punched out of the surrounding metal for ensuring frictional resistance, stability for and electrical continuity with the shielding member of the mating plug 2 once entered in this volume 7. Each tab 12 is oriented in the longitudinal direction X, and has a free end 12a oriented to be rearward-most with respect to the mating direction M, such that it may resiliently bend against the incoming plug 2, without substantially impeding access.

The shielding member 6 further includes at least one keying feature 15 as illustrated most clearly on figure 3, a partial cross-section of which is shown on figure 4a along a X-Z plane taken along line IV-IV of figure 1 b.

In this example, the keying feature 15 comprises a pair of tabs 15a, 15b provided on respective lateral faces 6b of the shielding member 6. The tabs 15a, 15b are provided symmetrically with respect to a X-Y centre-plane, and vertically above the X-Z centre-plane. In particular, each tab 15a, 15b is positioned about two-thirds of the way up of each lateral face 6b.

Each tab 15a, 15b has a hook shape comprising a first portion 16 extending from the forwardmost edge 6f forwardly (in the mating direction M). A second portion 17 of each tab 15a, 15b extends rearwardly from the first portion 16 so as to protrude into the front volume 7. This may be easily fabricated by crimping back a tab extending from the forward edge 6f of shielding member 6. Stress-relief notches 19 may be provided immediately around the tabs 15a, 15b.

Alternatively, the keying feature 15 may be provided by a localized tab punched out of the lateral face 6b and extending in the mating direction M to a free end 18 protruding into the front volume 7, as is illustrated in figure 4b.

Alternatively, the tabs 15a, 15b are bent towards the front volume 7 so that they are substantially aligned in the lateral direction Z (i.e. in the Y-Z plane).

Alternatively, the keying features 15 are provided by a stamping operation out of the surrounding metal sheet forming a localized protrusion into the front volume 7.

Of course, the number and disposition of the keying features 15 is not limited to the above examples.

It is to be noted that although the keying feature 15 was described with respect to the lateral wall, it should be understood that it may be placed on any face 6a-6c surrounding the front volume. Furthermore, the keying feature 15 should preferably be disposed to form rotational asymmetries between the socket's 1 and the plug's 2 possible mating orientations. For instance, a square-shaped socket has four possible mating orientations, each 90° apart; a rectangle has only two possible mating orientations, each 180° apart.

The keying feature 15 thus protrudes from a locally flat region of the shield member 6, and is part of, and disposed integrally with, the shielding member 6. The keying feature 15 has for function to prevent mating of incompatible plugs with the socket 1 by preventing incompatible plugs from entering the front volume 7 of the shielding member 6 (also known as "coding" the connectors).

Advantageously, the keying feature 15 also ensures correct mating orientation of the plug 2 with respect to the socket 1 when the cross-sectional profile of either the socket 1 or the plug 2 has at least one rotational symmetry (also known as "polarizing" the connectors).

The shielding member 6 may be manufactured as follows.

Aflat piece of metal sheet, for instance a sheet metal, is provided into which an external profile is cut out, the external profile corresponding to the flattened-out shielding member 6. Alternatively, a metal sheet is provided directly with the appropriate shape of the contour already cut out. The bending lines of the shielding member 6, for example at the intersection of the upper face 6a and each lateral wall 6a, are provided with a series of perforations 9 to ease the bending thereof and provide possible thermal evacuation to the socket 1.

The keying feature 15 is formed out of the surrounding metal sheet :

- by bending, and possibly followed by crimping, a tab extending from the front end 6f of the shield member 6 towards what will be the internal volume of the shielding member (see figure 4a); or

- by punching a localized portion of the metal sheet proximal to a front end 6f, thereby forming a tab feature having a free end 18 oriented towards the front end (see figure 4b); or

- by stamping a localized portion of the metal sheet proximal to a front end 6f, thereby forming a localized protrusion protruding towards an inside surface of the shield member 6. Localized surfaces may also be punched and partially bent so as to form the pressure tabs 11 , 12.

Lastly, the retention features 13 may be formed, and the metal sheet bent to form the shielding member 6 for assembling at least partially around the appropriate dielectric body 3.

The bending, punching, and/or stamping actions may be performed simultaneously or successively, depending on the manufacturing facilities available.

It is to be noted that the term "formed" refers to a metal sheet working process, which is not limited to the specific processes described above, but may include any forming processes such as, but not limited to: drawing, cutting, punching, brake forming, roll forming, rolling, stamping, bending, and/or ironing, to achieve the intended aims.

A complementary plug 2 to the socket 1 as described above is illustrated in figures 1 a and 1 b, and in more detail on figures 5a and 5b.

In relation to the plug 2 as illustrated on figure 5a, the plug 2 comprises an insulation body 21 and a plurality of passageways opening into apertures 22 on the front face of the insulation body 21 , each one of which being provided with a respective electrical contact means. The insulation body 21 is formed to be complementary to the front volume 7 of the socket 1 , and the distribution of the apertures 22 match the arrangement of the first end portion 4a of the contacts 4.

The plug 2 further comprises channel features 24 disposed from the front face 21 a and extending along the lateral face 21 b of the insulation body 21. The channels 24 are open to the exterior, and are designed to receive and/or engage the keying feature 15 of the socket 1 , i.e. the channels are adapted to receive the keying feature without hindrance.

Upon mating of the socket 1 with the plug 2, the keying features 15 are adapted to slide along the channels 24. The channels 24 may also be fitted with a beveled forward edges 24a for facilitating the cooperation of the keying features 15 with the channels 24, especially during the mating action.

The plug 2 is fitted with a shield element 23 surrounding the insulation body 21 but for the front face 21a. The shield element 23 is constructed similarly to the shielding member 6 described hereabove, and is illustrated on figures 1a and 1 b, and independently on figure 5b.

The shielding element 23 comprises cutouts 23a leaving free access to the channels 24 of the insulation body 21. With the above-described dispositions, there is provided a socket 1 and a plug 2 with are specifically provided to be complementary to each other. Furthermore, if the keying feature 15 is disposed along rotational asymmetries, then the socket/plug assembly is provided to be complementary in only one rotational position, and only with a compatible set of connectors 1 , 2. It is thus possible to prevent inadvertent mating of incompatible connectors.

Furthermore, as the keying features 15 are provided integrally with the shielding member 6 of the socket 1 , the cost of providing these advantages are reduced, and the manufacturing is simplified. Likewise, the plug 2 may be shielded or unshielded depending on the application required.

Of course, the above description is given as a non-limiting example, and variants of this example could also be part of the invention as defined by the scope of the appended claims.

In particular, as shown on figure 6, the shielding member 6 or the shielding member 23 of the socket 1 or the plug 2 respectively may comprise clips 30 adapted to mount the connector to a panel. The clip 30 comprises a front resilient tab 31 adapted to be bent back into the shielding member 6 when it is fitted to a panel. Spaced from the front resilient tab 31 is an abutment feature 32 adapted to find support against the panel.

Claims

We Claim:

1. A connector assembly comprising a first electrical connector (1 ) for mating with a respective second electrical connector (2), each connector having a mating end, the first electrical connector (1 ) comprising:

- a dielectric body (3),

- at least one electrical contact (4);

- an electrically-conductive element (6) formed out of a metal sheet and arranged at least partially around the dielectric body (3);

- a keying feature (15) protruding from a locally flat region of the electrically-conductive element (6) and being integral with the electrically- conductive element (6), and being proximal to the mating end (6f) of the first connector; the second electrical connector (2) comprising:

- a dielectric body (21 ),

- at least one contact adapted to mate with the at least one contact of the first connector (1 );

- at least one receiving structure (24) adapted to receive the keying feature (15) of the electrically-conductive element during the mating action.

2. An electrical connector adapted for mating with a second electrical connector of the connector assembly according to claim 1 , comprising:

- a dielectric body (3) ,

- at least one electrical contact (4);

- an electrically-conductive element (6) formed out of a metal sheet and arranged at least partially around the dielectric body (3), the electrically- conductive element (6) presenting a mating end (6f) adapted to receive the second electrical connector (2);

- a keying feature (15) integral with the electrically-conductive element (6), and proximal to the mating end (6f).

3. An electrically-conductive element (6) for a connector assembly according to claim 1 , adapted to be fitted to a dielectric body of a connector, comprising:

- an electrically-conductive element (6) formed out of a metal sheet and adapted to at least partially surround a dielectric body (3), the electrically-conductive element (6) defining at least partially a volume (7) presenting a mating end (6f) adapted to receive the second electrical connector (2);

- a keying feature (15) being integral with the electrically-conductive element (6), the keying feature being proximal to the mating end (6f).

4. A connector assembly according to claim 1 , or an electrical connector according to claim 2, or an electrically-conductive element according to claim 3, wherein the keying feature (15) comprises at least one tab (15a, 15b) punched out of the surrounding electrically-conductive element (6).

5. A connector assembly according to claim 1 or 4, or an electrical connector according to claim 2 or 4, or an electrically-conductive element according to claim 3 or 4, wherein the keying feature (15) comprises at least one tab (15a, 15b) extending from the mating end (6f).

6. A connector assembly according to any one of claims 1 , 4 and 5, or an electrical connector according to any one of claims 2, 4 and 5, or an electrically-conductive element according to any one of claims 3, 4 and 5, wherein the keying feature (15) is disposed at positions of rotational asymmetries with respect to the cross-sectional geometry of the electrically- conductive element (6).

7. A connector assembly according to any one of claims 1 , and 4 to 6,

wherein the receiving structure (24) is disposed to extend from the front face (21 a) along a lateral face (21 b) of the dielectric body (21 ) of the second electrical connector (2).

8. A connector assembly according to any one of claims 1 , and 4 to 7, further comprising a shielding element (23) at least partially surrounding the dielectric body (21 ) of the second electrical connector, the shielding element (23) comprising cutouts that are complementary to the receiving structure (24) provided on the dielectric body.

9. A method of manufacturing an electrically-conductive element according to any one of claims 3 to 6, comprising the steps of: providing a metal sheet; cutting an external profile to the metal sheet according to a predetermined geometry; bending a tab (15a, 15b) extending from a front end (6f) of the metal sheet; bending the metal sheet to form an element (6) adapted to be fitted to at least partially surround a dielectric body, around a mating face of a the connector so that the tab of metal sheet extends at least partially through thye mating face.

10. A method according to claim 9, further comprising punching resilient tab features (11 ,12) towards an inside surface, the resilient tab features being adapted to provide pressure when the electrically-conductive element is fitted around a dielectric body.