WO2011076631A1

WO2011076631A1 - Connector assembly

Info

Publication number: WO2011076631A1
Application number: PCT/EP2010/069757
Authority: WO
Inventors: Jeroen De Bruijn; Gert Droesbeke
Original assignee: Fci
Priority date: 2009-12-21
Filing date: 2010-12-15
Publication date: 2011-06-30
Also published as: CN102714374A; CN102714374B

Abstract

A connector assembly comprises a first connector and a second connector configured for mating with each other to a mated state. The first connector comprises a first contact terminal with a first electrical contact surface portion on an exterior side of the first contact terminal. The second connector comprises a housing configured for receiving the first contact terminal, and a second contact terminal arranged at least partially within the housing and comprising a second electrical contact surface portion configured to contact the first electrical contact surface portion of the first contact terminal in the mated state of the first connector and the second connector. At least one of the housing and the first contact terminal is shaped to prevent mechanical contact between the housing and the first electrical contact surface portion when mating the first and second connectors.

Description

Connector assembly

TECHNICAL FIELD

The present disclosure relates to the field of connectors, in particular electrical power connectors. BACKGROUND

Electrical connectors generally comprise one or more conductive terminals configured for making electrical contact with terminals of a mating connector. The connector may comprise a protective housing. In particular in case of a power connector and in order to prevent accidental contact with the terminal of the connector, in particular human contact, such housing may be configured to substantially envelop the terminal and to receive a corresponding mating terminal to be contacted within the housing.

It has been found that after repeated cycles of mating and unmating connectors of a connector assembly of a first connector and a mating second connector the terminals may suffer from wear due to friction between the terminal against the housing of the mating connector. This may reduce contact reliability. Further, a rough contact area may lead to a decreased contact surface area and therewith to an increased electrical resistance of an established contact which increases losses. In particular in the case of power connectors, e.g. when transmitting several tens of amperes or more, such losses may lead to generation of significant heating which may pose dangers to nearby apparatus.

There is thus a desire for an improved connector assembly reducing the above mentioned problems. SUMMARY

In a connector assembly according to claim 1 the first electrical contact surface portion of a first terminal of a first connector is prevented from mechanically contacting the housing of a mating second connector to which electrical contact is to be made. Thus wear of the terminal by scraping against the housing at the surface portion where electrical contact is to be established is prevented or reduced. In this way the shape and surface quality of the first terminal can be maintained for more mating and unmating cycles than in a connector assembly in which such contact occurs. This improves reliability of the contact to be made and it reduces increase of contact resistance due to a poor or deteriorating electrical contact surface.

The connector assembly of claim 2 facilitates mating the first connector and the second connector. The portion shaped for guiding, or guiding portion for short, of the connector assembly may further determine a particular position and/or orientation of the first contact terminal with respect to the housing and/or the second terminal, such as to ensure electrical contact between the first and second electrical contact surface portions and to prevent establishing electrical contact aside from the first and/or second electrical contact surface portions. The guiding portion may comprise one or more lead-in portions. Providing the housing with a guiding portion, in particular a lead-in portion, obviates providing the second terminal with a guiding portion. This may reduce the size of the second terminal and thus of the second connector as a whole. It may also reduce material consumption for the second terminal and thus may reduce manufacturing costs. Further, in such connector assembly the second contact terminal need not be configured for both contacting and guiding and thus may be optimised for establishing electrical contact alone.

The connector assembly of claim 3 ensures that mechanical contact between the housing and the first electrical contact surface portion be prevented at the predetermined position and/or orientation of the first terminal. The predetermined position and/or orientation may be defined by suitable means, e.g. polarisation and/or keying of the connector. The shape of the aperture in combination with the shape of the first terminal may also serve for defining the predetermined position and/or orientation. It has been found that an electrical contact between substantially plane contact surfaces of contact terminals usually is not established over the entire intended surface area of the contact terminals, but only at a small number of contact points providing point-like contact surfaces, e.g. due to wear and/or to manufacturing tolerances of the terminals and of the connectors as a whole. The result is a low total contact surface and thus a higher contact resistances causing losses and heating. The contact points may vary in number and position, depending on wear as a result of mating / unmating cycles. A solution to this is to provide a terminal with a convex portion which may extend from an adjacent portion of the contact terminal, which allows establishing contact reliably to that convex portion.

The connector according to claim 4 reduces wear of such convex portion. The convex portion preferably extends along the first direction for a significant portion of the corresponding length of the contact terminal, for providing a substantially linear contact surface with increased total contact surface area, thus reducing associated losses.

The connector assembly of claim 5 allows increasing a radius of curvature of the convex portion, allowing increasing a resulting surface area of an electrical contact between the first and second contact terminals at the first and second electrical contact surface portions.

The connector assembly of claim 6 provides protection for the first electrical contact surface portion also against mechanical contact with other objects.

At least a portion of at least one of the first and second electrical contact surface portions may be plated with a conductive material for improving electrical contact. Suitable plating materials, e.g. gold, silver, may prevent oxidation of the contact surface (s) and/or provide a generally high conductivity.

The connector assembly of claim 7 prevents establishing electrical contact between the first and second electrical contact surface along an edge of a terminal. This obviates manufacturing steps for preventing burrs etc. along the edge, reducing manufacturing costs. Further, it has been found that plating material tend to adhere less strong to sharply curved portions such as edge portions of plated objects so that the plating may wear off faster along such edge portion than aside from the edge portion e.g. more to the middle of a surface portion. In addition, as a result of manufacturing, plating material may collect along an edge portion, reducing planarity of the contact surface. This may cause these portions to protrude somewhat beyond adjacent portions and in turn lead to increased wear of the counter contact terminal by these protruding portions. The connector assembly of claim 7 assists preventing such problems.

Further aspects are defined in claims 8-10.

BRIEF DESCRIPTION OF DRAWINGS

Fig. 1 is a perspective view of a first connector of a connector assembly;

Fig. 2 is a perspective view of a second connector of a connector assembly;

Fig. 3A is a perspective view of a plug contact terminal ;

Figs. 3B and 3C are partial perspective views of alternative plug portions of a plug contact terminal;

Fig. 4 is a perspective view of a second contact terminal ;

Fig.5 is a partial perspective view of the connector of Fig. 2;

Fig. 6 illustrates the relative positions of the plug portion of a first contact terminal and a portion of the housing second connector of Fig. 2 when mating;

DETAILED DESCRIPTION OF EMBODIMENTS Various aspects and benefits will hereafter be more fully explained with reference to the drawings showing an embodiment by way of example. It should be noted that in the following, like objects are identified with like reference signs .

Fig. 1 shows a first connector 100 and Fig. 2 shows a second connector 200 which together form a power connector assembly for transmitting electrical power, being configured for mating with each other along respective mating directions M to a mated situation (not shown) . In the shown embodiment the first connector 100 is configured as a board connector and the second connector 200 is configured as a cable connector, but any configuration of mating connectors is conceivable within the scope of the appended claims.

The first connector 100 comprises a housing 101 having a rear side RS and a mating side MS, its mating direction M being generally in a direction from its rear side RS towards its mating side MS. The first connector 100 further comprises two first terminals 102 disposed in the housing 101, although more or less terminals may be provided. The first terminals 102, shown in Fig. 3A, are male (or plug) terminals 102 comprising a plug portion 103 extending substantially in the mating direction M towards the mating side MS and being configured to contact an appropriately shaped further terminal of the second connector 200.

The second connector 200 comprises a housing 201 having a rear side RS and a mating side MS, its mating direction M being generally in a direction from its rear side RS towards its mating side MS. The second connector 200 further comprises two second terminals 202 disposed within the housing 201, although more or less terminals may be provided. The second terminals 202, shown in Fig. 4, are female terminals 202 comprising a receptacle portion 203 extending substantially in the mating direction M towards the mating side MS and being configured for receiving a plug terminal of the first connector 100 to contact it.

Referring now to Fig. 3A, the male terminal 102 of the connector 100 of Fig. 1 comprise a plug portion 103 which extends from a body portion 104. Contact means 105 are provided for contacting the male terminal 102 to a further object, here a circuit board. In the shown embodiment, the plug portion 103 is formed by two contact blades 106 having exterior sides 107. A portion 108 of the plug portion 103 is configured to have a substantially convex cross-sectional shape as seen in a plane substantially perpendicular to the mating direction M. In the shown embodiment the convex portion

108 is substantially elongated in a direction substantially in the mating direction M. First electrical contact surface portions 109 are provided on the exterior sides 107 at the convex portions 108 of the plug portion 103, thus the first electrical contact surface portions 109 are substantially elongated and extend substantially in the mating direction M, for providing a substantially linearly extending contact surface for establishing a line-contact with an appropriately shaped mating terminal.

In the shown embodiment of the male terminal 102, the convex portion 108 is arranged along the plug portion 103 such that the plug portion 103 comprises a tip portion 110 with another cross-sectional shape towards the mating side MS. Here, the convex portion 108 is formed by reducing the thickness of the material of the contact blades 106 in edge portions 111 adjacent the electrical contact surface portion

109 and the tip portion 110 is left with a substantially rectangular cross-sectional shape.

Figs. 3B and 3C show two alternative shapes of plug portions 103 comprising two contact blades 106. In the plug portion 103 of Fig. 3B the contact blades 106 have a convex, substantially semi-circular cross-sectional shape in a plane substantially perpendicular to the mating direction M. In the plug portion 103 of Fig. 3C the contact blades 106 have a generally elongated cross-sectional shape, having opposed relatively long sides and opposed relatively short sides with respect to each other. The contact blades 106 comprise a convex portion in the form of an elongated protruding rib 108A extending inbetween edge portions 111 in a direction along the mating direction M along a portion of the plug portion 103. In the plug portions 103 shown in Figs. 3B and 3C, the contact portions 109 extend substantially linearly along the respective mating directions M towards the mating side MS of the respective plug portions 103.

Although substantially cylindrical or solid plug portions 103 may also be employed, a plug portion 103 comprising two or more separated contact blades 106 or contact segments 106 in general may provide resiliency to the plug portion 103 for regulating contact pressure between a contact blade and a further object. A reduced contact force may reduce wear when a contact blade 106 scrapes against another object. A plurality of contact segments 106 may also allow a fluid flow, e.g. an air flow, through the plug portion 103 in between the segments which may improve cooling of the terminal 102.

Referring now to Fig. 4, the female (receptacle) terminal 202 of the second connector 200 of Fig. 2 comprise a receptacle portion 203 which extends from a body portion 204. Contact means 205 are provided for contacting the contact terminal to a further object, here a wire of a cable. The receptacle portion 203 comprises an interior side 207 providing second electrical contact surface portions 209 configured to contact the first electrical contact portion 109 of the plug terminal 102 in the mated state of the first and second connectors 100, 200. In the shown embodiment, the receptacle portion 203 comprises a substantially U-shaped cross-sectional shape in a plane substantially perpendicular to the mating direction M. The thickness of the material in the cross-sectional plane may be substantially constant or it may vary, e.g. comprising one or more convex portions for establishing an electrical point contact or an electrical line contact, which may be preferred.

The electrical contact surface portions 109, 209 and adjacent portions may be plated for increasing conductivity and/or reducing contact resistance of an electrical contact established at the electrical contact surface portions.

As seen best in Fig. 5, the housing 201 of the second connector 200 comprises apertures 212 for receiving the first terminals 102 within the interior side of the aperture for contacting the second terminals 202. The apertures 212 comprise a rim 213 defining the shape of the mating side of the aperture 212.

In the shown embodiment the aperture 212 has a substantially elongated cross-sectional shape in a plane substantially perpendicular to the mating direction M, defining for receiving a plug contact 102 in a defined relative orientation and position. The rim 213 is bevelled towards the interior side of the aperture 212 for guiding a plug contact 102 into the interior side of the aperture 212 when mating the connectors 100 and 200.

Towards the interior side of the aperture 212 the rim

213 comprises recessed portions in the form of chamfered grooves 214. The grooves 214 are arranged at positions corresponding to the position of the electrical contact surfaces 109 of the contact terminals 102 when mating the first connector 100 and the second connector 200.

Fig. 6 schematically illustrates the relative position of the housing 201 and a generally convex plug portion 109 in a position for mating (only one half of the connector 200 is shown) . In Fig. 6 the mating side MS of the second connector 200 is visible, together with the cross- sectional shape of the contact blades 106 of a plug portion 109 of a first terminal 102, as seen along the mating direction M of the first contact terminal 102 in a direction from its rear side RS towards its mating side MS.

It will be appreciated that, when mating the connectors 100 and 200, the contact blades 106 of the plug contact 102 are guided by the bevelled rim 213 into the aperture 212 for facilitating contacting the receptacle contact terminal 202 of the second connector 200 (not shown in Fig. 6) . By this guiding (the tip portions 110 of) the contact blades 106 may scrape along (the rim 213 of) the housing 201. When mating, the portions of the rim 213 adjacent each groove

214 bear against the contact blades 106, whereas due to the presence of the groove 214 at the appropriate position, the electrical contact surface portions 109, here arranged substantially in the middle of the contact blades 106, are prevented from mechanically contacting the housing material and thus they are not scraped by the housing 201.

Since insulating housings of connectors may generally comprise glass-filled epoxy, which has proven particularly abrasive with repeated mating-unmating cycles, the present assembly reduces abrasive wear of the electrical contact surface portions 109.

The beneficial effects of the disclosed subject matter may extend beyond the above described embodiments which can be varied in a number of ways within the scope of the claims .

For instance, the first terminal 102 may comprise a plurality of electrical contact surface portions 109 adjacent each other when seen in a cross-sectional plane substantially perpendicular to the mating direction M and the housing 201 may comprise a plurality of recesses 214 corresponding to the positions of the electrical contact surface portions 109.

Claims

1. Connector assembly, comprising

a first connector (100) and a second connector (200) configured for mating with each other to a mated state,

the first connector comprises a first terminal (102) with a first electrical contact surface portion (109) on an exterior side of the first terminal,

the second connector comprises a housing (201) configured for receiving the first terminal, and a second terminal (202) arranged at least partially within the housing and comprising a second electrical contact surface portion (209) configured to contact the first electrical contact surface portion of the first contact terminal in the mated state of the first connector and the second connector,

wherein at least one of the housing and the first terminal is shaped to prevent mechanical contact between the housing and the first electrical contact surface portion when mating the first and second connectors.

2. Connector assembly according to claim 1,

wherein at least a portion of at least one of the first terminal (102) and the housing (201) of the second connector (200) is configured for guiding the first terminal when mating the first connector (100) and the second connector (200) .

3. Connector assembly according to any one of the preceding claims,

wherein the housing (201) of the second connector (200) comprises an aperture (212) having an interior side configured for receiving the first contact terminal in a predetermined position and/or orientation when mating the first connector (100) and the second connector (200), the aperture comprising a rim (213),

wherein at least the rim of the aperture comprises a recessed portion (214) towards the interior side at a position corresponding to the position of the first electrical contact surface (109) of the first contact terminal (104) when mating the first connector and the second connector in the predetermined position and/or orientation.

4. Connector assembly according to claim 3,

wherein the first terminal (102) is a plug terminal extending in a first direction and having a cross-sectional shape in a plane substantially perpendicular to the first direction,

wherein at least a portion (108; 108A) of the cross- sectional shape is convex, which convex portion comprises the first electrical contact surface portion (109),

wherein the recessed portion (214) of the aperture (212) of the housing (201) is shaped for receiving at least a portion of the convex portion of the first terminal.

5. Connector assembly according to claim 4,

wherein the cross-sectional shape of the first contact terminal (102) is substantially elongated having opposed relatively long sides and opposed relatively short sides with respect to each other, and wherein the convex portion (108; 108A) is arranged at a relatively long side.

6. Connector assembly according to any one of the preceding claims,

wherein at least a portion (107) of the cross- sectional shape is concave, which concave portion comprises the first electrical contact surface portion (109).

7. Connector assembly according to any one of the preceding claims,

wherein at least one of the first terminal (102) and the second contact terminal (202) extend in a main direction of extension and has an edge portion (111) along the direction of extension,

and wherein the first electrical contact surface portion (109) and the second electrical contact surface portion (209) are configured to establish electrical contact aside from the edge portion.

8. Connector assembly, comprising

wherein the first connector comprises a first terminal (102) with a first electrical contact surface portion (109) on an exterior side of the first contact terminal

wherein the second connector comprises a housing (201) having an aperture (212) with an interior side and a rim (213) configured for receiving and guiding the first terminal in a predetermined position and/or orientation when mating the first connector and the second connector, and

a second terminal (202) arranged at least partially within the housing and comprising a second electrical contact surface portion (209) configured to contact the first electrical contact surface portion of the first contact terminal in the mated state of the first connector and the second connector,

wherein at least the rim of the aperture comprises a recessed portion (214) towards the interior side at a position corresponding to the position of the first electrical contact surface of the first contact terminal when mating the first connector and the second connector in the predetermined position and/or orientation for preventing mechanical contact between the housing and the first electrical contact surface portion when mating the first and second connectors.

9. Connector assembly, comprising

a first connector (100) and a second connector (200) configured for mating with each other to a mated state, wherein the first connector comprises a first terminal (102) with a first electrical contact surface portion (109) on an exterior side of the first contact terminal

a second terminal (202) arranged at least partially within the housing and comprising a second electrical contact surface portion (209) configured to contact the first electrical contact surface portion of the first terminal in the mated state of the first connector and the second connector,

wherein at least the rim (213) of the aperture comprises a recessed portion (214) towards the interior side shaped for receiving at least a portion of the convex portion of the first terminal when mating the first connector and the second connector in the predetermined position and/or orientation for preventing mechanical contact between the housing and the first electrical contact surface portion when mating the first and second connectors.

10. Second connector (200) of a connector assembly according to any one of the preceding claims, Comprising:

a housing (201) having an aperture (212) with an interior side and a rim (213) configured for receiving and guiding a first terminal (102) in a predetermined position and/or orientation when mating a first connector (100) comprising the first contact terminal and the second connector (200), and

a second terminal (202) arranged at least partially within the housing and comprising a second electrical contact surface portion (109) configured for being in contact with a first electrical contact surface portion (109) of the first terminal in the mated situation of the first connector and the second connector, wherein at least the rim (213) of the aperture comprises a recessed portion towards the interior side for preventing mechanical contact between the housing and the first electrical contact surface portion when mating the first and second connectors.