RELATED APPLICATION INFORMATIONThis is a Continuation-in-Part of U.S. patent application Ser. No. 08/005,690 filed Jan. 19, 1993, now U.S. Pat. No. 5,295,843.
FIELD OF THE INVENTIONThe present invention relates to an electrical connector having electrical contacts, wherein the contacts are prevented from being wiped with insulation during mating connection with another, mating connector.
BACKGROUND OF THE INVENTIONAn electrical connector, known from U.S. Pat. No. 3,760,335, comprises, an insulating housing and conductive signal contacts. The contacts are grouped in pairs, with an insulative divider of the housing separating one contact of the pair from the other contact of the pair. Multiple pairs of the contacts are distributed along the insulative divider. The pairs of contacts are especially suitable for connection to twisted pair wires used in the communications industry for data and voice transmission. Each pair of the twisted pair wires are connected to one pair of the contacts. To shield the connector from ESD, electrostatic discharge, a conductive metal shell surrounds the insulative housing of the connector. For example, a shielded connector is disclosed in U.S. Pat. No. 5,158,481.
A desirable shielded connector provides ESD protection for the electrical contacts of the connector during mating connection of the connector with another, mating connector. During mating connection of two mating connectors, an electrostatic voltage charge on one or both of the connectors should be discharged to ground electrical potential via the shield on one or both of the connectors, whereby the voltage charge is shunted away from electrical contacts in the connectors.
SUMMARY OF THE INVENTIONA feature of the invention resides in a shield covered connector with tips of electrical contacts being recessed from a mating end of the connector, and being covered by insulative material that provides ESD protection for the contacts.
Another feature of the invention resides in a connector with insulative wiping surfaces that provide ESD protection for electrical contacts, the wiping surfaces being offset from contact surfaces of the contacts, in the direction of mating insertion, to avoid insulative material being wiped onto the contact surfaces during mating connection with another, mating connector.
DESCRIPTION OF THE DRAWINGSAn embodiment of the invention will now be described by way of example with reference to the drawings according to which;
FIG. 1 is a fragmentary perspective view of an electrical connector;
FIG. 2 is a section view of the connector shown inFIG. 1;
FIG. 3 is a fragmentary perspective view of another, mating electrical connector for mating connection with the connector shown inFIG. 1;
FIG. 4 is a section view of the connector shown inFIG. 3;
FIG. 5 is an elevation view in section of the connector shown inFIG. 4;
FIG. 6 is a view similar toFIG. 5, illustrating signal contacts in the connector shown inFIG. 3;
FIG. 7 is an elevation view in section of the connectors shown inFIGS. 1 and 3 prior to mating engagement with each other;
FIG. 8 is a view similar toFIG. 7, illustrating the connectors in mating engagement with each other; and
FIG. 9 is a section view similar toFIG. 8, illustrating mating engagement of power contacts of the connectors.
With reference toFIGS. 1 through 6, each of two mating embodiments of an electrical connector1 comprises, aninsulative housing2, multiple pairs3 ofconductive signal contacts4,5, accompanied by at least onepower contact6, in thehousing2. The pairs3 of thesignal contacts4,5 are distributed along aninsulative divider7 in aninterior8 of thehousing2. Thesignal contacts4,5 of each pair3 are on opposite sides of thedivider7 that separates thesignal contacts4,5 of each pair3. Thesignal contacts4,5 are in rows, and are parallel to one another. A pair ofcontact fingers9 on thepower contact6 are on opposite sides of thedivider7, and extend parallel to thesignal contacts4,5. The surface area of each of thefingers9 is larger than that of each of thesignal contacts4,5, and is sufficiently broad to radiate heat from electrical power dissipation. In addition, each of thefingers9 is of greater mass than each of thesignal contacts4,5 to carry electrical current. When electrical current is transmitted by thepower contact6, dissipation of electrical power generates heat. The heat is radiated from the surface area of thepower contact6. A larger surface area and a higher mass of thepower contact6 will limit the temperature attained by thepower contact6.
Thedivider7 bridges between, and is joined toside walls10,11 of thehousing2. Thedivider7 extends from afront mating end12 of thehousing2 and rearwardly in theinterior8 of thehousing2. Spaced apartpartitions13 in theinterior8 bridge between thedivider7 and atop wall14 of thehousing2, and between thedivider7 and abottom wall15 of thehousing2. Thepartitions13 join thedivider7 and the top andbottom walls14,15. Thewalls14,15 bridge between and join theside walls10,11 to form the exterior of thehousing2. Contact receivingcavities16 in thehousing2 are defined between thepartitions13 and extend behind thedivider7 to receive thesignal contacts4,5. With respect to thepower contact6,FIGS. 5 and 9, thefingers9 are connected to abody portion17 having a surface area sufficiently broad to radiate heat from electrical power dissipation. Apocket18 in thehousing2, between aside wall14,15 and apartition13, and behind thedivider7, receives thebody portion17. Each of thecontact receiving cavities16 is smaller than thepocket18. Thepower contact6 can be inserted in thehousing2 unmistakenly in thepocket18 that is larger than each of the smaller, contact receivingcavities16 that is smaller than thebody portion17. Thedivider7 extends forwardly of thepartitions13, and is provided with a series ofgrooves19 on its opposite sides aligned with the contact receiving passages. Thegrooves19 receive thesignal contacts4,5 and thecontact fingers9. Thegrooves19 that receive thecontact fingers9 are larger than thegrooves19 that receive thesignal contacts4,5. Projecting lances20 on each signal contact4,5,FIGS. 7 and 8, and on thepower contact6 impinge againstwalls21 of thehousing2, and resist withdrawal of thecontacts4,5 and6 from thegrooves19. Each of thesignal contacts4,5 and thepower contact6 is of unitary construction, stamped and formed from a strip of metal.
With respect toFIGS. 3-7, a circuit board connector1, meaning a version of the connector1 for mounting on a circuit board, not shown, will be described. Thedivider7 is spaced apart from the top andbottom walls14,15 of thehousing2. Thegrooves19 face toward the top andbottom walls14,15. The pairs3 ofsignal contacts4,5 are adapted to be connected to a circuit board, not shown. Anelectrical termination22 in the form of a post extends laterally downward from each of thesignal contacts4,5 for connection to a circuit board, not shown, and more particularly, to a plated aperture, not shown of the circuit board. Theterminations22 extend laterally downward by bending thesignal contacts4,5 along their lengths, thesignal contact4 being longer in length than thesignal contact5.
With reference toFIGS. 5 and 9, thebody portion17 has a thickness that is the same thickness as each of thecontact fingers9. Thefingers9 are bent to extend outward from thebody portion17 such that the thickness of thebody portion17 is in a plane perpendicular to a plane of thickness of each of thecontact fingers9. Atermination22 in the form of a pair of posts extend laterally downward of eachbody portion17 for connection to a circuit board, not shown, and more particularly, for connection in plated apertures, not shown, of the circuit board. Each of theterminations22 is larger in surface area and mass than that of each of theterminations22 on thesignal contacts4,5, thereby to conduct electrical current, and to radiate heat resulting from dissipation of electrical power.
Theterminations22 are on thesignal contacts4,5 where they emerge from a rear of thedivider7. Theterminations22 are on thepower contact6 where it emerges from a rear of thedivider7. A series ofslots23 in thebottom wall15 of thehousing2 have open ends communicating with arear end24 of thebottom wall15. Theterminations22 project through theslots23, with theterminations22 of each pair3 of thecontacts4,5 being spaced apart along thesame slot23. Thebottom wall15 of thehousing2 provides a base from which knob shapedfeet25,FIGS. 6-8, extend for resting against a circuit board, not shown.
With reference toFIGS. 1,2 and7-9, a cable connector1, meaning a connector1 for connection to an electrical cable, not shown, will be described. The cable connector1 is adapted for mated connection with the version of the connector1.FIGS. 3 and 4, for mounting on a circuit board, not shown. Thedivider7 of the cable connector1 is bifurcated by apassage26 at thefront mating end12 for receiving thedivider7 of the version of the connector1 for mounting on a circuit board, not shown. Thegrooves19 face toward thepassage26, such that thecontacts4,5 on opposite sides of thedivider7 face toward thepassage26. The pairs3 ofsignal contacts4,5 are adapted to be connected to respective pairs3 ofsignal wires27 of a single electrical cable, not shown, or of multiple electrical cables, not shown. Thesignal wires27 can be a twisted pair ofsignal wires27. InFIG. 7, each of thesignal contacts4,5 further comprises atermination22 havingarms28 that extend outward laterally of each other, the arms being bendable into an open barrel configuration to encircle and connect with thesignal wire27. Another set ofarms29 extend laterally of each other, thearms29 being bendable into an open barrel configuration to encircle and connect withinsulation30,FIG. 8, encircling thesignal wire27.
With reference toFIG. 9, thecontact fingers9 extend from a connection to an electricalpower transmitting wire31 larger in diameter than each of thesignal wires27. Thewire31 may comprise an electrical power cable. In particular, thebody portion17 comprises atermination22 having sets ofarms32,33 that extend outward laterally of each other, thearms32 being bendable into an open barrel configuration to encircle and connect with the electricalpower transmitting wire31. Thewire31 is larger in diameter than each of thesignal wires27 to carry electrical current. Thesignal wires27 are smaller in diameter, as they are required to transmit electrical signals of which the voltage, not the electrical power, is of paramount importance. The set ofarms33 extend laterally of each other, and are bendable into an open barrel configuration to encircle and connect with insulation encircling thewire31.
With reference toFIG. 1, projectinglocks34 are on the exterior of thewall14. Thelocks34 are in the form of inclined wedge projections tapering toward thefront mating end12. Themating end12 has aprofile including chamfers35,FIG. 2, that intersect thewall14, making thewall14 less wide than thewider wall15, thereby providing the connector1 with polarity for orienting themating end12.
With reference toFIGS. 1 and 2, shielding36 for both electrical connectors1, comprises; two conductive,telescopic shells37,38 that fit and slide one within the other. Each of theshells37,38 is of unitary construction, stamped and formed from a metal plate. Theshells37,38 each are bent on themselves, forming wrapped sections, and forming telescopic first and secondtubular enclosures39,40, with open front ends41,42 defining mating ends of theshells37,38.
A number offolds47 in thetubular enclosure39 conform to an exterior shape of thehousing2 of the connector1. Thefolds47 define the circumference of the profile on the mating end41.Folds47 in theenclosure40 define the circumferences of the open ends42,44. Thefolds47 conform theshell38 with the shape of thefirst shell37. Aseam45 extends along thetubular enclosure39.Multiple locks48, in the form of openings, located on both sides of theseam45, lock to the connector1 by locking to the projectinglocks34 on thehousing2. Anovermold57,FIG. 8, in the form of a molded insulation of desired shape, covers and adheres to thecable25 and the strain relief portions51,52.
With reference to FIGS.2 and5-9 both connectors1 will be described further.Flanges58 on thedivider7 of thehousing2 overhang the front ends of thegrooves19 and overhang both lateral sides of each of thegrooves19. Theflanges58 overlap front tips on thecontacts4,5 and front tips of thecontact fingers9 that are inrespective grooves19. The front tips of thecontacts4,5 and of thecontact fingers9 are recessed from themating end12 of thehousing2.
With reference to the circuit board connector1 shown inFIGS. 3 and 4, each of thecontacts4,5, and thecontact fingers9, are inclined and bowed along their lengths to project outwardly bowed from thegrooves19. The bowedcontacts4,5, and the bowedcontact fingers9, are resiliently deflectable by flattening their bowed configurations. For example, during mating connection of the connectors1, one to the other,FIG. 8, thecontacts4,5 and thecontact fingers9, of one connector1, are matingly inserted into the other, mating connector1. The bowedcontacts4,5, and the bowedcontact fingers9, of the circuit board connector1 engagerespective contacts4,5, andcontact fingers9, of the cable connector1, and are flattened somewhat to exert pressure engagement with thecontacts4,5, and thecontact finger9, of the cable connector1.
The cable connector1 provides ESD protection, electrostatic discharge protection, for thesignal contacts4,5. ESD protection is provided for thepower contacts6, as well. With reference to the cable connector1 shown inFIGS. 1 and 2, theflanges58, that overhang sides of thegrooves19, overlaplateral edge margins59,FIG. 2, on each of thecontacts4,5 on each of thecontact fingers9. Thelateral edge margins59 are received inrespective grooves19. On eachsignal contact4,5, and on eachcontact finger9, a raised, conductive,contact surface60 is allocated to a central section on eachcontact4,5 and on eachcontact finger9 between thelateral edge margins59. Theconductive surface area60 is raised with respect to thelateral edge margins59. With respect to thecontacts4,5, theconductive surface area60 is separated from thelateral edge margins59 by slits. With respect to thepower contacts9, theconductive surface area60 is raised by bending thepower contacts9 lengthwise along theedge margins59.
Within thepassage26 and on themating end12 of thehousing2, are multiple, insulative wiping surfaces61 in the form of inclined ramps. The wiping surfaces61 are spaced apart one from another, and appear as a castellated structure. The wiping surfaces61 are interposed between the tips of thecontacts4,5 and themating end12 of thehousing2. The wiping surfaces61 are over the front tips of thecontacts4,5 and of thecontact fingers9. The wiping surfaces61 are in axial alignment with theedge margins59 on thecontacts4,5, and on thecontact fingers9, and are offset laterally from the contact surfaces60 on thecontacts4,5 and on thecontact fingers9. The wiping surfaces61 project along paths of mating insertion of thecontacts4,5, and thecontact fingers9, and are interposed between themating end12 of thehousing2 and the exposedcontacts4,5 and the exposedcontact fingers9.
With reference toFIG. 7, with theconductive shells37,38 engaged, thecontacts4,5 and thecontact fingers9, of the circuit board connector1, will engage the insulative wiping surfaces61, prior to engagement with therespective contacts4,5 andcontact fingers9, of the cable connector1. At least theshell38 of the circuit board connector1 will be referenced to ground electrical potential, by virtue of being connected to a ground plane of a circuit board, not shown. The engagedconductive shells37,38 discharge electrostatic voltages to ground before thecontacts4,5 and thecontact fingers9 of the connectors1 engage one another. The engagedconductive shells37,38 are engaged while the insulative wiping surfaces61 are interposed between thecontacts4,5 of the two connectors1, and between thecontact fingers9 of the two connectors1. To mate the connectors1, thecontacts4,5 and thecontact fingers9, of the circuit board connector1 will wipe against, and ride over, the insulative wiping surfaces61 as mating connection of the connectors1 takes place.
During mating engagement of one connector1 and the other connector1, thecontacts4,5 of the circuit board connector1 will wipe, or stroke against, thecontacts4,5 of the cable connector1, as shown in FIG.8. It is desired to avoid wiping of thecontacts4,5 and thecontact fingers9 against theinsulative material61 of thehousings2, particularly at the same places where thecontacts4,5 engage one another, and where thecontact fingers9 engage one another. Such wiping against theinsulative material61 would tend to apply insulative material on thecontacts4,5 and on thecontact fingers9. The presence of insulative material on thecontacts4,5 and on thecontact fingers9, where they engage one another during mating connection, would reduce electrical conductivity, undesireably. The contact surfaces60 onrespective contacts4,5 are rearward of the insulative wiping surfaces61 in thepassage26. Thecontacts4,5 of the circuit board connector1 wipe against the insulative wiping surfaces61 prior to engagement with thecontacts4,5 of the cable connector1. However, the insulative wiping surfaces61 are offset laterally from the contact surfaces60 of thecontacts4,5 in the cable connector1. Themating contacts4,5 of the circuit board connector1 are axially aligned in the direction of mating insertion with thecontacts4,5 of the cable connector1. The wiping surfaces61 are aligned with theside margins59 of thecontacts4,5 and thecontact fingers9, of the circuit board connector1, in the direction of mating insertion. The middle surface areas, between thelateral side margins59, of thecontacts4,5 and thecontact fingers9, of the circuit board connector1, are offset laterally of the wiping surfaces61, during mating insertion into the cable connector1. These middle surface areas pass between the insulative wiping surfaces61, and are unwiped by the insulative wiping surfaces61 during passage of the side margins of thecontacts4,5 and thecontact fingers9 over the wiping surfaces61. The contact surfaces of thecontacts4,5 and thecontact fingers9, of the cable connector1, engage these unwiped, middle surface areas of themating contacts4,5 andcontact fingers9, of the circuit board connector1. Thereby, the presence of insulative material is avoided on thecontacts4,5 and on thecontact fingers9, at the locations where they engage one another during mating connection of the connectors1.
An advantage of the invention resides in a connector1 with tips ofcontacts4,5 being recessed from amating end12 of the connector1 and covered by insulative material that provides ESD protection for thecontacts4,5.
Another advantage of the invention resides in a connector1 with insulative wiping surfaces61 that provide ESD protection forelectrical contacts4,5, the wiping surfaces61 being offset from thecontacts4,5 in the direction of mating insertion to avoid insulative material being wiped onto contact surfaces of thecontacts4,5 during mating connection with another, mating connector1.
Other advantages, and other embodiments and modifications of the invention are intended to be covered by the spirit and scope of the accompanying claims.