CN1902789B - Power contact and connector including the same - Google Patents

Abstract

The invention provides an electrical connector and a contact for transmitting electrical power. One power contact embodiment includes a first plate forming a first non-deflecting beam and a first deflectable beam and a second plate forming a second non-deflecting beam and a second deflectable beam. The first and second plates are arranged alongside one another to form a power contact.

Description

Power contacts and connectors including power contacts

Cross References to Related Applications

This application claims priority to the following U.S. Provisional Patent Applications: No. 60/533822 filed December 31, 2003; No. 60/533749 filed December 31, 2003; No. 60/533749 filed December 31, 2003; 60/533,750, 60/534,809, filed January 7, 2004, and 60/545,065, filed February 17, 2004, all of which are incorporated herein by reference.

technical field

The present invention relates to electrical contacts and connectors designed and constructed for carrying electricity. At least some preferred connector embodiments include both power contacts and signal contacts disposed in the housing unit.

Background technique

Electrical device and system designers face challenging factors in the development of new electrical connectors and power contacts. For example, increased power transfer is often challenged by size constraints and undesired heat buildup. In addition, typical power connector and contact beam structures result in high mating forces. When significant mating forces are transmitted into the connector housing structure, the plastic can creep, causing dimensional changes that can affect the mechanical and electrical performance of the connector. The unique connectors and contacts provided by the present invention seek to balance those structural factors that have limited the performance of the prior art.

Contents of the invention

The present invention provides power contacts for use in electrical connectors. According to a preferred embodiment of the present invention, there is provided a power contact, which includes a first plate-shaped body member, and a second plate-shaped body member stacked on the first plate-shaped body member, thereby The first plate-shaped body member and the second plate-shaped body member contact each other along at least a portion of opposing body member surfaces.

According to another preferred embodiment of the present invention there is provided a power contact comprising juxtaposed first and second plate-shaped body members forming the width of a composite plate. The first body member includes a first terminal and the second body member includes a second terminal. The distance between the corresponding distal ends of the first terminal and the second terminal is greater than the composite board width.

According to another preferred embodiment, there is provided a power contact comprising opposing first and second plate-shaped body members. A set of clamping beams extend from opposing plate-shaped body members for engaging straight beams connected to mating power contacts. At least one straight beam also extends from the opposing plate-shaped body member for engaging the angled beam associated with the mating power contact.

According to another preferred embodiment, there is provided a power contact comprising a first plate defining a first non-deflecting beam and a first deflectable beam, and defining a second non-deflecting beam and a second deflectable beam. Second plate of the deflection beam. The first plate and the second plate are arranged alongside each other to form power contacts.

The invention also provides mating power contacts. According to a preferred embodiment of the present invention there is provided mating power contacts comprising a first power contact comprising opposed first and second plate-shaped body members; and a first Two power contacts, which include opposite third and fourth plate-shaped body members. At least one pair of the first and second body members and the third and fourth body members are laminated to each other.

According to another preferred embodiment there is provided mating power contacts comprising a first power contact comprising a pair of straight beams and a pair of angled beams; and a second power contact comprising A second pair of straight beams and a second pair of angled beams. The pair of straight beams aligns with the second pair of angled beams; and the pair of angled beams aligns with the second pair of straight beams.

According to another preferred embodiment, mating power contacts are provided, said power contacts comprising a first power contact and a second power contact. The first power contact includes a body member, a deflecting beam extending from the body member, and a non-deflecting beam extending from the body member. The second power contact includes a second body member, a second deflecting beam extending from the second body member, and a second non-deflecting beam extending from the second body member. When the first power contact and the second power contact are mated, the deflecting beam engages the second non-deflecting beam, and the non-deflecting beam engages the second deflecting beam such that a mating force is applied in the opposite direction to move the first Stress in each of the first power contact and the second power contact is minimized.

According to another preferred embodiment, mating power contacts are provided, said power contacts comprising a first power contact and a second power contact. The first power contact and the second power contact each include a pair of opposing non-deflecting beams and a pair of opposing deflectable beams, respectively.

The invention also provides an electrical connector. A preferred electrical connector may include the power contacts described above. In addition, according to a preferred embodiment of the present invention, an electrical connector is provided, and the electrical connector includes a housing and a plurality of power contacts arranged in the housing. Each power contact includes a plate-shaped body member comprising at least one of an upper portion in which a cutout is formed and a separate lower portion adapted to to fit in the cutout. Some of the power contacts are disposed in the housing such that adjacent power contacts include only one of upper and lower portions.

According to another preferred embodiment, an electrical connector is provided, and the electrical connector includes a plug electrical connector and a socket electrical connector. The plug connector includes a plug housing and plug contacts arranged in the plug housing. The plug contact includes a pair of plate-shaped body members and a plurality of beams extending therefrom. The receptacle connector includes a receptacle housing and receptacle contacts disposed in the receptacle housing. The receptacle contact includes a second pair of plate-shaped body members and a second plurality of beams extending therefrom. The force required to mate the plug electrical connector with the receptacle electrical connector is about 10N or less per contact.

According to another preferred embodiment of the present invention, an electrical connector is provided, and the electrical connector includes a housing, a first power contact and a second power contact. The second power contact has a higher rated amperage than the first power contact.

Description of drawings

FIG. 1 is a front perspective view of an exemplary plug connector provided by the present invention.

FIG. 2 is a front perspective view of an exemplary receptacle connector that may mate with the plug connector shown in FIG. 1 .

3 is a perspective view of an exemplary vertical receptacle connector including power contacts and signal contacts.

FIG. 4 is a front view of the plug connector shown in FIG. 1 mated with the socket connector shown in FIG. 2 .

FIG. 5 is a front view of an exemplary plug connector mated with the receptacle connector shown in FIG. 3 .

6 is a front perspective view of another exemplary plug connector according to the present invention.

7 is a front perspective view of a receptacle connector that may mate with the plug connector shown in FIG. 6 .

8 is a front view of the receptacle connector showing a preferred centerline spacing of the power and signal contacts.

9 is a perspective view of an exemplary power contact provided by the present invention.

10 is a perspective view of a power contact that may mate with the power contact shown in FIG. 9 .

11 is a perspective view of the power contact shown in FIG. 9 mated with the power contact shown in FIG. 10 .

12-14 are front views of exemplary power contacts at three engagement levels.

15-19 are graphs illustrating representative mating force versus insertion distance for various exemplary power contacts provided by the present invention.

Figure 20 is a perspective view of a split contact according to the present invention.

21 is a perspective view of a power contact that may mate with the upper and lower portions of the split contact shown in FIG. 20. FIG.

22 is a perspective view of a plug connector including power contacts having different amperage ratings.

Fig. 23 is a perspective view of another mating power contact provided by the present invention.

24-26 are perspective views of mating power contacts each comprising four laminated body members.

Figure 27 is a perspective view of another power contact using four laminated body members.

28 is a perspective view of an embodiment of a power contact having laminated body members having flared regions that collectively form a contact receiving space.

29 is a perspective view of a power contact insertable into the contact receiving space of the power contact shown in FIG. 28 .

Figure 30 is a perspective view of a stamped strip used to form the power contact of the present invention.

31 is a perspective view of the stamped strip shown in FIG. 30 including material overmolded over a portion of the stamped strip.

32 is a perspective view of the power contact subassembly that has been separated from the strip shown in FIG. 31. FIG.

33 is a perspective view of a signal contact subassembly in accordance with the present invention.

34 is a perspective view of an exemplary connector including a power contact subassembly and a signal contact subassembly as shown in FIGS. 32 and 33, respectively.

35 is a perspective view of an example power contact having opposing plates stacked together in a first region and spaced apart in a second region.

Detailed ways

Referring to FIG. 1 , there is shown an exemplary plug connector 10 including a connector housing 12 and a plurality of power contacts 14 disposed therein. Housing 12 optionally includes openings 15 and 16 for improved heat transfer. The openings 15 and 16 can protrude into the housing cavity where the power contact 14 is located, thereby forming a heat dissipation channel from the inside of the connector to the outside of the connector. An exemplary mating receptacle connector 20 is shown in FIG. 2 . The receptacle connector 20 includes a connector housing 22 and a plurality of power contacts disposed therein and accessible through apertures 24 . For example, housing 22 may also employ heat transfer structures such as openings 26 . Preferably, the connector housing unit is molded or formed from an insulating material such as glass filled high temperature nylon or other materials known to those of ordinary skill in the art of electrical connector design and manufacture. An example is disclosed in US Patent No. 6,319,075, the entire contents of which are incorporated herein by reference. The housing unit of the electrical connector can also be made of non-insulating material.

Both the plug connector 10 and the receptacle connector 20 are configured to connect at right angles to the printed circuit structures, whereby the corresponding printed circuit structures lie in the same plane. The present invention can also provide vertical mating structure by configuring an electrical connector to connect vertically with the printed circuit structure. As an example, a vertical receptacle connector 30 is shown in FIG. 3 . The receptacle connector 30 includes a housing 32 including a plurality of power contacts disposed therein and accessible through apertures 34 . Connector 30 also includes optional heat dissipation openings 33 . In both coplanar mating configurations and vertical mating configurations, it is advantageous to minimize the spacing between the two corresponding printed circuit configurations to which the connector connects. Plug connector 10 mated with receptacle connector 20 is shown in FIG. 4 . The electrical connectors engage the coplanar printed circuit structures 19 and 29 . The edge-to-edge spacing 40 between the printed circuit structures 19 and 29 is preferably 12.5mm or less. A vertical mating structure with a plug connector 10b and a receptacle connector 30 is shown in FIG. 5 . The edge-to-edge spacing 42 between the printed circuit structure 19 and the printed circuit structure 39 to which the vertical receptacle connector 30 engages is still preferably 12.5 mm or less. The edge to edge spacing is approximately 9 to 14 mm, preferably 12.5 mm. It is also possible to use other spacings.

At least some preferred electrical connectors include both power contacts and signal contacts. Referring now to FIG. 6, an exemplary plug connector 44 is shown that includes a housing 45, an array of power contacts 15, an array of signal contacts 46, and optional heat transfer openings 47 and 48 formed in the housing 45. . A receptacle connector 54 suitable for mating with the plug connector 44 is shown in FIG. 7 . Receptacle connector 54 includes a housing 55 , an array of power contacts accessible through aperture 24 , an array of signal contacts accessible through aperture 56 , and an optional heat transfer opening 58 extending through housing 55 .

Preferred connector embodiments are very compact in nature. Referring now to FIG. 8 , the centerline-to-centerline spacing 60 of adjacent power contacts is preferably 6 mm or less, and the centerline-to-centerline spacing 62 of adjacent signal contacts is preferably 2 mm or less. It is to be noted that the connectors of the present invention may include contact spacings other than this preferred range.

A number of preferred power contact embodiments suitable for use in the connectors described above will now be described. A preferred power contact 70 is shown in FIG. 9 . The power contacts 70 may be used in a variety of different connector embodiments including, for example, the plug connector 10 shown in FIG. 1 . The power contact 70 includes a first plate-shaped body member 72 (also referred to as a “plate”) laminated on a second plate-shaped body member 74 . A plurality of straight or flat beams 76 (also referred to as vanes) and a plurality of curved or angled beams 78 alternately extend from corresponding body members. The number of straight and curved beams can be as few as one or more than shown in the figure. With body members of laminated construction, the beams 78 contract to define "clamp" or "socket" beams. The contact beam configuration minimizes potential variations in contact normal force over the life of the product by alternating opposing clamping beams. The beam structure serves to eliminate a number of additional contact forces that would otherwise be transmitted into the shell structure. The opposing clamping beams also help to maintain the clamped plate-shaped body members together during mating of the complementary connectors. The contact structure provides multiple mating points for low normal force requirements on each beam, thereby minimizing the negative effects of multiple mating structures.

When the power contacts 70 mate with complementary power contacts, the beams 78 necessarily bend, deflect, or otherwise deviate from their non-engaged positions, while the beams 76 remain substantially in their non-engaged positions. The power contacts 70 also include a plurality of terminals 80 extending from a flared portion 82 of each body member 72 and 74 . The non-splayed portion forms a combined panel width CPW. Flared portion 82 provides accurate alignment of terminals 80 to the connection structure of the printed circuit structure so that in a preferred embodiment the distance between the distal ends of opposing terminals is greater than the composite board width CPW. The terminals themselves may be beveled outward so that when the contact body members are stacked or otherwise positioned close to each other, there is no need to flare the body portions to create proper spacing (see, eg, the terminals in FIG. 28 ). Flared portion 82 may also provide channels for heat dissipation primarily by convection. Additional heat dissipation channels may also be provided by gaps 84 formed between beams 78 and gaps 86 formed between adjacent beams extending from the contact body members.

Referring now to FIG. 10 , there is shown a power contact 90 adapted to mate with the power contact 70 . The power contact 90 includes a pair of laminated plate-shaped body members 92 and 94 . Straight beams 96 and angled beams 98 extend from the body member and are arranged in exact alignment with beams 78 and 76 of power contacts 70 , respectively. That is, beam 78 will engage beam 96 and beam 76 will engage beam 98 . Each body member 92 and 94 includes a plurality of terminals 95 extending from flared portion 93 for electrically connecting power contacts 90 to a printed circuit structure. The power contacts 70 and 90 in a mated configuration are illustrated in FIG. 11 .

In order to reduce the mating force of the complementary power contacts and the electrical connector housing the contacts, the contact beams may have staggered extended positions through dimensional differences or biasing techniques. As an example, FIGS. 12-14 show illustrative power contacts 100 and 110 at different mated positions (or insertion distances) from initial engagement to substantially final engagement. In FIG. 12 , which represents a first level of mating, the longest straight beam or blade 102 of the contact 100 engages the corresponding clamping beam 112 of the contact 110 . The force in the first level of mating will initially peak due to the amount of force required to separate or deflect the clamped beams by inserting the straight beams or blades. Afterwards, the mating force in the first level of mating is mainly due to the frictional resistance created when the straight and angled beams slide against each other. A second level of mating is shown in FIG. 13 , where the second longest straight beam or blade 114 of the contact 110 engages the corresponding clamping beam 104 of the contact 100 . The mating force during the second level of mating is due to the additional clamping beams being deflected apart and the cumulative friction of the engaged beams during the first level of mating and the second level of mating. A third level of mating is shown in FIG. 14 , where the remaining straight beams or blades 116 of the contact 110 engage the remaining corresponding clamping beams 106 of the contact 100 . Those of ordinary skill in the art will readily recognize that the present invention may contemplate fewer or more levels of mating than three levels in a particular power contact and in an array of power contacts within the same connector. As mentioned above, the electrical connector of the present invention can employ both power contacts and signal contacts. The signal contacts may also be staggered in length relative to each other and, optionally, relative to the length of the power contacts. For example, the signal contacts can have at least two different signal contact lengths, and these lengths can be different from either power contact length.

15-19 are graphs showing representative relationships between mating force and insertion distance for various exemplary power contacts (described above or below). The mating force of an exemplary power contact using three levels of mating is shown in FIG. 15, where the peaks represent the deflection of the clamping beam engaging the straight beam at each level of mating. If the power contacts had not been staggered, the initial force would be substantially 2.5 times the first peak of about 8N or 14.5N. With staggered mating points, the maximum force observed over the entire insertion distance was less than 10N.

It will be clear to those skilled in the art that the overall size of a power connector according to the invention is theoretically limited only by the effective surface area on the busbar or printed circuit structure and the effective connector height measured from the printed circuit structure. Accordingly, a power connector system may include a plurality of plug power contacts and plug signal contacts, and a plurality of receptacle power contacts and receptacle signal contacts. By changing the mating order of the individual power contacts and signal contacts, the initial force required to mate the plug with the receptacle when the two power connectors are far apart (initial contact) will be reduced, and as the connector plug and connector The distance between the receptacles decreases and the stability between the partially mated plug and receptacle increases. The application of increased force in response to the reduced distance between the connector plug and connector receptacle cooperates with the mechanical advantage and helps prevent buckling of the connector plug and receptacle during initial mating.

Another exemplary power contact 120 is shown in FIG. 20 . The power contact 120 includes a first plate-shaped body member 122 and a second plate-shaped body member 124 . The power contact 120 , which may be referred to as a split contact, includes an upper section 126 with a cutout 128 formed therein for receiving a lower section 130 . Upper section 126 is shown as having an L-shape; however, other geometries could equally be used. The lower section 130 is configured to substantially fit within the cutout 128 . As shown, upper section 126 and lower section 130 respectively include a pair of angled beams 132 and a pair of straight beams 134 extending from the front edge, and a plurality of terminals 133 for engaging printed circuit structures. The number and geometry of the beams can vary from what is shown in the drawings. FIG. 21 shows a pair of parallel nearly identical power contacts 140 , 140 a adapted to mate with the upper and lower sections of the split contact 120 . Each power contact 140 , 140 a has a pair of straight beams 142 insertable between the retracted angled beams 132 of the contacts 120 and a pair of retracted angled beams 144 for receiving the straight beams 134 of the contacts 120 .

It is to be noted that for a single contact position, as shown in FIG. 22 , the electrical connector of the present invention may also use only one of the upper side section or the lower side section. By alternating the upper and lower contacts in adjacent contact positions, additional contact-to-contact separation distances can be obtained, allowing the contacts to transmit approximately 350V, which, based on published safety standards, The voltage is higher than the corresponding 0 to 150V ratings for the above contacts as shown in FIGS. 9 and 10 and FIGS. 20 and 21 . The void area 160 formed by the portion of the corresponding split contact where no contact exists can provide a heat dissipation channel. When used in the context of an overall connector assembly, complete contacts, split contacts and upper or lower sections of split contacts may be arranged such that multiple amperages may be applied within one connector and voltage levels. For example, the exemplary connector 150 shown in FIG. 22 includes an array of upper and lower contact portions 152 configured for high voltages as described above, an array of full contacts 154 capable of transmitting approximately 0 to 50 A, for reduced The array of split contacts 156 and the array of signal contacts 158 are pitched to transmit approximately 0 to 25A. The number of power contacts of different amperages can be less or more than three. Also, the configuration of the power contacts and signal contacts may be different than that shown in FIG. 22 . Finally, the rated amperage of the different power contacts may differ from that stated above.

Referring now to FIG. 23, an additional mating power contact embodiment is shown. The receptacle power contact 170 includes a first plate-shaped body member 172 laminated on a second plate-shaped body member 174 . The first and second plate-shaped body members each include a set of cutouts 173 and 175, respectively. Preferably, cutout set 173 is out of phase with cutout set 175 . The cutouts of one plate-shaped body member and the solid portion of the other plate-shaped body member define a plurality of contact receiving spaces 176 . Contact receiving space 176 is configured to receive a beam of mating plug contact, such as plug contact 180 . At least one of the first plate-shaped body member and the second plate-shaped body member also includes terminals 171 for connection with a printed circuit structure. In an alternative receptacle contact embodiment (not shown), a single plate-shaped body member is used that includes a set of cutouts on the outside surface, wherein the cutouts have a width that is smaller than that of the single plate-shaped body member.

The plug contact 180 includes a first plate-shaped body member 182 laminated on a second plate-shaped body member 184 . The first and second plate-shaped body members each include a plurality of extension beams 186 for engaging the contact receiving spaces 176 . As shown, a pair of beams 186 are dedicated to engage each corresponding individual contact receiving space 176 of the receptacle contacts 170 . Multiple individual beams can also be used. Each pair of beams 186 includes a gap 188 that may improve heat transfer. The beam 186 is compliant and will flex when engaged with the contact receiving space 176 . The beam 186 may optionally include a bulbous end 190 . The contact body members 182 and 184 are shown in an optional staggered configuration to provide a mate-first-break configuration.

While the power contacts described above have included two plate-shaped body members, some power contact embodiments (not shown) provided by the present invention include only a single plate-shaped body member. And other power contact structures of the present invention include more than two plate-shaped body members. Exemplary receptacle contacts 200 and plug contacts 230 are shown in FIGS. 24-26 , respectively. The receptacle contacts 200 and the plug contacts 230 each use four plate-shaped body members.

The receptacle power contact 200 includes a pair of outer plate-shaped body members 202 and 204 and a pair of inner plate-shaped body members 206 and 208 . The figures show the outer pair of plate-shaped body members and the inner pair of plate-shaped body members in a preferred stacked configuration; that is, substantially no gaps are formed between the adjacent body members along most of the opposing surfaces of the adjacent body members. between. A plurality of terminals 201 extend from one or more plate-shaped body members, and preferably, all four body members. Each of the pair of outer plate-shaped body members 202, 204 includes a flared portion 203, respectively. The flared portion 203 provides suitable clearance for connecting the terminal to the printed circuit structure and may facilitate heat dissipation through the defined clearance 205 . A first pair of beams 210 extends from the outer body members 202 , 204 and a second pair of beams 212 extends from the inner body members 206 , 208 . In a preferred embodiment, the first pair of beams 210 substantially adjoins the second pair of beams 212 as shown. In alternative embodiments, beams 210 and 212 extend to different positions to provide a different mating sequence. The beams 210, 212 are designed and configured to engage the structure of the mating plug contacts 230 and may also define one or more heat dissipation channels between adjacent beams 210, 212 and by the opposing beams 210 and 212 themselves 215 and 216. Beams 210 and 212 are shown in a "clamped" or collapsed configuration, but other configurations could equally be used. The outer pair of body members and inner pair of body members may use additional beams other than those shown above for engaging the plug power contacts.

The plug contact 230 also includes a pair of outer plate-shaped body members 232 and 234 , and a pair of inner plate-shaped body members 236 and 238 . Similar to the receptacle contacts, each of the outer plate-shaped body members 232, 234 includes a flared portion 233, respectively, to provide suitable clearance for the terminals 231 to extend from the body member. Preferably, the outer plate-shaped body members 232 , 234 include cut-out portions 240 . The cut-out portion 240 exposes a portion of the inner plate-shaped body members 236, 238 to provide accessibility for engagement by mating receptacle power contacts 200, and may facilitate heat dissipation, eg, by convection. As an example and as shown in FIG. 26 , beam 210 of receptacle contact 200 clamps exposed portions of inner plate-shaped body members 236 and 238 of plug contact 230 .

Another exemplary power contact 241 using four laminated body members is shown in FIG. 27 . The power contact 241 includes a pair of outer plate-shaped body members 242 and 244, wherein each outer plate-shaped body member includes a plurality of cantilevered straight beams 246 extending from the front side edge. The power contact 240 also includes a pair of inner plate-shaped body members 248 and 250 positioned between the outer plate-shaped body members 242 and 244 . Inboard plate-shaped body members 248 and 250 include a plurality of angled cantilever beams 252 that shrink to define clamping or socket beams. Straight beams 246 are spaced apart to allow angled beams 252 to be positioned between them. A preferred mating power contact (not shown) would include a similar structure with clamping beams aligned with counter beams 246 and straight beams aligned with counter beams 252 . During mating, the force experienced by beam 246 will tend to hold the outer plate-shaped body members 242 and 244 together, while the force experienced by beam 252 will tend to push the inner plate-shaped body members 248 and 250 apart. The forces act together to counteract each other to provide a stable stack of plate-shaped body members with a minimal amount of force being transferred to the load-bearing shell. Outer panels 242 and 244 will also tend to hold inner panels 248 and 250 together.

Each of the power contact embodiments so far shown and described employs a plurality of plate-shaped body members stacked on top of each other. In such a laminated structure, the body members contact each other along at least a portion of opposing body member surfaces. The figures show plate-shaped body members in mutual contact with each other along most of their opposing surfaces. However, alternative contact embodiments contemplated by the present invention may have small portions of their opposing surfaces contact each other. For example, the exemplary contact 253 shown in FIG. 35 includes a pair of plate-shaped body members 254 and 255 . The contact 253 includes a first region 256 in which plate-shaped body members are laminated to each other and a second region 257 in which the body members are spaced apart. The first region 256 and the second region 257 are interconnected by a beveled region 258 . For example, the second region 257 includes an intermediate gap 259 that may facilitate heat dissipation by convection. It is to be noted that the laminated and spaced portions of the plate-shaped body member may differ from that shown in FIG. 35 . In addition to being stacked to some extent, the plurality of plate-shaped body members may be spaced apart completely so as to define intermediate gaps between adjacent contact body members. Intermediate gaps can aid in heat transfer. In addition, one mating contact may include a laminated plate-shaped body member while the other does not—an example of which is shown as mating contacts 260 and 290 in FIGS. 28 and 29, respectively, and will be described below.

The contact 260 shown in FIG. 28 includes a first plate-shaped body member 262 laminated on top of a second plate-shaped body member 264 along most of the inner surfaces of the first plate-shaped body member 262 and the second plate-shaped body member 264. superior. Front side portions 263, 265 of each of the plate-shaped body members flare outwardly to define contact receiving spaces 266 for engaging mating contacts 290 (shown in FIG. 29 ). Optional openings 268 are shown in the flared front portions 263, 265 to improve heat dissipation.

Contact 290 includes juxtaposed body members 292 and 294 that are preferably spaced apart from each other to define an intermediate gap 296 therebetween. The surface areas of the body members 292, 294 combine with the intermediate gap 296 to allow heat dissipation primarily by convection. A plurality of compliant beams 300 , 302 extend from respective juxtaposed body members 292 , 294 . In a preferred embodiment, beams 300 , 302 alternately extend from body members 292 and 294 . Each beam 300 , 302 includes an adjacent portion 304 and a distal portion 306 . Opposite side portions 308 and 310 are connected by connecting portions 312 , all of which are disposed between adjacent portion 304 and distal portion 306 . Preferably, the connection portion 312 defines a closed beam end disposed distally from the body members 292 , 294 . The portions of the aforementioned beams collectively form a spherical (or arrow-shaped) beam that provides at least two points of contact for each individual beam 300 , 302 . Although all contact beams 300, 302 are shown to be identical in size and geometry, the present invention also contemplates a variety of beams that differ from one another, varying along one body member, and from body member to body member. The number of beams shown in Figure 29 can also be varied to include more or fewer beams.

As shown in FIG. 29 , the distal portion 306 of each beam 300 , 302 is spaced from the body member that does not extend therefrom, thereby defining a slit 316 . The slit 316 helps to allow the beams 300 , 302 to deflect when inserted into the contact receiving space 266 . A gap 318 is also defined between adjacent beams 300 , 302 on each body member 292 , 294 . The gap 318 has a height H1 which is preferably equal to or greater than the height H2 of the beams 300 , 302 so that the beam 300 of one body member 292 can intermesh with the beam 302 of the other body member 294 .

Crack 316 and gaps 296, 318 and 320 allow heat dissipation from the body member and compliant beam. In FIG. 29 , the contacts 290 extend along an imaginary longitudinal axis L that coincides with the plane P of the page. In the configuration of Figure 29, heat will be dissipated by convection generally upwards and along the imaginary longitudinal axis L. Beams 300 , 302 and body members 292 , 294 define a chimney-like structure that facilitates the conduction of heat away from contacts 290 . If the contact 290 is rotated 90 degrees in the plane P of the page, heat can still be dissipated through the gaps 316 and 318 and through the open ends of the gaps 296 and 320 .

Preferred contacts of the present invention may be stamped or otherwise formed from suitable strip material. The contacts may be formed individually or alternatively in groups of two or more. Preferably, the strip is die stamped to define the plurality of contact structures in pre-finished or finished form. Additional operations may be required after the die stamping operation, such as joining the structures together or changing the initial stamping orientation or configuration of the structures (eg, bending cantilever beams or contact body portions). Referring to Figure 30, there is shown exemplary straps 330 and 332, each strap comprising a plurality of plate-shaped body members comprising straight and curved beams (preferably formed after a stamping operation ) and a plurality of terminals extending from the plate-shaped body member. Where the power contact comprises a first body member and a second body member, both the left and right side structures may be stamped and provided in a single strip.

The individual contact elements may be separated from the remaining structure of the straps 330 and 332 and then inserted into the connector housing. In an alternative technique, the strips may be laminated together and then placed into a mold used to form the overmolded contact subassembly. A single strap may also be used where the contacts employ only a single body member. And more than two strips can be laminated and overmolded. A suitable thermoplastic material flows and cures around the majority of the laminated body members to form the plastic shell 334 as shown in FIG. 31 . The contact subassembly 336 is then separated from the strip, as shown in FIG. 32 . Beams 340 extend from housing 334 to engage mating power contacts, and terminals 342 extend from housing 334 for connecting the overmolded contacts to a printed circuit structure. A signal contact subassembly can also be made by overmolding a set of signal contacts in strip form or individually. For example, an overmolded signal contact subassembly 350 including a housing 352 and a set of signal contacts 354 is shown in FIG. 33 . FIG. 34 shows an exemplary electrical connector 360 including a housing 362 , two power contact subassemblies 336 and a plurality of signal contact subassemblies 350 .

The power and signal contacts of the present invention are made of suitable materials known to those skilled in the art, such as copper alloys. The contacts can be plated with a variety of different materials including, for example, gold or a combination of gold and nickel. The number of contacts and their configuration in the connector housing are not limited to what is shown in the drawings. Some preferred power contacts of the present invention include plate-shaped body members stacked on top of each other. Laminated body members allow the connector to carry large currents due to increased cross-sectional area (less resistance) and have the potential to increase surface area to facilitate convective heat transfer. Those of ordinary skill in the art will readily recognize that the plate-shaped body member may be flat or non-flat in shape. The invention also includes juxtaposing plate-shaped body members such that the body members are spaced apart to define an intermediate gap therebetween. The intermediate gap also improves heat transfer primarily by convection. The contact plate shaped body member may also include openings or other heat transfer structures. The housing unit of the electrical connector provided by the present invention may also include structures for improving heat dissipation, such as passages extending from the exterior of the connector to the interior of the connector, and housing voids or portions of the surface adjacent to the retained power contacts. gap.

The number, location and geometry of the cantilever beams extending from the contacts are not limited to what is shown in the figures. Some of the beam structures described above have the benefits described; however, other beam structures of the present invention may not have the same benefits described.

Although the present invention has been described in connection with preferred embodiments of the various drawings, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiments for implementing the present invention without departing from the present invention. Invented the same function. Therefore, the present invention should not be limited to any single embodiment, but rather in breadth and scope recited in the claims.

Claims (5)

1. A mating power contact, comprising: a) a first power contact comprising a first pair of opposing non-deflecting beams and a first pair of opposing deflectable beams; and b) a second power contact comprising a second pair of opposing non-deflecting beams and a second pair of opposing deflectable beams; wherein said first pair of opposing non-deflecting beams aligns said second pair of opposing deflectable beams, said first pair of opposing deflectable beams aligns said second pair of opposing non-deflecting beams, said The first power contact includes at least one pair of opposing plate-shaped body members, each of the at least one pair of opposing plate-shaped body members including a terminal for connection to a printed circuit board. 2. The mating power contact of claim 1, wherein said at least one pair of opposing plate-shaped body members has an intermediate gap therebetween. 3. The mating power contact of claim 1, wherein said at least one pair of plate-shaped body members are laminated to each other. 4. The mating power contact of claim 1, wherein said at least one pair of plate-shaped body members includes a first plate-shaped body member disposed adjacent a second plate-shaped body member such that said first plate-shaped body member A plate-shaped body member and the second plate-shaped body member are in mutual contact with each other along at least a portion of the surfaces of the first plate-shaped body member and the second plate-shaped body member. 5 . The mating power contact according to claim 1 , further comprising an insulating housing, the first power contact being connected to the insulating housing.

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