HK1196031B - Single element wire to board connector - Google Patents

Abstract

A single element electrical connector includes a single conductive contact element formed into a cage structure having a wire insert end and a wire contact end along a longitudinal centerline axis of the connector. The cage structure defines an upper pick-up surface having a surface area suitable for placement of a suction nozzle of a vacuum transfer device, as well as a pair of contact tines biased towards the centerline axis to define a contact pinch point for an exposed core of a wire inserted into the connector. A contact surface is defined by a member of the cage structure for electrical mating contact with a respective contact element on a component on which the connector is mounted.

Description

Single component wire to board connector

Technical Field

The present invention relates generally to the field of electrical connectors and, more particularly, to a connector for connecting insulated conductors to components such as Printed Circuit Boards (PCBs).

Background

Different types of connectors for forming a connection between an insulated conductor and any manner of electronic component are known in the art. These connectors are commonly used as sockets, plugs, and shielded headers and plated accessories in a wide range of sizes and spacings. Many of these conventional connectors are referred to as Insulation Displacement Connectors (IDCs) because they include one or more contact elements that contain a set of blades or clips that pass through the insulation surrounding the wire and make electrical contact with the conductive core in a single step, thus eliminating the need for wire stripping and crimping or other wire preparation. IDCs are widely used in the communications industry, and more commonly in Printed Circuit Board (PCB) applications.

Various attempts have been made to construct IDCs for Surface Mount Technology (SMT) applications. For example, U.S. patent No.7,320,616 describes an IDC particularly for SMT mounting to a PCB. The connector assembly has at least one contact member having a piercing, cutting or skiving end slidably disposed in a body and a mounting end extending from the body and connected to a printed circuit board using a conventional SMT process. An insulated conductor, such as a wire, cable and/or cord, is inserted into the passage in the body without being penetrated by the penetrating end of the contact member. When the user pushes down on the top of the body, the contact member slides into the channel and through the insulated conductor. The top of the body also provides a surface for the vacuum pick-up nozzle in the automated pick-and-place assembly step.

AVX corporation of south carolina, usa provides a series of low profile IDC wire to board connectors (series 9175-9177) that are SMT (surface mount technology) mounted to a circuit board by means of a hand tool prior to insertion of wires into contact slots. This step severs the wire insulation and allows the wire core to form a secure conductive bond with the connector.

IDC wire to board connectors, however, are not suitable for all applications where it is necessary to connect one or more wires to a component. For example, the IDCs of the above-cited references are relatively complex because they require multiple parts that move relative to each other. The main insulator is a separate component from the contact member and all or part of the main body must be movable or slidable relative to the contact member to make a final connection with the wire after the end of the contact member has been inserted into a through hole on the PCB or surface mounted to the PCB. The main insulation of a conventional IDC may also take up valuable space on the PCB (finished circuit board). In this regard, IDCs are relatively complex, large in size, and costly in some applications.

The present invention provides an alternative to IDC wire to board connectors that is robust, reliable and compact in design.

Disclosure of Invention

Objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

According to some aspects of the present invention, an electrical connector is provided that is particularly useful for connecting at least one insulated conductive core wire to an electronic component, such as a PCB. It should be understood that the connector according to the present invention is not limited to use with circuit boards, but may be used in any application where a reliable electrical connection between wires and any other type of component is desired. For illustrative purposes only, the connector will be described herein as being used to connect wires to a PCB.

According to some aspects of the invention, the connector is a "single element" connector in that the connector is formed from a single conductive contact member and does not include an insulative body or molding. The connector is particularly suited for pick and place mounting processes where a vacuum delivery device places the connector for subsequent surface mounting to a PCB, as will be appreciated by those skilled in the art. However, the connector is not limited to this mounting technique.

One embodiment of a single element electrical connector according to aspects of the present invention includes a single conductive contact element forming a cage structure defining a wire insertion end and a wire contact end disposed along a longitudinal central axis of the connector. The cage structure includes a wall structure at the insertion end that defines an insertion opening for a lead at the insertion end. For example, in one embodiment, the wall structure includes a plurality of walls forming a box-like structure at the insertion end, with one of the walls defining an upper pickup surface having a surface area suitable for placement of a suction nozzle of a vacuum delivery device. The cage structure further includes a pair of contact tips biased toward a central axis of the connector downstream of the wall structure at the insertion end in an insertion direction of the wire into the connector, the contact tips defining contact pinch points for a bare core of the wire. The assembly of the cage structure, such as a PCB, to which the connector is mounted, defines a contact surface for electrical mating contact with respective contact elements or pads on the assembly.

In certain embodiments, the connector is formed from a single stamped metal plate that is bent or otherwise formed into the cage structure. Any number and configuration of cuts, indentations (relief), or other structures may be formed in the metal sheet to facilitate bending or otherwise forming the metal sheet into a cage-like structure having the features described herein.

As noted above, in certain embodiments, the cage structure includes a plurality of walls bent into a box-like structure having top, bottom and side walls at the insertion end of the connector, the top wall defining a pick-up surface. In this embodiment, the top wall may be a curved extension of one side wall that extends to the opposite side wall.

In one embodiment, the top wall and the bottom wall may be substantially parallel, one or both of the top wall and the bottom wall including a front portion that is inclined toward a central axis of the connector to define an upper wire guide (top wall) and/or a lower wire guide (bottom wall).

The contact tips can be configured differently by the cage structure. In a particular embodiment, the contact tip is a front portion of the sidewall that is inclined toward the central axis at the wire contacting end of the connector. The tip may include a release tab extending from a forward-most portion of the contact tip, the release tab configured to be engaged by a tool to separate the contact tips for removal of a wire inserted into the connector. The release tab may extend substantially parallel to the central axis.

In another embodiment, the cage structure may include an end wire retention wall formed forward of the contact tip in a direction of insertion of a wire into the connector, the retention wall defining an endmost position of the conductive core of the wire in the connector. The retaining wall may be configured differently by the cage structure. For example, in one embodiment, the bottom wall extends below the contact tip, and the retaining wall is defined by a front portion of the bottom wall that curves upward toward the central axis.

As mentioned above, the connector is not limited to use with PCBs or other components by its mounting technique. In one embodiment, the contact surface is defined by a portion of a bottom wall of the cage structure such that the connector can be surface mounted to a contact pad on a PCB, the central axis being substantially parallel to the PCB. In another embodiment, the connector may be used in a through board or top mount configuration, where the connector extends substantially perpendicular to the PCB. In such a configuration, the contact surface may be defined by a contact foot extending generally transversely from the wall (bottom, top or side).

The present invention also includes any manner of electronic assembly that includes the unique connector element introduced above and described in detail below for electrically connecting one or more wires to the electronic assembly. For example, the assembly may include a PCB in electrical mating contact with one or more wires through an electrical connector.

Specific embodiments of the unique insulation displacement connector are described in more detail below in connection with examples illustrated in the figures.

Drawings

FIG. 1 is a perspective view of one embodiment of a connector according to aspects of the present invention;

FIG. 2 is a side cross-sectional view showing the connector embodiment of FIG. 1;

FIG. 3 is a perspective view of the top end and insertion end of a connector according to aspects of the present invention;

FIG. 4 is a side perspective view of the connector embodiment of FIG. 3;

FIG. 5 is a top view of the connector embodiment of FIG. 3;

FIG. 6 is a side view of the connector embodiment of FIG. 3;

FIG. 7 is an end view of the connector embodiment of FIG. 3; and

fig. 8 is a perspective view of an alternative embodiment of a connector according to aspects of the present invention.

Detailed Description

Referring now to embodiments of the invention, one or more embodiments are shown. These examples are intended to be illustrative of the invention and are not intended to be limiting. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield still a further embodiment. The present invention includes these and other modifications and variations as fall within the scope and spirit of the invention.

Fig. 1-8 illustrate an exemplary embodiment of an electrical connector 10 according to some aspects of the present invention. The electrical connector 10 is configured for connecting the conductive core of the insulated conductor to a variety of electronic components, such as Printed Circuit Boards (PCBs). For ease of explanation and illustration, the connector 10 is described and referenced herein in the context of connecting wires to a PCB. Additionally, the connector 10 is illustrated in the figures as a "single-pass" connector because it includes only one wire position. It should be understood that the connector 10 is not limited to the number of wire positions and that multiple configuration embodiments are contemplated within the scope and spirit of the present invention. For example, in addition to the single-way connector shown, the present invention also includes embodiments in which the cage structure is formed as a two-way or three-way connector.

Referring generally to the drawings, embodiments of a single element electrical connector 10 according to aspects of the present invention are described. The connector 10 is particularly useful for connecting the wires 12 to a wide variety of electronic components, such as PCBs. The wire 12 may be a multi-core or solid wire having a core 14 surrounded by an insulating material 16. Prior to insertion of the wire 12 into the connector 10, a portion of the insulating material 16 is stripped from the core 14 near the end of the wire 12, as particularly illustrated in fig. 1 and 2.

As mentioned above, the connector 10 is a "single element" connector in that it is formed from a single conductive contact element 18. The element 18 may be any suitable conductive metal material having a gauge (gauge) and other physical characteristics suitable for maintaining the shape of the connector 10 during installation and in the operating environment of the electronic assembly in which the connector 10 is installed.

The single conductive element 18 forms a cage-like structure generally shown as element 20 in fig. 1. The cage structure 20 includes a wire insertion end 22, the wire insertion end 22 defining an insertion opening 18 for inserting the conductive core 12 into the connector 10. The cage 20 also defines a wire contacting end 24 (fig. 1) at which the bare conductive core 14 of the wire 12 is contacted by the contact element 18. The insertion end 22 and the wire contacting end 24 are aligned along a central longitudinal axis 26 of the connector 10, as shown in fig. 1 and 2.

In the illustrated embodiment, the cage structure 20 includes a wall structure 30 that substantially surrounds the lead 12. The wall structure 30 may include any number and any configuration of walls, such as circular walls, semi-circular wall assemblies, and the like. At least a portion of the wall structure 30 defines an upper pickup surface 32. The surface 32 has a surface area suitable for placement of a suction nozzle of a vacuum delivery device so that the connector 10 can be delivered to an electronic component such as a PCB in a conventional pick and place process, as will be appreciated by those skilled in the art. In a desirable embodiment, the connectors 10 are supplied in the form of a tape that is fed to a conventional vacuum transfer device during pick and place.

The cage structure 20 includes a pair of contact tips 34, the contact tips 34 being offset toward the central axis 26 of the connector 10 downstream of the wall structure 30 in the direction of insertion of the conductor 12 into the connector 10. These contact tips 34 are formed by portions of the individual contact elements 18 or by a cut-out of the individual contact elements 18 and define contact pinch points 36 (fig. 3) for abutting against the bare core 14 of the contact wire 12. The pinch points 36 also serve as pinch points to prevent accidental removal of the conductor 12 from the connector 10.

The connector 10 includes a contact surface 38, which contact surface 38 may be formed by any portion or any segment of the cage structure 20. The contact surfaces 38 are used to electrically mate the various contact elements on the contact electronics assembly. For example, the contact surface 38 may be formed by any portion of the bottom or bottom wall of the cage structure 20 that engages a corresponding contact pad on the PCB, where the connector 10 may be surface mounted directly to the contact pad of the PCB.

In the illustrated embodiment, the connector 10, and in particular the contact elements 18, are formed from a single sheet of metal material that is bent or otherwise formed into a cage structure 20. Any manner of cuts, indentations, or other structures may be cut or stamped into the individual contact elements 18 to facilitate forming the contact elements 18 into the unitary structure of the connector 10 described herein.

In the illustrated embodiment, the wall structure 30 includes a plurality of walls that are bent into a box-like structure 40 having a top wall 42, a bottom wall 44, and opposing side walls 46. The top wall 42 defines the pick-up surface 32 as described above. It should be understood that any other wall may also define the pick-up surface 32. The box-like structure 40 can also be defined by walls in different ways. For example, in the illustrated embodiment, the side walls 46 are upwardly curved members relative to the bottom wall 44, while the top wall 42 is formed by an extension of one side wall 46 that curves toward the opposite side wall 46.

Certain embodiments of the connector 10 may also include a guide surface in the cage structure 20 for physically contacting and aligning the wires 12 in the cage structure 20. In the illustrated embodiment, for example, the upper wire guide 48 is defined by an inclined portion of the top wall 42. The upper wire guide 48 is inclined from the generally parallel top wall (parallel to the bottom wall 44) toward the central axis 26, as particularly illustrated in fig. 2 and 3. Similarly, the bottom wall 44, which is parallel to the top wall 42, may have a front portion that is inclined toward the central axis 26 to define a lower wire guide 50, as particularly illustrated in fig. 2, 6 and 7.

As mentioned, the contact tips 34 can be configured differently in the cage structure 20. In the illustrated embodiment, the tip 34 is formed by a front portion of each sidewall 46 that curves or slopes toward the central axis 26 to the pinch point 36. In this manner, the tips 34 are angled toward each other (and the central axis 26). When a wire is inserted through the tip 34, the tip 34 separates and engages the conductive core 14 of the wire.

Referring specifically to fig. 3 and 5, in certain embodiments, it may be desirable to include a release tab 52 formed on each contact tip 34 generally forward of the pinch point 36. These release tabs 52 provide an insertion location for a tool between the tines 34 to open the tines 34 as needed to remove the lead 12. The release tab 52 may be configured differently. In the illustrated embodiment, the release tab 52 is formed by a generally forwardly extending tab that is substantially parallel to the central axis 26, with the conductor 12 removed from the connector 10, as particularly illustrated in fig. 5.

As shown in the drawings, it is also desirable in some embodiments to include a lead retaining wall 54 at the end of the lead contacting end 24 of the cage 20. The contact wall 54 provides a surface against which the conductive core 14 of the wire 12 abuts in the fully inserted position of the wire 12, as shown in fig. 2. The contact wall 54 may be configured differently. In the illustrated embodiment, the contact wall 54 is formed by an upward bend in the bottom wall 44. The contact wall 54 may also include an overhang or lip 58 that extends rearward toward the pinch point 36 of the contact tip 34. The overhang 58 can serve to prevent inadvertent removal of the wire 12 in a vertical direction relative to the connector 10.

As noted, the contact surface 38 may be formed by any portion of the bottom wall 44 (or any other wall) that aligns with a mating contact pad on the PCB. In this embodiment, the connector 10 is particularly suited for use in conventional surface mount processes.

In an alternative embodiment shown in fig. 8, the connector 10 may be configured for through-board connection, wherein the connector extends through a hole in the PCB. The contact feet 56 are used to mate with contact pads on either side of vias on the PCB. Similarly, the contact feet 56 may be used for surface mounting of the connector 10 on a PCB, wherein the connector 10 assumes a relatively vertical (i.e., perpendicular) orientation with respect to the PCB. In the embodiment shown in fig. 8, the contact foot 56 is formed by an outwardly curved portion of each side wall 46. In an alternative embodiment, the contact feet 56 may also be formed by outwardly curved portions of the bottom wall 44 and the top wall 42.

Those skilled in the art will readily appreciate that various modifications and variations may be made to the illustrated and described embodiments of the present invention without departing from the spirit and scope of the invention. Such modifications and variations are intended to be included herein within the scope of the appended claims.

Claims (13)

1. A single element electrical connector configured for connecting a wire to an assembly, the connector comprising:

a single conductive contact element forming a cage structure having a wire insertion end and a wire contact end along a longitudinal central axis of the connector;

said cage structure comprising a wall structure at said insertion end defining an insertion opening for the leads, said wall structure defining an upper pick-up surface having a surface area adapted to seat a suction nozzle of a vacuum delivery device;

the cage structure further comprising a pair of contact tips biased toward the central axis downstream of the wall structure in an insertion direction of the wire into the connector, the contact tips defining contact pinch points for a bare core of the wire; and

a contact surface defined by a portion of the cage structure for electrically mating contact with a respective contact element on the component.

2. The single element electrical connector of claim 1, wherein said connector is formed from a single stamped metal plate, said metal plate being bent into said cage structure.

3. The single element electrical connector of claim 2, wherein said wall structure comprises a plurality of walls bent into a box-like structure having a top wall, a bottom wall and side walls at said insertion end, said top wall defining said pickup surface.

4. A single element electrical connector as in claim 3 wherein said top wall is a curved extension of one of said side walls and extends to the opposite of said side wall.

5. The single element electrical connector of claim 3, wherein said top wall is generally parallel to said bottom wall and further comprises a front portion that slopes toward said central axis to define an upper wire guide.

6. The single element electrical connector of claim 3, wherein said bottom wall is generally parallel to said top wall and further comprises a front portion that slopes toward said central axis to define a lower wire guide.

7. The single element electrical connector of claim 3, wherein the contact tip is a front portion of the sidewall that is angled toward the central axis.

8. The single-element electrical connector of claim 7, further comprising a release tab extending from a forwardmost portion of the contact tip, the release tab configured to be engaged by a tool to separate the contact tips for removal of a wire inserted into the connector.

9. The single element electrical connector of claim 8, wherein the release tab extends generally parallel to the central axis.

10. The single element electrical connector of claim 3, wherein said cage structure further comprises an end wire retention wall formed forward of said contact tips along a wire insertion direction into said connector.

11. The single element electrical connector as recited in claim 10, wherein the bottom wall extends below the contact tip, and the top wall is defined by a front portion of the bottom wall that curves upward toward the central axis.

12. The single element electrical connector of claim 3, wherein the contact surface is defined by a portion of the bottom wall such that the connector is surface mounted to an assembly with the central axis substantially parallel to the assembly.

13. The single element electrical connector of claim 3, wherein the contact surfaces are defined by contact feet extending generally transversely from the walls in any combination such that the connector is mounted to an assembly with the central axis generally perpendicular to the assembly.