U.S. patent application number 14/972267 was filed with the patent office on 2017-06-22 for power terminal with compliant pin for electrical power connector.
The applicant listed for this patent is TYCO ELECTRONICS CORPORATION. Invention is credited to Alan Weir Bucher.
Application Number | 20170179624 14/972267 |
Document ID | / |
Family ID | 58737998 |
Filed Date | 2017-06-22 |
United States Patent
Application |
20170179624 |
Kind Code |
A1 |
Bucher; Alan Weir |
June 22, 2017 |
POWER TERMINAL WITH COMPLIANT PIN FOR ELECTRICAL POWER
CONNECTOR
Abstract
An electrical power connector includes a power terminal having a
first contact and a second contact arranged back-to-back. The first
contact has a first thickness. The first contact has a first mating
segment having a mating interface. The first contact has a first
mounting segment including a first compliant pin. The second
contact has a second thickness approximately equal to the first
thickness. The second contact has a second mating segment having a
mating interface. The second contact has a second mounting segment
including a second compliant pin. The first compliant pin is
aligned with the second compliant pin and arranged back-to-back
such that both the first and second compliant pins are received in
a common plated via of a circuit board.
Inventors: |
Bucher; Alan Weir; (Manheim,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TYCO ELECTRONICS CORPORATION |
Berwyn |
PA |
US |
|
|
Family ID: |
58737998 |
Appl. No.: |
14/972267 |
Filed: |
December 17, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R 12/7076 20130101;
H01R 12/585 20130101; H01R 12/724 20130101; H01R 12/7088
20130101 |
International
Class: |
H01R 12/70 20060101
H01R012/70 |
Claims
1. An electrical power connector comprising: a power terminal
having a first contact and a second contact arranged back-to-back;
the first contact having a first thickness, the first contact
having a first mating segment having a mating interface at which
the first contact is configured to mate with a first mating
contact, the first contact having a first mounting segment
comprising a first compliant pin; the second contact having a
second thickness approximately equal to the first thickness, the
second contact having a second mating segment having a mating
interface at which the second contact is configured to mate with a
second mating contact, the second contact having a second mounting
segment comprising a second compliant pin; wherein the first
compliant pin is aligned with the second compliant pin and arranged
back-to-back such that both the first and second compliant pins are
received in a common plated via of a circuit board; and wherein the
first compliant pin has a first opening having a first width at a
widest part of the first opening, the first contact having a first
width-to-thickness (W/T) stamping ratio, the second compliant pin
has a second opening having a second width at a widest part of the
second opening, the second contact having a second W/T stamping
ratio equal to or greater than the first W/T stamping ratio, and
the first and second compliant pins are aligned back-to-back to
form a terminal compliant pin of the power terminal having at least
one terminal compliant pin opening defined by the first and second
openings, the terminal compliant pin opening having a third width
at a widest part thereof equal to the wider of the first and second
openings, the terminal compliant pin having a third thickness equal
to a sum of the first and second thicknesses, the terminal
compliant pin having a third W/T stamping ratio less than the first
and second W/T stamping ratios.
2. The electrical power connector of claim 1, wherein the first
compliant pin includes a first opening and the second compliant pin
includes a second opening, the first and second openings being
aligned to create a common terminal compliant pin opening through
the power terminal.
3. The electrical power connector of claim 1, wherein the first
contact includes an interior surface and an exterior surface, the
second contact includes an interior surface and an exterior
surface, the interior surfaces abutting against each other, the
exterior surfaces defining the mating interfaces of the first and
second mating segments.
4. The electrical power connector of claim 3, wherein the inner
surfaces of the first and second compliant pins are flat, the
exterior surfaces of the first and second compliant pins are coined
and include rounded edges along portions of the first and second
compliant pins.
5. The electrical power connector of claim 1, wherein the first
compliant pin includes a first tip and a first compliant portion
including a bulbed section having a first opening therethrough with
legs on opposite sides of the first opening, the second compliant
pin includes a second tip and a second compliant portion including
a bulbed section having a second opening therethrough with legs on
opposite sides of the second opening.
6. The electrical power connector of claim 1, wherein the first
width-to-thickness (W/T) stamping ratio is greater than 1.0,
wherein the second W/T stamping ratio is greater than 1.0, and
wherein the third W/T stamping ratio of is less than 1.0.
7. The electrical power connector of claim 1, wherein the third W/T
stamping ratio of the terminal compliant pin is approximately half
of the first W/T stamping ratio of the first compliant pin.
8. The electrical power connector of claim 7, wherein the third W/T
stamping ratio of the terminal compliant pin is approximately half
of the second W/T stamping ratio of the second compliant pin.
9. An electrical power connector comprising: a power terminal
having a first contact and a second contact arranged back-to-back;
the first contact having a first mating segment having a mating
interface at which the first contact is configured to mate with a
first mating contact, the first contact having a first mounting
segment comprising a first compliant pin, the first compliant pin
having a first opening having a first width at a widest part of the
first opening, the first contact having a first thickness, the
first contact having a width-to-thickness (W/T) stamping ratio of
greater than 1.0; the second contact having a second mating segment
having a mating interface at which the second contact is configured
to mate with a second mating contact, the second contact having a
second mounting segment comprising a second compliant pin, the
second compliant pin having a second opening having a second width
at a widest part of the second opening, the second contact having a
second thickness, the second contact having a W/T stamping ratio of
greater than 1.0; wherein the first and second compliant pins are
aligned back-to-back to form a terminal compliant pin of the power
terminal having a terminal compliant pin opening defined by the
first and second openings, the terminal compliant pin opening
having a third width at a widest part thereof equal to the wider of
the first and second openings, the terminal compliant pin having a
third thickness, the terminal compliant pin having a W/T stamping
ratio of less than 1.0.
10. The electrical power connector of claim 9, wherein the W/T
stamping ratio of the first contact is a ratio of the first width
to the first thickness, the W/T stamping ratio of the second
contact is a ratio the second width to the second thickness, and
the W/T stamping ratio of the terminal compliant pin is a ratio of
the third width to the third thickness.
11. The electrical power connector of claim 9, wherein the W/T
stamping ratio of the terminal compliant pin is approximately half
of the W/T stamping ratio of the first compliant pin.
12. The electrical power connector of claim 11, wherein the W/T
stamping ratio of the terminal compliant pin is approximately half
of the W/T stamping ratio of the second compliant pin.
13. The electrical power connector of claim 9, wherein the first
thickness is approximately equal to the second thickness and
wherein the first width is approximately equal to the second
width.
14. The electrical power connector of claim 9, wherein the first
and second contacts are stamped and formed contacts, the first and
second contacts being stamped and formed prior to being
aligned.
15. The electrical power connector of claim 9, wherein the first
contact includes an interior surface and an exterior surface, the
second contact includes an interior surface and an exterior
surface, the interior surfaces abutting against each other, the
exterior surfaces defining the mating interfaces of the first and
second mating segments.
16. The electrical power connector of claim 9, wherein the first
compliant pin includes a first tip and a first compliant portion
including a bulbed section having the first opening therethrough
with legs on opposite sides of the first opening, the second
compliant pin includes a second tip and a second compliant portion
including a bulbed section having the second opening therethrough
with legs on opposite sides of the second opening.
17. An electrical power connector comprising: a power terminal
having a first contact and a second contact, the first and second
contacts being mirrored halves arranged back-to-back; the first
contact having a first mating segment and a first mounting segment,
the first mounting segment comprising a first compliant pin having
a first tip and a compliant portion including a bulbed section
having a first opening therethrough with legs on opposite sides of
the first opening; the second contact having a second mating
segment and a second mounting segment, the second mounting segment
comprising a second compliant pin having a second tip and a
compliant portion including a bulbed section having a second
opening therethrough with legs on opposite sides of the second
opening; wherein the first compliant pin is aligned with the second
compliant pin such that the first and second openings are aligned
to create a common terminal compliant pin opening and the legs are
aligned to create common terminal compliant pin legs, both the
first and second compliant pins being received in a common plated
via of a circuit board with the legs of both the first and second
compliant pins being compressed in the plated via of the circuit
board; and wherein the first opening has a first width at a widest
part of the first opening, the first contact having a first
thickness, the first contact having a width-to-thickness (W/T)
stamping ratio of greater than 1.0, wherein the second opening has
a second width at a widest part of the second opening, the second
contact having a second thickness, the second contact having a W/T
stamping ratio of greater than 1.0, and wherein the terminal
compliant pin opening has a third width at a widest part thereof
equal to the wider of the first and second openings, the terminal
compliant pin having a third thickness equal to a sum of the first
and second thicknesses, the terminal compliant pin having a W/T
stamping ratio of less than 1.0.
18. The electrical power connector of claim 17, wherein the first
contact includes an interior surface and an exterior surface, the
second contact includes an interior surface and an exterior
surface, the interior surfaces being flat and abutting against each
other, the exterior surfaces of the first and second compliant pins
being coined and include rounded edges along portions of the first
and second compliant pins.
19. (canceled)
20. The electrical power connector of claim 17, wherein the W/T
stamping ratio of the terminal compliant pin is approximately half
of the W/T stamping ratio of the first compliant pin.
Description
BACKGROUND OF THE INVENTION
[0001] The subject matter described and/or illustrated herein
relates generally to power supplies for supplying electrical power
to electrical systems.
[0002] Power supplies that supply electrical power to electronic
systems are being designed to have greater power capacity (e.g.,
supply more electrical wattage) to accommodate the increased
electrical power consumption of contemporary electronic systems. To
accommodate the increased power capacity, the power terminals are
manufactured from thick stock material to handle high amperes by
lowering resistance and thus maintaining low operating
temperatures. In some cases, the material thickness is too large
for stamping and forming features, such as compliant pins, via
conventional stamping processes. For example, the thick material
makes punching difficult because the dies used to create the
features are thin and thus susceptible to damage. Some known
processes locally thin the material to make punching through the
material easier, such as by skiving or coining the material
thickness in localized regions. However, skiving adds significant
cost and coining alters material properties, such as via cold work
of the material.
[0003] A need remains for power terminals that are suitable for
high power transmission and can be manufactured in a cost effective
and reliable manner.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In an embodiment, an electrical power connector is provided
including a power terminal having a first contact and a second
contact arranged back-to-back. The first contact has a first
thickness. The first contact has a first mating segment having a
mating interface at which the first contact is configured to mate
with a first mating contact. The first contact has a first mounting
segment including a first compliant pin. The second contact has a
second thickness approximately equal to the first thickness. The
second contact has a second mating segment having a mating
interface at which the second contact is configured to mate with a
second mating contact. The second contact has a second mounting
segment including a second compliant pin. The first compliant pin
is aligned with the second compliant pin and arranged back-to-back
such that both the first and second compliant pins are received in
a common plated via of a circuit board.
[0005] In another embodiment, an electrical power connector is
provided including a power terminal having a first contact and a
second contact arranged back-to-back. The first contact has a first
mating segment having a mating interface at which the first contact
is configured to mate with a first mating contact. The first
contact has a first mounting segment including a first compliant
pin having a first opening having a first width at a widest part of
the first opening. The first contact has a first thickness and a
width-to-thickness (W/T) stamping ratio of greater than 1.0. The
second contact has a second mating segment having a mating
interface at which the second contact is configured to mate with a
second mating contact. The second contact has a second mounting
segment including a second compliant pin having a second opening
having a second width at a widest part of the second opening. The
second contact has a second thickness and a W/T stamping ratio of
greater than 1.0. The first and second compliant pins are aligned
back-to-back to form a terminal compliant pin of the power terminal
having a terminal compliant pin opening defined by the first and
second openings. The terminal compliant pin opening has a third
width at a widest part thereof equal to the wider of the first and
second openings. The terminal compliant pin has a third thickness
and a W/T stamping ratio of less than 1.0.
[0006] In a further embodiment, an electrical power connector is
provided including a power terminal having a first contact and a
second contact. The first and second contacts are mirrored halves
arranged back-to-back. The first contact has a first mating segment
and a first mounting segment. The first mounting segment includes a
first compliant pin having a first tip. The first mounting segment
includes a compliant portion including a bulbed section having a
first opening therethrough with legs on opposite sides of the first
opening. The second contact has a second mating segment and a
second mounting segment. The second mounting segment includes a
second compliant pin having a second tip. The second mounting
segment includes a compliant portion including a bulbed section
having a second opening therethrough with legs on opposite sides of
the second opening. The first compliant pin is aligned with the
second compliant pin such that the first and second openings are
aligned to create a common terminal compliant pin opening and the
legs are aligned to create common terminal compliant pin legs. Both
the first and second compliant pins are received in a common plated
via of a circuit board with the legs of both the first and second
compliant pins being compressed in the plated via of the circuit
board.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of an embodiment of an
electrical power connector formed in accordance with an exemplary
embodiment and poised for mating with an electrical power
supply.
[0008] FIG. 2 is a front perspective view of a power terminal of
the electrical power connector shown in FIG. 1 and formed in
accordance with an exemplary embodiment.
[0009] FIG. 3 is a bottom perspective view of the power terminal
showing first and second contacts poised for mating together.
[0010] FIG. 4 is a bottom perspective view of the electronic
system.
DETAILED DESCRIPTION OF THE INVENTION
[0011] FIG. 1 is a perspective view of an embodiment of an assembly
10 of an electronic system 12 and an associated electrical power
supply 14. The power supply 14 is configured to be mated with the
electronic system 12 to supply the electronic system 12 with
electrical power to drive operation of the electronic system 12.
FIG. 1 illustrates the electronic system 12 and the power supply 14
in an unmated condition. The power supply 14 includes one or more
electrical power connectors 16 that are configured to mate with a
corresponding electrical power connector 18 of the electronic
system 12 for supplying the electronic system 12 with electrical
power. Optionally, the power supply 14 and/or the electronic system
12 may include signal contact(s) for transmitting data signals
between the electronic system 12 and the power supply 14 or another
component (not shown). Each electrical power connector 16 and each
electrical power connector 18 may be referred to herein as a
"mating connector" and may include corresponding mating
contacts.
[0012] The power supply 14 may be any type of electrical power
supply having any components, structure, and/or the like. In the
illustrated embodiment, the power supply 14 includes a circuit
board 20. The power connector 16 of the power supply 14 is coupled
to the circuit board 20. In addition or alternative to the circuit
board 20, the power supply 14 may include one or more electrical
wires or cables (not shown) and/or other components (not shown).
For example, the power connector 16 may be cable mounted rather
than being board mounted. The power supply 14 may include any
number of the power connectors 16 for mating with the electronic
system 12. As shown herein, the power supply 14 includes a single
power connector 16 and the electronic system 12 includes a single
power connector 18. But, the electronic system 12 may include any
number of power connectors 18 for mating with any number of power
supplies 14.
[0013] In the illustrated embodiment, the electronic system 12
includes a circuit board 22, such as a backplane; however the
electronic system 12 may include other types of components, such as
a power bus bar assembly or other component in alternative
embodiments. The electronic system 12 also includes other
components that are not shown herein for clarity. Such other
components of the electronic system 12 that are not shown herein
may include, but are not limited to, processing components, storage
components, display components, and/or the like. The electronic
system 12 may be any type of electronic system, such as, but not
limited to, a line card, a motherboard, a processing unit, and/or
the like. Optionally, the electronic system 12 includes one or more
signal connectors (not shown), and/or one or more of the power
connectors 18 includes signal contact(s) for transmitting signals
between the electronic system 12 and another component (not
shown).
[0014] The electrical power connector 16 includes a housing 30 and
one or more electrical power contacts 32 held by the housing 30.
The housing 30 includes a mating interface 34 at which the housing
30 mates with the corresponding power connector 18 of the
electronic system 12. In the illustrated embodiment, the mating
interface 34 includes one or more plugs 36 for mating with the
corresponding power connector 18; however, other types of mating
interfaces, such as receptacles, may be used in alternative
embodiments. The power contacts 32 include mating segments 38 for
mating with corresponding electrical power contacts of the power
connector 18. The power contacts 32 define mating contacts, and may
be referred to hereinafter as mating contacts 32, for mating with
the power contacts of the power connector 18.
[0015] In the illustrated embodiment, the power contacts 32 are
arranged in pairs defining receptacles or sockets for receiving the
electrical power contacts of the power connector 18 and for
engaging opposite sides of the power contacts of the power
connector 18. Optionally, the pairs of power contacts 32 may stem
from a common power terminal as a split beam type of power terminal
having two or more power contacts; however, other types of power
contacts or power terminals may be used in alternative embodiments.
The power contacts 32 may be spring beams configured to be
elastically deflected when mated with the power contacts of the
power connector 18, which causes the power contacts 32 to press
against the power contacts of the power connector 18, to ensure a
reliable electrical connection is made with the power connector 18.
Each mating segment 38 includes a mating interface 40 at which the
mating segment 38 mates (i.e., engages in physical contact and
thereby electrical connection) with the corresponding power contact
of the power connector 18. Although shown as including six power
contacts 32, the power connector 16 may include any number of the
power contacts 32.
[0016] The electrical power connector 18 of the electronic system
12 includes a housing 50 and one or more power terminals 60 which
are held by the housing 50. Although shown as including three power
terminals 60, the power connector 18 may include any number of the
power terminals 60. The power terminals 60 and the housing 50 are
mounted to the circuit board 22. The housing 50 includes a mating
interface 52 at which the housing 50 mates with the corresponding
power connector 16 of the power supply 14. In the illustrated
embodiment, the mating interface 52 includes one or more
receptacles that receive corresponding plugs 36 of the power
connector 16. But, the mating interface 52 of the power connector
18 may additionally or alternatively include any other structure
(such as, but not limited to, a plug) for mating with the
corresponding power connector 16.
[0017] In an exemplary embodiment, each power terminal 60 includes
a pair of power contacts, namely first and second power contacts
62, 64, which may be referred to hereinafter as power contacts 62,
64 or simply contacts 62, 64 with or without the first and second
identifiers. Additionally, other parts of such contacts 62, 64 may
be identified with the designator first and second, respectively.
Optionally, the first and second power contacts 62, 64 may be
similar and may include similar features. Some features may be
described with reference to the first power contact 62 or with
reference to the second power contact 64 without corresponding
description of such same or similar feature on the other power
contact 62, 64.
[0018] In an exemplary embodiment, the power contacts 62, 64 are
mirrored halves that are arranged back-to-back to form the power
terminal 60. However, the power contacts 62, 64 may not be mirrored
halves in alternative embodiments. The power contacts 62, 64 may be
permanently coupled together, such as by soldering, welding,
adhering, fastening, and the like. Alternatively, the power
contacts 62, 64 may be non-permanently coupled together, such as
being held together by an interference fit, by stiction, or by
being pressed together by the housing 50 and/or the circuit board
22.
[0019] The power contacts 62, 64 have first and second mating
segments 66, 68 for mating with corresponding electrical power
contacts 32 of the power connector 16. The mating segments 66, 68
include first and second mating interfaces 70, 72 (72 shown in FIG.
3) at which the mating segments 66, 68 mate (i.e., engages in
physical contact and thereby electrical connection) with the
corresponding mating segments 38 of the first and second mating
contacts 32 of the power connector 16. In the illustrated
embodiment, the mating segments 66, 68 are on opposite sides of the
power terminal 60 and define multiple points of contact for the
power terminal 60 with the corresponding power contacts 32.
[0020] FIG. 2 is a front perspective view of the power terminal 60
formed in accordance with an exemplary embodiment. FIG. 3 is a
bottom perspective view of the power terminal 60 showing the first
and second contacts 62, 64 poised for mating together. The first
and second contacts 62, 64 each include a main body 74, 76,
respectively. In an exemplary embodiment, the main bodies 74, 76
are generally planar; however, the main bodies 74, 76 may have
non-planar sections in alternative embodiments (for example, the
contacts may be right angle contacts or have other bends or folds).
The first and second contacts 62, 64 are manufactured from metal
sheets, such as being stamped and formed, to form the main bodies
74, 76. Optionally, the first and second contacts 62, 64 may be
stamped from metal sheets having approximately equal
thicknesses.
[0021] The mating segments 66, 68 are provided along the main body
74, 76, such as at or near the front of each main body 74, 76.
Optionally, the mating segments 66, 68 may be tapered at the front
of each main body to reduce stubbing during mating with the power
contacts 32 (shown in FIG. 1) of the power connector 16 (shown in
FIG. 1). The main bodies 74, 76 are arranged back-to-back such that
interior surfaces 80, 82 of the first and second contacts 62, 64
abut against each other, such as along a majority of the main
bodies 74, 76. Exterior surfaces 84, 86 of the first and second
contacts 62, 64 face in opposite directions. The exterior surfaces
84, 86 define the mating interfaces 70, 72 of the first and second
mating segments 66, 68.
[0022] The first contact 62 has a first thickness 90 (FIG. 3)
defined between the interior surface 80 and the exterior surface 84
thereof. The second contact 64 has a second thickness 92 (FIG. 3)
defined between the interior surface 82 and the exterior surface 86
thereof. Optionally, the first and second thicknesses 90, 92 may be
approximately equal. The thicknesses 90, 92 are defined by the
thicknesses of the sheets of material from which the contacts 62,
64 are stamped. When the contacts 62, 64 are mated together and
arranged back-to-back, the power terminal 60 has a third thickness
94 (FIG. 2) being the sum of the first and second thicknesses 90,
92. In alternative embodiments, more than two stamped and formed
contacts may be stacked to form the power terminal 60, such as
three or more contacts, where the thickness 94 is the sum of all of
the thicknesses of all of the contacts. The type of material and
the thicknesses 90, 92 of the material of the contacts 62, 64
affect the power transfer capability of the power terminal 60. For
example, using both contacts 62, 64 increases the thickness 94 of
the power terminal 60, thereby allowing the power terminal 60 to
transfer higher current and higher power. Using both contacts 62,
64 lowers the resistance of the power terminal 60 and thereby
reduces the operating temperature of the power terminal 60.
[0023] Using two contacts 62, 64 to form the power terminal 60
allows each of the contacts 62, 64 to be manufactured separately,
which may ease manufacture of the components. For example, because
each contact 62, 64 is approximately half the thickness 94,
stamping the contacts 62, 64 may be easier. For example, the dies
used to stamp the contacts 62, 64 may more easily punch through the
thickness 90, 92 of each contact 62, 64 individually, as opposed to
punching through the greater thickness 94 of the power terminal 60.
The dies are less susceptible to damage and the parts of the
contacts 62, 64 are less susceptible to damage because the contacts
62, 64 are thinner than the power terminal 60 having the thickness
94. The dies may be made thinner, which may allow various parts of
the contacts 62, 64 to be made smaller or more complex in shape.
The parts of the contacts 62, 64 (for example, the compliant pins)
may be manufactured more accurately because the dies may more
easily punch through the material during stamping.
[0024] With specific reference to FIG. 3, the first and second
contacts 62, 64 include first and second mounting segments 100, 102
extending from the main bodies 74, 76. The mounting segments 100,
102 may be mounted to the circuit board 22 (shown in FIG. 1). In an
exemplary embodiment, the first and second mounting segments 100,
102 include first and second compliant pins 104, 106, respectively.
When the power terminal 60 is assembled, the first compliant pin
104 is aligned with the second compliant pin 106 and arranged
back-to-back such that both the first and second compliant pins
104, 106 are configured to be received in a common plated via 174
(shown in FIG. 4) of the circuit board 22. In the illustrated
embodiment, the first contact 62 includes two compliant pins 104
and the second contact 64 includes two compliant pins 106. The
mounting segments 100, 102 may include any number of compliant pins
104, 106. Having multiple compliant pins 104, 106 allows multiple
attachment points to the circuit board 22, which may increase the
power throughput of the power terminal 60. Having multiple
compliant pins 104, 106 increases the surface area of the interface
between the power terminal 60 and the circuit board 22 to lower the
resistance between the power terminal 60 and the circuit board 22
and increase the current being transferred between the power
terminal 60 and the circuit board 22.
[0025] Each first compliant pin 104 includes a first tip 110 and a
first compliant portion 112. The tip 110 is provided at the distal
end of the compliant pin 104. The compliant portion 112 is
configured to be loaded into the plated via 174 of the circuit
board 22 and is configured to be mechanically and electrically
coupled to the circuit board 22. In the illustrated embodiment, the
compliant portion 112 is an eye-of-the-needle pin. The compliant
portion 112 includes a bulbed section 114 having a first opening
116 therethrough with legs 118, 120 on opposite sides of the first
opening 116. The bulbed section 114 is wider than the tip 110. The
legs 118, 120 are bowed outward on opposite sides of the opening
116 to form the bulbed section 114. In the illustrated embodiment,
the opening 116 is oval-shaped; however, the opening 116 may have
other shapes in alternative embodiments. The legs 118, 120 may be
flexed inward when the compliant portion 112 is loaded into the
plated via 174 of the circuit board 22. The opening 116 provides a
space for the legs 118, 120 to flexed inward. The elastic
deflection of the legs 118, 120 causes the legs 118, 120 to press
outward against the plated via 174 of the circuit board 22 to
mechanically and electrically connect the power terminal 60 to the
circuit board 22.
[0026] Each second compliant pin 106 includes a second tip 130 and
a second compliant portion 132. The tip 130 is provided at the
distal end of the compliant pin 106. The compliant portion 132 is
configured to be loaded into the plated via 174 of the circuit
board 22 and is configured to be mechanically and electrically
coupled to the circuit board 22. In the illustrated embodiment, the
compliant portion 132 is an eye-of-the-needle pin. The compliant
portion 132 includes a bulbed section 134 having a second opening
136 therethrough with legs 138, 140 on opposite sides of the second
opening 136. The bulbed section 134 is wider than the tip 130. The
legs 138, 140 are bowed outward on opposite sides of the opening
136 to form the bulbed section 134. In the illustrated embodiment,
the opening 136 is oval-shaped; however, the opening 136 may have
other shapes in alternative embodiments.
[0027] In an exemplary embodiment, during manufacture of the
contacts 62, 64, the compliant pins 104, 106 may be stamped and
formed to form rounded exterior edges 122, 142 along the legs 118,
120 and the legs 138, 140, respectively. For example, the compliant
pins 104, 106 may be coined to form the curved edges 122, 142. In
an exemplary embodiment, the edges 122, 142 are rounded only along
the exterior surfaces 84, 86 and not along the interior surfaces
80, 82. Rather, the interior surfaces 80, 82 along the compliant
pins 104, 106 are flat in an exemplary embodiment, allowing the
compliant pins 104, 106 to be arranged back-to-back in abutting
relationship and ensuring maximum surface area for contact between
the compliant pins 104, 106 at the interior surfaces 80, 82.
[0028] In an exemplary embodiment, with additional reference to
FIG. 2, the first and second compliant pins 104, 106 have similar
or identical forms allowing the first and second compliant pins
104, 106 to be aligned back-to-back to form one or more terminal
compliant pins 150 (FIG. 2) of the power terminal 60. In
alternative embodiments, either the first compliant pin 104 or the
second compliant pin 106 may be longer than the other such that the
compliant pins 104, 106 are vertically offset, such as for
sequenced mating with the plated via 174 of the circuit board 22.
The openings 116, 136 may be vertically offset. The tips 110, 130
may be vertically offset. The legs 118, 120 and the legs 138, 140
may be vertically offset. Optionally, portions of the compliant
pins 104, 106 may be horizontally offset in addition to or
alternatively to being vertically offset. The vertical and/or
horizontal offset may be within limits that allow the first and
second compliant pins 104, 106 to both be inserted into a common
plated via 174 of the circuit board 22.
[0029] The terminal compliant pins 150 are configured to be loaded
into corresponding plated vias 174 of the circuit board 22. The
first compliant pin 104 defines approximately half of the terminal
compliant pin 150 while the second compliant pin 106 forms
approximately half of the terminal compliant pin 150. The terminal
compliant pin 150 includes at least one terminal compliant pin
opening 152 (FIG. 2). In an exemplary embodiment, the at least one
terminal compliant pin opening 152 is defined by the first opening
116 and/or the second opening 136. In the illustrated embodiment,
the first and second openings 116, 136 are aligned to form a
single, common terminal compliant pin opening 152. However, in
embodiments where the first and second openings 116, 136 are
vertically offset and not aligned, the terminal compliant pin 150
may include multiple terminal compliant pin openings 152 which may
or may not extend entirely through the terminal compliant pin
150.
[0030] The first opening 116 has a first width 160 defined at a
widest part of the first opening 116 between the legs 118, 120. The
first width 160 is measured in a width direction, which is
generally perpendicular to the thickness direction and generally
perpendicular to a longitudinal direction or a loading direction of
the compliant pin 104 into the plated vias 174 of the circuit board
22. Optionally, the widest part of the opening 116 may be
approximately centered along the legs 118, 120; however the widest
part of the opening 116 may be located closer to the tip 110 or
further from the tip 110 along the legs 118, 120 in other various
embodiments. The first contact 62 has a width-to-thickness (W/T)
stamping ratio of greater than 1.0. The W/T stamping ratio of the
first contact 62 is a ratio of the first width 160 to the first
thickness 90. Having a W/T stamping ratio of greater than 1.0 means
that the width of the first opening 116 is wider than the thickness
of the first contact 62. The W/T stamping ratio affects the
stamping dies. Having a W/T stamping ratio greater than 1.0 makes
stamping easier than a W/T stamping ratio less than 1.0.
[0031] The second opening 136 has a second width 162 defined at a
widest part of the second opening 136 between the legs 138, 140.
Optionally, the widest part of the opening 136 may be approximately
centered along the legs 138, 140; however the widest part of the
opening 136 may be located closer to the tip 130 or further from
the tip 130 along the legs 138, 140 in other various embodiments.
The second contact 64 has a W/T stamping ratio, which is a ratio of
the second width 162 to the second thickness 92, of greater than
1.0.
[0032] The terminal compliant pin opening 152 has a third width 164
defined at a widest part of the terminal compliant pin opening 152.
The third width 164 may be defined as the widest part of the first
opening 116 or the widest part of the second opening 136, which may
be the same in some embodiments. As such, the third width 164 is
equal to the wider of the first width 160 or the second width 162.
The terminal compliant pin 150 has a W/T stamping ratio, which is a
ratio of the third width 164 to the third thickness 94, of less
than 1.0. Having a W/T stamping ratio of less than 1.0 means that
the thickness 94 of the terminal compliant pin 150 is greater than
the width of the terminal compliant pin opening 152. Stamping
through a part having a W/T stamping ratio less than 1.0 would be
more difficult than stamping through a part having a W/T stamping
ratio greater than 1.0.
[0033] The lower the W/T stamping ratio, the more difficult it is
to manufacture and punch through the thickness of the material to
form the features thereof. Hence, having the first and second
contacts 62, 64 stamped and formed separately prior to being
aligned and brought together to form the power terminal 60 makes
manufacturing simpler because both the first contact 62 and the
second contact 64 have a higher W/T stamping ratio than would a
power terminal having the dimensions of the power terminal 60. The
power terminal 60 is not itself stamped, but rather the individual
first and second contacts 62, 64 are stamped prior to assembly of
the power terminal 60.
[0034] In an exemplary embodiment, the W/T stamping ratio of the
terminal compliant pin 150 is approximately half of the W/T
stamping ratio of the first compliant pin 104. Similarly, the W/T
stamping ratio of the terminal compliant pin 150 is approximately
half of the W/T stamping ratio of the second compliant pin 106.
Thus, individually stamping both the first compliant pin 104 and
the second compliant pin 106 is easier than stamping the terminal
compliant pin 150 after the first and second contacts 62, 64 are
joined to form the power terminal 60. By separating stamping of the
terminal compliant pin 150 into two separate stamping operations,
namely stamping of the first compliant pin 104 and the stamping of
the second compliant pin 106 with the first and second contacts 62,
64, respectively, manufacturing is easier and the stamping dies are
less susceptible to damage.
[0035] FIG. 4 is a bottom perspective view of the electronic system
12 showing the electrical power connector 18 mounted to the circuit
board 22. The housing 50 includes posts 170 extending through
openings 172 in the circuit board 22. The posts 170 align the
housing 50 to the circuit board 22. The posts 170 may include
retention features to retain the housing 50 on the circuit board
22. The posts 170 may be used to locate the terminal compliant pins
150 relative to the plated vias prior to press-fitting of the
terminal compliant pins 150 into the plated vias 174.
[0036] The power terminals 60 are shown mechanically and
electrically connected to the circuit board 22. The terminal
compliant pins 150 are received in corresponding plated vias 174 in
the circuit board 22. Both compliant pins 104, 106 of the first and
second contacts 62, 64 are received in each of the respective
plated vias 174. As such, the first contact 62 of each power
terminal 60 and the second contact 64 of each power terminal 60 are
electrically connected to the circuit board 22 through the
corresponding plated via 174.
[0037] In an exemplary embodiment, the first and second compliant
pins 104, 106 fit tightly in the plated vias 174. As such, the
circuit board 22 presses together the first and second compliant
pins 104, 106, and thus the first and second contacts 62, 64, to
ensure electrical contact between the first and second contacts 62,
64. In an exemplary embodiment, features of the housing 50, such as
internal walls or channels, also help to pinch the first and second
contacts 62, 64 together to ensure electrical connection between
the first and second contacts 62, 64 of the power terminals 60.
[0038] The embodiments described and/or illustrated herein provide
a power terminal that includes a pair of (optionally mirrored)
contacts arranged back-to-back to form the power terminal. Dividing
the power terminal into two contact halves reduces the thickness of
each part to be stamped, thereby making manufacture easier and
making the stamping dies and parts of the contacts less susceptible
to damage. For example, by making the stamping ratio larger, the
dies are less susceptible to damage or breakage and/or the features
can be made smaller.
[0039] It is to be understood that the above description is
intended to be illustrative, and not restrictive. For example, the
above-described embodiments (and/or aspects thereof) may be used in
combination with each other. In addition, many modifications may be
made to adapt a particular situation or material to the teachings
of the invention without departing from its scope. Dimensions,
types of materials, orientations of the various components, and the
number and positions of the various components described herein are
intended to define parameters of certain embodiments, and are by no
means limiting and are merely exemplary embodiments. Many other
embodiments and modifications within the spirit and scope of the
claims will be apparent to those of skill in the art upon reviewing
the above description. The scope of the invention should,
therefore, be determined with reference to the appended claims,
along with the full scope of equivalents to which such claims are
entitled. In the appended claims, the terms "including" and "in
which" are used as the plain-English equivalents of the respective
terms "comprising" and "wherein." Moreover, in the following
claims, the terms "first," "second," and "third," etc. are used
merely as labels, and are not intended to impose numerical
requirements on their objects. Further, the limitations of the
following claims are not written in means-plus-function format and
are not intended to be interpreted based on 35 U.S.C. .sctn.112(f),
unless and until such claim limitations expressly use the phrase
"means for" followed by a statement of function void of further
structure.
* * * * *