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EP-4742459-A1 - ELECTRICAL CONNECTOR AND SUBASSEMBLY FOR DIFFERENTIAL SIGNALS

EP4742459A1EP 4742459 A1EP4742459 A1EP 4742459A1EP-4742459-A1

Abstract

An electrical connector (100) is disclosed, for connecting one or more differential pair cables (690) to a circuit board (670). The electrical connector (100) includes one or more terminal pairs; and overmolds for each terminal pair, the overmolds covering a portion of the respective terminal pair between distal ends and proximal ends of the respective terminal pair. The proximal ends of the terminals project out of the overmolds in a mating direction (199) toward the circuit board (670). A pair of conductive leads are at opposite sides of each overmold. The electrical connector (100) includes a shield 150 for shielding the terminal pairs and a holder (610) for handling. A subassembly for forming the connector (111) is also disclosed.

Inventors

  • TUIN, JACOBUS NICOLAAS
  • SMINK, RUTGER WILHELMUS

Assignees

  • TE Connectivity Nederland B.V.

Dates

Publication Date
20260513
Application Date
20241106

Claims (15)

  1. A connector subassembly (300) for an electrical connector (100), comprising: a terminal pair (200); an overmold (140), through which the terminal pair (200) extends; a pair of conductive leads 190a, 190b at opposite sides (359a, 359b) of the overmold (140); wherein a proximal end (210) of the terminal pair (200) projects out of the overmold (140) in a mating direction (199).
  2. The connector subassembly (300) of claim 1, wherein the terminal pair (200) includes a curve (614) such that a distal end (230) of the terminal pair(200) extends along a second mating direction (198) which is oblique to the mating direction (199).
  3. The connector subassembly (300) of claim 2, wherein the curve (614) of the terminal pair (200) is at least partially within the overmold (140).
  4. The connector subassembly (300) of claim 2 or 3 wherein the conductive leads (190a, 190b) include a curve which is parallel to the curve of the terminal pair.
  5. The connector subassembly (300) of any one of claims 1-4, wherein the proximal end (210) of the terminal pair (200) projects along the mating direction farther than the conductive leads (190a, 190b).
  6. The connector subassembly (300) of any one of claims 1-5, wherein the conductive leads (190a, 190b) include inner surfaces (191i, 192i) that face the terminal pair (200) and abut the opposite sides (359a, 359b) of the overmold (140).
  7. The connector subassembly (300) of claim 6, wherein the opposite sides (359a, 359b) of the overmold include recesses (360) that abut the inner surfaces (191i, 192i) of the conductive leads (190a, 190b).
  8. The connector subassembly (300) of any one of claims 1-7, wherein the proximal ends (230) of the terminal pair (200) are curved to present an inclining surface (231) at the proximal tip (232) of the terminal pair (200).
  9. The connector subassembly (300) of any one of claims 1-8, further comprising: a shield (150) forming a cavity (450) in which the overmold (140) is disposed; wherein optionally the shield includes an upper shield (170) and a lower shield (160); wherein optionally the upper shield (160) is attached to an upper surface of the conductive leads (190a, 190b) the lower shield (170) is attached to a lower surface of the conductive leads (190a, 190b); wherein optionally the lower shield (160) extends farther proximally along the mating direction (199) than the upper shield (170).
  10. A connector (100), comprising: a plurality of connector subassemblies (300) according to any one of claims 1-8; at least one shield (150) forming at least one respective cavity (450); wherein each of the respective connector subassemblies (300) are disposed in each respective cavity.
  11. A connector (100), comprising: a plurality of connector subassemblies (300) of any one of claims 1-8; a shield (150) which includes a row (420) of cavities (450); wherein the conductive leads (190a, 190b) include immediately neighboring conductive leads (190a, 190b) between adjacent overmolds (140) of the subassemblies (300); wherein the overmolds (140) are separate from each other; wherein the immediately neighboring conductive leads (190a, 190b) are connected, and optionally are monolithic.
  12. The connector (100) of claim 10 or 11, further comprising: a holder (610) which holds the shield or the at least one shield (150) such that the shield or at least one shield (150) projects upward from the holder (610), wherein the terminal pairs (200) are accessible from the bottom of the holder.
  13. A header (710), comprising: a housing (810) extending in a plane; a plurality of sets (820) of fingers (680) extending out of the plane; wherein the distal ends (830) of the fingers (680) are elastically deformable in directions parallel to the plane; a plurality of spacers (840), each spacer (840) being surrounded by a respective set (820) of the sets (820) of fingers (680); wherein the spacers (840) are configured to pass, along a direction perpendicular to the plane, at least one of a terminal pair (200) or a pin pair (660); wherein the distal ends (830) of the fingers (680) of the sets (820) of fingers (680) are configured to mate with a shield (150) of a connector (100).
  14. A connection assembly (111), comprising: the header (710) of claim 13; the connector (100) according to any one of claims 10-12; circuit board (670); and a plurality of pin pairs (660) in electrical contact with the circuit board (670) and respective terminal pairs (200), wherein the pin pairs (660) extend along the mating direction (199).
  15. A method (1300) of forming an electrical connector (100), comprising: stamping and bending (1310) a metal sheet to form a lead frame (180) including at least one terminal pair (200) and at least one pair of conductive leads (190a, 190b); forming (1320) at least one overmold (140), wherein each overmold of the at least one overmold (140) covers exactly one respective terminal pair (200) of the at least one terminal pair (200) between a distal end (230) and a proximal end (210) of the respective terminal pair (200) such that the proximal end (210) of the at least one terminal pairs (200) extends below the at least one overmold (140) along a mating direction (199) and the pair of conductive leads 190a, 190b are at opposites sides (359a, 359b) of the overmold (140); optionally further comprising: stamping and bending (1400) at least one additional metal sheet; welding (1340, 1360) the at least one additional metal sheet to the lead frame (180) to form a shield (150) that includes at least one cavity (450); wherein each overmold (140) of the at least one overmold (140) is disposed within one respective cavity (450) of the at least one cavity (450).

Description

Electrical connectors are used for enabling data communication between devices at various interfaces. Electrical connectors can be used to connect cables to circuit boards. It is desirable to reduce electrical devices' sensitivity to vibration or shock. It is also desirable to make electrical devices small. It is desirable to shield electrical connectors and/or devices from noise, such as noise that could be picked up at a connection. It is also desirable to keep manufacturing costs low; simplify assembly and/or disassembly procedures; and ensure robust electrical contact between contacting elements. The ability to routinely make robust low-noise electrical connections with reduced sensitivity to noise can be important for fast data transfer. The use of differential signaling can reduce susceptibility to noise. Connections to differential pair cabling, particularly multiple differential pair cables, can benefit from inventive ways of reducing noise and/or providing robust connections, e.g. between differential pair cables and a circuit board. Herein is disclosed an electrical connector which can be used for connecting one or more differential pair cables to a circuit board, and method of manufacture thereof. The electrical connector may include one or more connector subassemblies, as described herein. A header, as described herein, can be used to connect the electrical connector to a circuit board. A connector subassembly for an electrical connector is disclosed, including a terminal pair; an overmold, through which the terminal pair extends; and a pair of conductive leads at opposite sides of the overmold. The conductive leads can provide a connection surface for a shield and/or shielding of a cable. The proximal end of the terminal pair projects out of the overmold in a mating direction. The overmold can aid in physically supporting the terminal pairs and/or conductive leads. The proximal direction can have a component along the mating direction, and can include a component pointing below the overmold from above. There can be a pair of channels in the overmolds for the terminal pairs. The overmold can go between terminal pairs. The terminal pairs can abut walls of the channels. The subassembly can include a lead frame that includes the conductive leads and a bridge that connects the distal ends of the conductive leads. The distal direction can be toward the cable side. The proximal direction can be the header/circuit board side. Connector subassemblies, electrical connectors, and methods of manufacture can include the following further developments and/or embodiments, which can be combined singly or multiply, independently of each other unless indicated otherwise, for further embodiments. The invention is defined by the claims. The terminal pair can include a curve such that a distal end of the terminal pair extends along a second mating direction which is oblique to the mating direction, e.g. the mating direction at the proximal end. The proximal end and distal end of the terminal pair can extend along different directions, e.g. due to the curve of the terminal pair which can be between the ends. A distal direction can be opposite to the proximal direction, and/or include a vector component that points in the same direction as above the overmold from below. The curve can allow the cables to extend at an oblique angle to the connector/subassembly, and may save space. The curve of the terminal pair can be at least partially within the overmold. The terminal pair can include a curve distal to the bottom of the overmolds. Optionally, the curve of the terminal pair is at least partially covered by the overmolds. The overmold can physically support the curved region of the terminal pair. The conductive leads can include a curve which is parallel to the curve of the terminal pair. The parallel curves can aid in alignment of the cable to be attached to the subassembly. Alternatively/additionally, the parallel curves can simplify the formation of the subassembly. The conductive leads can be parallel to the terminal pair. The curves of the conductive leads can be at opposite lateral sides of the overmolds. The terminal pair and conductive leads can be at least partially parallel; for example, be parallel in a region covered by the overmold, the curved region. The distal ends of the terminal pair and conductive leads, e.g. projecting from the overmold along the second mating direction, can be parallel. The proximal end of the terminal pair can project along the mating direction farther than the conductive leads. This can aid in allowing electrical contact at the proximal side of the subassembly. For example, the conductive leads extend to the bottom of the lateral sides of the overmold. The interaction of the conductive leads and lateral sides of the overmold can aid in physically stabilizing the subassembly, e.g. during manufacture. The conductive leads can extend farther distally than the distal ends of the termi