Power terminal and power connector

Abstract

A hybrid edge connector includes an insulating housing having a slot aligned with signal terminals in a signal portion and power terminals in a power portion. The power terminals may be made of multiple layers, each layer being formed as one or more fingers. Each finger may be configured to contact an edge of a card inserted into the slot, such that each terminal has multiple contact points to the card and can carry a large current. To support a large current, the card may be a hybrid card having a signal portion formed using a conventional PCB manufacturing technique and a power portion formed using one or more blades mechanically coupled to the signal portion. The slot in the connector housing may have different widths in the signal portion and the power portion, and the centerlines of the portions may be offset relative to each other.

Description

Technical Field

[0001] The technologies disclosed in this article are generally related to electrical interconnect systems, and more specifically, to edge-type electrical connectors and power terminals that can be used in high-power applications. Prior Technology

[0002] Electrical connectors are used in many electrical systems. Various types of connectors are available for electronic devices, whose primary purpose is to enable the transmission of data, commands, power, and / or other signals between electronic assemblies. Connectors that carry either signals or power are sometimes referred to as hybrid connectors. It is often easier and more cost-effective to manufacture an electrical system as a separate electronic assembly that can be mated with an electrical connector. For example, one type of electronic assembly is a printed circuit board (“PCB”). The terms “card” and “PCB” are used interchangeably herein.

[0003] In some cases, one- or two-piece connectors are used to join two assemblies. A single connector can be installed onto each assembly. Mating connectors can be used to create a connection between the two assemblies.

[0004] In some other cases, a PCB can be directly attached to another electronic assembly via a one-piece connector (which may be configured as a snap-on connector). The PCB may have pads along one edge of an electrical connector designed to be inserted into and attached to the other assembly. Contacts within the electrical connector can contact the pads, thus connecting the PCB to the other assembly.

[0005] As will be understood, the connection provided by an electrical connector is an electrical connection that can transmit electrical signals and / or power (e.g., current and / or voltage). Summary of the Invention

[0006] The structure of high-power electrical connectors and connector terminals capable of carrying electrical power and signals is very important for electrical systems that may require high-power operation and / or a small size.

[0007] According to some embodiments of the present technology, a power terminal for a connector is provided. The power terminal may include a first plurality of first fingers and a second plurality of second fingers. The first plurality may be greater in number than the second plurality. The first plurality of first fingers may include first ends spaced apart from each other in a first direction and second ends connected to each other. The second plurality of second fingers may include first ends spaced apart from each other in the first direction and second ends connected to each other. The first ends of the second fingers may be spaced apart from the first ends of the first fingers in a second direction perpendicular to the first direction.

[0008] The second ends of the first fingers may be electrically connected to the second ends of the second fingers at a mating region. The first ends of the first fingers may have first contact points configured to contact a first side of a card, and the first ends of the second fingers may have second contact points configured to contact the first side of the card. The first contact points may be different from the second contact points.

[0009] According to some embodiments of the present technology, a power terminal assembly for a snap-fit ​​connector is provided. The terminal assembly may include a first terminal and a second terminal, and an insulating housing supporting the first terminal and the second terminal. Each of the first terminal and the second terminal may include: a first plurality of first fingers, each including a first end spaced apart from each other in a first direction and a second end connected to each other; and a second plurality of second fingers, each including a first end spaced apart from each other in the first direction and a second end connected to each other. For each of the first terminal and the second terminal: the first ends of the second fingers may be spaced apart from the first ends of the first fingers in a second direction perpendicular to the first direction; the first plurality may be greater than the second plurality; and the second ends of the first fingers may be electrically connected to the second ends of the second fingers at a mating region.

[0010] For the first terminal, the first ends of the first fingers may have first contact points configured to contact a first side of a card, and the first ends of the second fingers may have second contact points configured to contact the first side of the card, and the first contact points may be different from the second contact points. For the second terminal, the first ends of the first fingers may have first contact points configured to contact a second side of the card, and the first ends of the second fingers may have second contact points configured to contact the second side of the card, and the first contact points may be different from the second contact points. A portion of each of the first terminal and the second terminal may be disposed in the insulating housing such that the first contact points and the second contact points of the second terminal may face the first contact points and the second contact points of the first terminal across a gap.

[0011] According to some embodiments of the present technology, a power terminal for a connector is provided. The power terminal may include a first conductive sheet and a second conductive sheet. The first conductive sheet may include at least two first fingers, each first finger including a first end spaced apart from each other and a second end connected to each other. The second conductive sheet may include a second finger, the second finger including a first end and a second end.

[0012] Each of the first ends of the first finger and the second finger may have a contact surface thereon. The first end of the second finger may be positioned in a space between the first ends of adjacent first fingers. The second finger may include: a first segment including the first end of the second finger and having a first average width; and a second segment joined to the first segment and having a second average width greater than the first average width.

[0013] According to some embodiments of the present technology, a power terminal for a connector is provided. The terminal may include a first terminal portion comprising a plurality of metal layers stacked in a layer direction. Each metal layer may include fingers arranged in a column direction different from the layer direction. The fingers of the metal layers may form a column of contact surfaces such that a first column of contact surfaces corresponding to a first of the metal layers may be parallel to a second column of contact surfaces corresponding to a second of the metal layers.

[0014] The first type of the metal layers may include distal ends bent into hooks with convex surfaces. The first row of contact surfaces may be disposed on the convex surfaces of the hooks of the first type of the metal layers. The second type of the metal layers may include bent distal ends with convex surfaces. The second row of contact surfaces may be disposed on the convex surfaces of the bent distal ends of the second type of the metal layers. The rows of contact surfaces of the metal layers of the first terminal portion may be configured to contact a similar mating surface.

[0015] The features described herein may be used separately or in any combination in any of the embodiments discussed herein. Simple Explanation of the Diagram

[0016] The various forms and embodiments of the art disclosed herein are described below with reference to the accompanying drawings. It should be understood that the drawings are not necessarily drawn to scale. Items appearing in multiple drawings may be indicated by the same component symbols. For clarity, not every component may be labeled in every drawing.

[0017] Figures 1A, 1B and 1C each show an example of a printed circuit board (PCB) configured to connect to an edge connector.

[0018] Figure 2A is a diagram of one type of vertically oriented connection configuration.

[0019] Figure 2B is a diagram of a connection configuration with right-angle orientation.

[0020] Figure 2C illustrates one of the parallel plate (span assembly) connection configurations.

[0021] Figure 3 shows a plan view of one of the card receiving surfaces of an edge connector.

[0022] Figure 4 shows a hybrid card mated with a hybrid connector according to one embodiment of the present technology.

[0023] Figures 5A, 5B, 5C and 5D schematically illustrate an example of a hybrid card in which a signal portion and a power portion are combined to form a single assembly according to an embodiment of the present technology.

[0024] Figure 5E schematically shows a cross-section of a laminated assembly according to one embodiment of the present technology.

[0025] Figure 6 illustrates a hybrid card mated with a hybrid connector according to one embodiment of the present technology.

[0026] Figures 7A, 7B, 7C, 7D and 7E schematically illustrate examples of front views of the insertion edge of circuit board assemblies or hybrid cards with different configurations according to embodiments of the present technology.

[0027] Figures 8A and 8B illustrate a hybrid connector that can be used to connect to a hybrid card according to an embodiment of the present technology.

[0028] Figure 9 shows a plan view of one of the connection surfaces of a hybrid connector according to one embodiment of the present technology.

[0029] Figure 10 shows a plan view of one of the connection surfaces of a hybrid connector according to one embodiment of the present technology.

[0030] Figure 11 shows a plan view of one of the connection surfaces of a hybrid connector according to one embodiment of the present technology.

[0031] Figure 12 shows a plan view of one of the connection surfaces of a hybrid connector according to one embodiment of the present technology.

[0032] Figure 13A shows a plan view of one of the power terminals according to one embodiment of the present technology.

[0033] Figure 13A' shows a plan view of one of the power terminals according to one embodiment of the present technology.

[0034] Figure 13B shows a cross-sectional view of a power terminal assembly comprising one of the two power terminals shown in Figure 13A (or Figure 13A') within a housing according to one embodiment of the present technology.

[0035] Figure 13C shows a cross-sectional view of a power terminal assembly having a mounting portion configured for a right-angle connector according to one embodiment of the present technology.

[0036] Figure 13D is a perspective view of a mating portion of a power terminal according to one embodiment of the present technology.

[0037] Figures 14A and 14A' show a perspective view of one of the power terminals according to one embodiment of the present technology.

[0038] Figure 14B shows an exploded view of one of the power terminals in Figure 14A.

[0039] Figure 14C shows a perspective view of a power terminal assembly according to one embodiment of the present technology.

[0040] Figures 15A, 15A', 15B and 15B' show a top plan view and a bottom plan view of a power terminal assembly according to one embodiment of the present technology.

[0041] Figures 15C, 15C', 15D and 15D' show top and bottom perspective views of the power terminal assembly in Figures 15A, 15A', 15B and 15B'.

[0042] Figure 15E shows a side plan view of one of the power terminal assemblies in Figures 15A and 15B.

[0043] Figure 16A shows a bottom plan view of one of the power terminals and one of the first fingers according to one embodiment of the present technology.

[0044] Figure 16B shows a bottom perspective view of one of the first fingers of Figure 16A.

[0045] Figure 16C shows a top perspective view of one of the first fingers of Figure 16A.

[0046] Figure 16D shows a side view of one of the first fingers of Figure 16A.

[0047] Figure 17A shows a bottom view of one of the second fingers according to one embodiment of the present technology.

[0048] Figure 17B shows a bottom-view perspective view of one of the second fingers of Figure 17A.

[0049] Figure 17C shows a side view of the second finger in Figure 17A. Implementation

[0050] The inventors have identified and understand interconnection designs for realizing compact, cheaper, and highly functional electronic systems. These systems need to deliver power to and from the assembly within a relatively small space. These designs include adaptations to card edge connectors and mating cards to support high power flow through a small space without undesirable effects (such as large heat generation and potential damage to the system due to the generated heat).

[0051] Figures 1A to 1C illustrate examples of PCBs 10A, 10B, and 10C configured for insertion into edge connectors. Electrical contacts (shown here as surface pads) can be placed on one or more edges of a PCB in various configurations. Figure 1A illustrates a portion of a PCB 10A. As can be seen, PCB 10A may have multiple vias exposed on one surface. The vias provide connections to conductive structures within PCB 10A. Semiconductor chips and other components can be mounted to PCB 10A by attaching their leads to the vias, allowing signals and power to travel between these components through the conductive structures. Within PCB 10A, signal traces patterned on various layers can carry signals. Power can be carried on power planes that can be distributed between the signal trace layers. When pads at the edges of PCB 10A are inserted into a connector, these pads can also connect to conductive structures within PCB 10A, allowing them to connect to other locations in an electronic system. Some pads used as signal terminals can connect to traces within PCB 10A, while others used as power terminals can connect to power planes within PCB 10A. Components attached to PCB 10A can consume power delivered to PCB 10A through the power terminals. Alternatively, components attached to PCB 10A can regulate or otherwise deliver power through the power terminals, which can then be routed to other components in an electronic system. Regardless of the direction of power flow (to or away from PCB 10A), the techniques described herein can be applied to both the PCB and the edge connector. However, in many electronic systems, a significant amount of power can flow from one of the PCBs used as a power supply and then through an edge connector, making the techniques described herein selectively applicable to these components in some embodiments.

[0052] Figure 1B illustrates another example of a PCB 10B configured for insertion into an edge connector. In this example, for simplicity, the PCB 10B is shown schematically without components, vias, or traces. In the illustrated example, electrical terminals 12a and 12b on the PCB 10B can be positioned on a main edge 14A of the PCB 10B. In a further example shown in Figure 1C, electrical terminals 12c and 12d on a PCB 10C can be positioned on edge protrusions 14B and 14C extending from a main edge 14D of the PCB 10C. The edges 14A, 14B, and 14C where the electrical terminals are positioned can be inserted into edges, which are configured to be inserted into edges in an edge connector.

[0053] Terminals 12a, 12b, 12c, and 12d can be configured to carry electrical signals and / or supply power (e.g., current, voltage). Within an electronic assembly, power and signals can be distinguished based on frequency, voltage, or current. Power is typically low-frequency, such as 60 Hz or less, and is usually DC. Power is also typically a voltage higher than a signal, having a voltage level of 5 V, 12 V, or higher. In contrast, signals may be less than 5 V, and typically less than 3 V. Similarly, power is typically high-current, usually in the range of several amperes or tens of amperes, while signals will be on the order of several milliamperes.

[0054] In the example of Figure 1B, terminal 12a can be configured to carry signals to and from PCB 10B, and terminal 12b can be configured to supply power. In another example, in PCB 10C, terminal 12c to the left of terminal 12d can be configured to carry power to and from PCB 10C, terminal 12d can be configured to carry signals, and terminal 12c to the right of terminal 12d can be configured to carry power. Figures 1A to 1C illustrate PCBs configured for mating with a card edge connector that can have any of several terminal configurations, and the techniques described herein can be applied with PCBs having any suitable terminal configuration.

[0055] Edge connectors can be configured to mate with a PCB in any of a number of orientations. For example, Figure 2A shows an example of a vertically oriented edge connector 20a configured to receive a PCB 22a in a slot 24. One mounting end of connector 20a can be configured to be mounted on a substrate 26a (which may be another printed circuit board, such as a backplane), wherein the slot 24 is positioned to receive the PCB 22a when it is oriented to extend vertically relative to the surface of substrate 26a.

[0056] Figure 2B illustrates an example of a right-angled edge connector 20b configured to receive a PCB 22b in a slot (not visible in the figure). One mounting end of the connector 20b can be configured to be mounted at a right angle to a substrate 26b. The substrate 26b can also be a PCB, such as a motherboard in an electronic system; however, it should be understood that the connector and card design can be used with any suitable type of substrate. In this example, the PCB 22b is parallel to the substrate 26b.

[0057] Figure 2C illustrates an example of a spanner edge connector 20c in which one of the PCBs 22c is inserted into a slot; one mounting end of the connector 20c can be configured for horizontal mounting on a substrate 26c. In the illustrated example, a contact tail extending from the connector 20c has a portion aligned with an upper surface of the substrate 26c. Another portion of the contact tail extending from the connector 20c is aligned with a lower surface of the substrate 26c. This configuration is sometimes referred to as a spanner and can be used to connect parallel plates. As will be understood, the edge connector can be configured to attach to a substrate in other orientations. The techniques described herein can be used in conjunction with the mounting orientations illustrated in Figures 2A to 2C or in any other suitable mounting orientation.

[0058] Figures 2A to 2C each illustrate a portion of an electronic system. A complete system may have multiple connectors mounted to a substrate, which provide connections between multiple PCBs inserted into these connectors. Furthermore, the substrate may be connected to other components via cables, busbars, or other means besides edge connectors.

[0059] Figure 3 illustrates a plan view of a card receiving surface of a card edge connector 30. The connector 30 may be, for example, a vertically oriented card edge connector 20a, a right-angle oriented card edge connector 20b, or a horizontally oriented card edge connector 20c. The connector 30 may include a slot 34 configured to receive a card. The slot 34 may include a power section 34A having a power terminal 38a configured to contact a corresponding power contact pad of a PCB. For example, terminal 38a may be configured to contact a power contact pad 21a of PCB 22a (or 22b or 22c). The slot 34 may also include a signal section 34B having a signal terminal 38b configured to contact a corresponding signal contact pad of a PCB. For example, terminal 38b may be configured to contact a signal contact pad 21b of PCB 22a (or 22b or 22c).

[0060] As illustrated in the example of Figure 3, the power terminal 38a may be wider than the signal terminal 38b. This design allows the power terminal 38a to carry more current than the signal terminal 38b without excessive heating. The larger cross-sectional area of ​​the power terminal 38a provides lower contact resistance, lower bulk resistance, and lower current density, all of which contribute to less heating within the connector when a relatively large amount of current travels through the power terminal 38a.

[0061] Figures 2A to 2C illustrate how a PCB designed for insertion into a card edge connector can be manufactured with power contact pads that mate with wider power terminals. For example, Figure 2A shows that power pad 21a may be wider than signal contact pad 21b. Similar relative dimensions of the signal pad and power pad are also shown for PCBs 22b and 22c.

[0062] The inventors have recognized and understand the design of power terminals for edge connectors that can transfer a relatively large amount of electrical power with an acceptable amount of heating. Current flow is commonly used as an indicator of delivered power because power and current are related, and heating is proportional to current flow. Acceptable heating can be expressed as a temperature rise at a rated current. As a specific example, a connector or a power terminal within a connector may have a rated current capacity that reflects the amount of current that will increase the temperature from ambient conditions by a set amount (such as 30˚C).

[0063] The following section, in conjunction with Figures 13A to 17C, presents examples of improved power terminals capable of transmitting large amounts of current.

[0064] The inventors have recognized and understand that, for high-power applications, connectors with improved terminal designs can handle more current than can pass through a PCB inserted into the connector without causing unacceptable heating within the PCB. For example, a design may require a PCB to deliver up to 480 amps, with a maximum temperature increase of 30˚C above ambient temperature. A conventional method for designing PCBs for higher current applications is to have more power planes, thus making the PCB thicker. Increased layer count is often necessary because the width of the PCB is typically set by the need to fit within a specific space. Furthermore, widely used PCB manufacturing processes tend to use copper foil, which has a thickness that prevents the thickness of each power plane from being arbitrarily increased to increase the current carrying capacity of the PCB within a predefined range. Therefore, increasing the layer count is a conventional method for increasing the current carrying capacity of a PCB. However, for some types of electronic systems that require portability and therefore a small size or weight, or in which low cost is desired, an increase in the number of PCB layers may be undesirable.

[0065] Different PCB design approaches can expand the usability of improved power terminals and card edge connectors. A hybrid PCB card (referred to as a "hybrid card," "hybrid board," or "hybrid circuit board assembly" in this document) can be used in high-power applications.

[0066] Figure 4 illustrates a hybrid card 40 mating with a hybrid connector 42 according to some embodiments of the present technology. The hybrid card 40 may be used, for example, as a sub-assembly of a power supply, but it may be configured for any suitable function as described above. The hybrid connector 42 may be mounted on a substrate 41. The substrate 41 may be a mother card, a backplane, or another assembly within an electronic system.

[0067] A slot 44 of the hybrid connector 42 may be structured to receive a hybrid card 40. The hybrid card 40 may have a signal portion 40a and a power portion 40b. The signal portion 40a may include signal contact pads 46 configured to contact the signal terminals of the hybrid connector 42. If the hybrid card 40 is a power supply, electronic components (such as those for adjusting or regulating power) may be mounted to the signal portion 40a using conventional printed circuit board manufacturing techniques.

[0068] The power supply section 40b may include blades made of a conductive material. For example, the power supply section 40b may include any of the following: - Solid components made of an elemental metal with high electrical conductivity (e.g., Cu, Al); - A solid part of an alloy of metals (e.g., a Cu alloy); or - Having a solid plate or core cladding of a highly conductive metal (e.g., a Cu plate cladding of Au, a steel plate cladding of Cu, or a resin plate cladding of Cu); or - A stack of highly conductive materials dispersed with a less conductive material. For example, the blade may include any of the following: a solid copper component; a core covered with a thick copper layer; a core covered with a thick copper layer and a gold surface layer; a core covered with a thick copper layer, a silver layer, and a gold surface layer; a laminated structure having a thin insulating layer separating two thicker conductive layers, etc. As will be understood, the highly conductive material may be a metallic alloy. The core may be made of any material having properties that allow it to be formed into a card-like or blade-like shape and to be covered with another material without adversely affecting other (covering) materials. For example, the core may be made of aluminum.

[0069] The power supply section 40b may have an edge suitable for a contact surface (as illustrated above with power pad 21a), which can be inserted into a portion of a hybrid connector containing power terminals. The contact surface may be due to the use of a suitable material for forming the blade or due to the application or plating (including, for example, a gold plating or a multilayer plating) of an oxidation-resistant coating onto a portion of the blade.

[0070] The power supply section 40b may be configured as a conductive blade, as illustrated in the examples herein. As will be understood, the conductive blade 40b may comprise any highly conductive material capable of conducting current sufficient for applications requiring at least 3000 W of power and having sufficient rigidity to withstand repeated mating and unmating with a connector. For example, the cladding may be a Cu layer having a thickness of at least 0.14 mm, at least 0.5 mm, at least 1 mm, or at least 1.5 mm.

[0071] Signal portion 40a and conductive blade 40b can be held together as a single assembly. One or more support members can be used to hold signal portion 40a and conductive blade 40b in a side-by-side configuration. In one example shown in FIG. 5A, at least one edge clip 52 can engage one edge of signal portion 40a and one edge of conductive blade 40b together. The support member may be attached to or may include portions of signal portion 40a and / or conductive blade 40b. In another example shown in FIG. 5B, one edge of conductive blade 40b may be structured to have a groove or recess 53 to receive one edge of signal portion 40a therein. The groove 53 may be outlined to have a pattern (dashed line), and the edge of signal portion 40a may be outlined with a complementary pattern to ensure that signal portion 40a and conductive blade 40b are aligned and mated together as desired. Conversely, in another example (not shown in the diagram but similar to Figure 5B), one edge of the signal portion 40a may be structured to have a groove or recess to accommodate one edge of the conductive blade 40b therein.

[0072] As mentioned above, Figure 5A illustrates a support member between the signal portion 40a and the conductive blade 40b. The support member may be in other locations. For example, one or more support members may form a frame partially or completely surrounding one or more signal portions 40a and one or more conductive blades 40b of a hybrid card 40. As a specific example, a signal portion 40a may contain control circuitry for a power supply and for supply and return lines of one or more circuits using power supplied from the power supply. The power supply may have an enclosure that serves as or contains one or more support members, wherein the signal portion 40a and the conductive blade 40b are mounted within the enclosure such that their insertion edges are exposed along a common edge of the enclosure. The resulting assembly may be a pluggable power supply that can be inserted into a rack or other electronic system such that the insertion edges of the signal portion 40a and the conductive blade 40b can be inserted into a connector within the system to establish signal and power connections.

[0073] In other examples, signal portion 40a and conductive blade 40b may share a common resin board 54. Signal portion 40a may be formed in a portion of resin board 54 and processed into a typical PCB, which will be processed to form signal contact pads 46. As depicted in FIG5C, another portion of resin board 54 may support conductive blade 40b. For example, this portion of resin board 54 may be covered with a highly conductive material layer 55 on one or both sides to form conductive blade 40b; (several) covering layers 55 may be, for example, at least 0.14 mm of Cu or a Cu alloy, or at least 0.5 mm of Cu or a Cu alloy. Alternatively, a conductive blade 40b may be mounted to the surface of resin board 54, such as using screws, adhesives, or other fasteners. As a further variation, a region 59 of resin board 54 under conductive blade 40b may be omitted, such that the mating edge of the hybrid board in power portion 40b may be formed by the edge of conductive blade 40b. The edge of the conductive blade 40b above region 59 may be parallel to the body of the conductive blade 40b above resin plate 54, or may be bent to align with the edge of the signal portion 40a.

[0074] As another alternative, as shown in Figure 5D, the conductive blade 40b may include a solid metal plate 58 configured to fit into one of the cuts or openings 56 of the resin plate 54. The cut 56 may be a surface groove or a hole extending through the entire thickness of the resin plate 54. Where appropriate, clamps 57, screws, adhesives, or other fasteners may be used to hold the metal plate 58 in the cut 56.

[0075] As will be understood, signal section 40a and power section 40b can be attached together in other ways. For example, a female-female edge-receptacle connection can be used to connect signal section 40a and power section 40b. The examples presented herein are illustrative and should be considered as non-limiting examples.

[0076] The conductive blade 40b in Figures 4 and 5A to 5D is shown as having a single continuous region on a first side (e.g., a top side, shown in the figure). As will be understood, the conductive blade in Figures 4 and 5A to 5D may also have a second side (e.g., a bottom side, not visible in the figure) opposite the first side, which may also have a contact surface along an edge.

[0077] In some embodiments, the circuit board assembly may include more than one conductive blade. The conductive blade may have contact surfaces on the same or opposite sides of the circuit board assembly. The conductive blades may be held together as an integrated component, with some or all of the conductive blades separated by an insulating layer. These electrically separated conductive blades can transmit power at different voltage levels. When the circuit board assembly includes multiple conductive blades, the blades may have a front edge adjacent to the insertion edge of the circuit board assembly. Some or all of the conductive blades may retract from the insertion edge of the circuit board assembly, and different conductive blades may retract from the insertion edge of the circuit board assembly by different amounts.

[0078] Figure 5E shows an exemplary cross-section of a multilayer assembly 40b' having an insulating layer L1 having a first surface L2 and a second surface L3, a first blade L4 disposed on the first surface L2, and a second blade L5 disposed on the second surface L3. For example, the multilayer assembly 40b' depicted in Figure 5E can be used instead of the conductive blade 40b in Figure 5D. The first surface L2 and the second surface L3 of the insulating layer L1 may be parallel to the surface of the PCB of the signal portion 40a in Figure 5D.

[0079] The first blade L4 may have a first insertion edge L6 retracted from the insertion edge L7 of the stacked assembly 40b' to a first insertion edge L6 of a first distance DL4, and the second blade L5 may have a second insertion edge L8 retracted from the insertion edge L7 of the stacked assembly 40b' to a second insertion edge L8 that may differ from the first distance DL4. Insertion edges L6, L7, and L8 may also be referred to herein as mating edges. The first distance DL4 may be in the range of 1 mm to 8 mm. The second distance DL5 may be in the range of 1 mm to 6 mm. As a specific example, the difference in retraction may be approximately 2 mm to 5 mm. This configuration may be used, for example, in a power supply in which one of blades L4 and L5 is connected to a supply line of a circuit of a power supply and the other blade L4 and L5 is connected to a return line of that circuit. This configuration achieves pre-mating of the circuit's supply line or return line by using the second blade L5 when the stacked assembly 40b' is inserted into a slot of a connector.

[0080] The insulating layer L1 may include a rigid plastic layer, which may include an end cap L9 extending above the first insertion edge L6 and the second insertion edge L8 of the first blade L4 and the second blade L5. Alternatively, the insulating layer L1 may include an insulating film. For example, the insulating film may have a thickness of about 0.1 mm and the conductive blades L4 and L5 may be copper sheets with a thickness of about 1 mm.

[0081] In one exemplary embodiment, the multilayer assembly 40b' may be incorporated into a power busbar such that a portion of the multilayer assembly 40b' extends from a recessed portion of an insulating housing of the power busbar. A first conductive blade L4 may be a current-inflow blade capable of providing 3000 watts of power at 48 V, and a second conductive blade L5 may be a current-outflow blade.

[0082] The laminated assembly 40b' may have a total thickness Y in the range of 1 mm to 6.5 mm. The thickness of each of the first conductive blade L4 and the second conductive blade L5 may be in the range of 0.5 mm to 3.5 mm.

[0083] As is evident from the above discussion, a hybrid card is not required to contain a single blade or a monolithic blade. Figure 6 illustrates another embodiment of a hybrid card 60 mating with a hybrid connector 62. The hybrid connector 62 may be mounted on a substrate 61. A slot 64 of the hybrid connector 62 may be structured to receive the hybrid card 60 therein.

[0084] The hybrid card 60 may have a signal section 60a and a plurality of power sections 60b, 60c. The signal section 60a may include signal contact pads 66 configured to contact signal terminals of the hybrid connector 62. The power sections 60b, 60c may include blades of a highly conductive material. For example, a first conductive blade 60b may be used to carry current from the hybrid card 60 to the substrate 61, and a second conductive blade 60c may provide a return path for carrying current from the substrate 61 to the hybrid card 60.

[0085] The conductive blades 60b, 60c and the signal portion 60a can be joined together to form a single assembly using the techniques described above or other joining techniques known in this art (e.g., insulating clamp 65). For example, each of the conductive blades 60b and 60c may be 1.6 mm thick and have a cross-sectional area in the range of 35 mm² to 50 mm², and may be able to carry a current greater than 300 amperes in a 50 mm² area at a maximum temperature increase of 30˚C above an ambient temperature. As will be understood, the conductive blades described herein may have a thickness other than 1.6 mm, such as in the range of 0.5 mm to 2 mm, or 1.6 mm to 3 mm, or 2 mm to 3 mm, or 3 mm to 4 mm, or 4 mm to 5 mm.

[0086] The blades can be held in parallel using a support member that provides electrical insulation between the conductive blades. However, each of the blades 60b and 60c can be electrically connected to the signal section 60a, so that components responding to control signals can be supplied with regulated power, for example, through the conductive blades 60b and 60c. This configuration can be achieved by attaching the conductive blades 60b and 60c to a surface of a PCB in which the signal section 60a is implemented. In this configuration, conductive structures within the PCB can establish a connection between the signal section 60a and the conductive blades 60b and 60c.

[0087] Alternatively or additionally, other structures may be used to establish a connection between the conductive blades 60b, 60c and the signal portion 60a. For example, although FIG. 6 illustrates both conductive blades 60b and 60c having straight side edges perpendicular to the edge of the hybrid card 60 inserted into the connector 62, either or both of the conductive blades 60b and 60c may have conductive protrusions extending to the signal portion 60a. In some embodiments, a connection may be established between the signal portion 60a and (e.g.) the conductive blade 60b on one side of the hybrid card 60 and / or a connection may be established between the signal portion 60a and the conductive blade 60c on the opposite side of the hybrid card 60.

[0088] It should be understood that, depending on the thickness of the power section and signal section of a hybrid card and the attachment mechanism between the power section and the signal section, the position of the contact surface on the signal section and the power section relative to the elongated dimension of the slot that receives the edge of the hybrid card may vary.

[0089] Figures 7A to 7E schematically illustrate examples of front views of the insertion edge of circuit board assemblies or hybrid cards with different configurations. These examples are not exhaustive, and as will be understood, other configurations of hybrid cards according to other embodiments of the present technology may be used.

[0090] In one example shown in Figure 7A, a hybrid card 70A may have a uniform insertion edge. In this example, a signal portion 70a and a conductive blade 70b of the hybrid card 70A may both have the same thickness t1 at their insertion edges. The outer surfaces 72a, 72b, 72c, and 72d of the signal portion 70a and the conductive blade 70b may be aligned, and a plane Ma of the signal portion 70a may be aligned with or coplanar with a plane Mb of the conductive blade 70b. This configuration may arise, for example, from a configuration shown in Figures 5C and 5D, in which the power portion and the signal portion are aligned and have the same thickness. This configuration may also result if, as described above in conjunction with Figure 5C, a curved conductive blade is mounted on the same PCB containing the signal portion. In this configuration, the body of the conductive blade may be offset from the signal portion in one direction perpendicular to the edge (or at another angle), but the edge of the conductive blade may be curved to align with the edge of the signal portion.

[0091] In another example shown in Figure 7B, a hybrid card 70B may have a non-uniform insertion edge. In this example, the signal portion 70a and the conductive blade 70b of the hybrid card 70B may both have the same thickness t1 at their insertion edges. However, for the hybrid card 70B, the plane Ma of the signal portion 70a may not be aligned with the plane Mb of the conductive blade 70b. This configuration may arise from a configuration where one of the conductive blades is mounted on the same PCB containing the signal portion, as discussed above in conjunction with Figure 5C. The PCB may be implemented without the cutout area 59.

[0092] In a further example shown in Figure 7C, a hybrid card 70C may have a non-uniform insertion edge. In this example, the signal portion 70a may have a thickness t2 at its insertion edge, and the conductive blade 70b may have a different thickness t3 at its insertion edge. Furthermore, the plane Ma of the signal portion 70a may not be aligned with the plane Mb of the conductive blade 70b. However, for the hybrid card 70C, an outer surface 72a of the signal portion 70a may be aligned with an outer surface 72b of the conductive blade 70b. This configuration can result, for example, if the edges of the conductive blade and the signal portion have different thicknesses in the examples of Figures 5A to 5D, or if the conductive blade is mounted on the top surface of a PCB containing the signal portion in the example of Figure 5C.

[0093] In another example shown in Figure 7D, a hybrid card 70D may have a non-uniform insertion edge. In this example, the signal portion 70a may have a thickness t4 at its insertion edge, and the conductive blade 70b may have a different thickness t5 at its insertion edge. However, the plane Ma of the signal portion 70a may be aligned with the plane Mb of the conductive blade 70b. For the hybrid card 70D, the outer surface of the non-signal portion 70a is aligned with one of the outer surfaces of the conductive blade 70b. This configuration may result, for example, if the edges of the conductive blade and the signal portion have different thicknesses in the examples of Figures 5A to 5D, or if the conductive blade is mounted on the top and bottom surfaces of the PCB containing the signal portion in the example of Figure 5C.

[0094] In a further example shown in Figure 7E, a hybrid card 70E may have a non-uniform insertion edge. In this example, the signal portion 70a may have a thickness t6 at its insertion edge, and the conductive blade 70b may have a different thickness t7 at its insertion edge. Furthermore, the plane Ma of the signal portion 70a may not be aligned with the plane Mb of the conductive blade 70b. For the hybrid card 70E, the outer surface of the signal portion 70a is not aligned with one of the outer surfaces of the conductive blade 70b.

[0095] Figures 8A and 8B are perspective views illustrating hybrid connectors 80A and 80B that can be used to connect to a hybrid card (e.g., hybrid card 70A). Connector 80A may be a parallel plate configuration spanning edge connector, and connector 80B may be a vertically oriented edge connector. The appearance of connectors 80A and 80B may be described below using the component symbol 80, as connectors 80A and 80B may have the same mating interface and other components.

[0096] The connector 80 may include an insulating housing 81, a plurality of first conductive terminals 82, and a plurality of second conductive terminals 83. The housing 81 may include a groove 84 having a first groove portion 84a and a second groove portion 84b. The first conductive terminals 82 may be disposed in the first groove portion 84a, and the second conductive terminals 83 may be disposed in the second groove portion 84b. For example, the first conductive terminals 82 may be arranged in rows on opposite sides of the first groove portion 84a, and the second conductive terminals may be arranged in rows on opposite sides of the second groove portion 84b.

[0097] The first conductive terminal 82 may be a signal terminal and may be configured to carry an electrical signal. The second conductive terminal 83 may be a power terminal and may be configured to carry a relatively large current at a relatively high voltage. For example, each second conductive terminal 83 may be configured to carry up to 40 A. In another example, each second conductive terminal 83 may be configured to carry up to 50 A at up to 400 V. The first conductive terminal 82 may be electrically isolated from the second conductive terminal 83. The dimensions of the first conductive terminal 82 may differ from the dimensions of the second conductive terminal 83. The structural configuration of a power terminal according to the present technology, which may be used as one of the second conductive terminals 83, is described in more detail below.

[0098] Slot 84 may be configured to receive a hybrid card (e.g., 70A). For example, a first slot portion 84a may be configured to receive an edge of a circuit board (e.g., 70a) into which the hybrid card is inserted. A first conductive terminal 82 may be disposed in the first slot portion 84a to engage and physically contact a signal contact pad disposed on the circuit board when the hybrid card is mated with a connector 80. A second slot portion 84b may be configured to receive an edge of a conductive blade (e.g., 70b) into which the hybrid card is inserted. A second conductive terminal 83 may be disposed in the second slot portion 84b to engage and physically contact one or more conductive blades when the hybrid card is mated with the connector 80.

[0099] Figures 9 and 10 show plan views of one connection surface of the hybrid connector 90. The connectors 90 and 90' may include an insulating housing 91 having a slot 94. The slot 94 may include a first slot portion 94a and a second slot portion 94b. The first slot portion 94a may include a first inner surface 95a and a second inner surface 95b, and the second slot portion 94b may include a third inner surface 96a and a fourth inner surface 96b.

[0100] The first conductive terminal 92 may be disposed in a first array 97a on the first inner surface 95a and in a second array 97b on the second inner surface 95b. The first array 97a may face the second array 97b, such that a first card receiving space 98a may be formed between the first array 97a and the second array 97b.

[0101] Similarly, the second conductive terminal 93 may be disposed on the third inner surface 96a in a third array 99a and on the fourth inner surface 96b in a fourth array 99b. The third array 99a may face the fourth array 99b, such that a second card receiving space 98b may be formed between the third array 99a and the fourth array 99b.

[0102] As shown in Figure 10, the first card receiving space 98a may include a first mid-plane M1 located between the first array 97a and the second array 97b and equidistant from both the first array 97a and the second array 97b. The second card receiving space may include a second mid-plane M2 located between the third array 99a and the fourth array 99b and equidistant from both the third array 99a and the fourth array 99b.

[0103] The first intermediate plane M1 and the second intermediate plane M2 may have a predetermined relationship relative to one of them. For example, the first intermediate plane M1 may be coplanar with the second intermediate plane M2; this is schematically depicted in Figures 9 and 10. In another example, the first intermediate plane M1 may not be coplanar with the second intermediate plane M2; this is schematically depicted in Figures 11 and 12.

[0104] As will be understood, the first intermediate plane M1 and the second intermediate plane M2 may be coplanar, parallel, intersecting, or neither parallel nor coplanar, etc.

[0105] A distance between the first inner surface 95a and the second inner surface 95b of the first slot portion 94a can be designated as a height H1 of the first slot portion 94a. A distance between the third inner surface 96a and the fourth inner surface 96b of the second slot portion 94b can be designated as a height H2 of the second slot portion 94b. The height H1 of the first slot portion 94a may be equal to or different from the height H2 of the second slot portion 94b. Even if the height H1 of the first slot portion 94a is the same as the height H2 of the second slot portion 94b, the height of the first card receiving space 98a may be different from the height of the second card receiving space 98b due to a size difference between the first conductive terminal 92 and the second conductive terminal 93. For example, as schematically depicted in FIG11, a distance between a plane P1 corresponding to a contact surface of the first array 97a and a plane P2 corresponding to a contact surface of the second array 97b may be different from a distance between a plane P3 corresponding to a contact surface of the third array 99a and a plane P4 corresponding to a contact surface of the fourth array 99b.

[0106] The housing 91 may include a first housing portion 91a in which a first groove portion 94a is disposed, and a second housing portion 91b in which a second groove portion 94b is disposed. The first housing portion 91a and the second housing portion 91b may be integrally formed as a single unit or may be connected together to form a single unit, as schematically depicted in FIG12.

[0107] Connectors can be constructed to accommodate hybrid cards with various configurations schematically illustrated in Figures 7A to 7E. One connector illustrated in Figure 9 can be used with the topology of Figure 7A. One connector illustrated in Figure 10 can be used with the topology of Figure 7D. One connector illustrated in Figure 11 can be used with the topology of Figure 7C. One connector illustrated in Figure 12 can be used with the topology of Figure 7B. Other connector configurations can be used with other topologies.

[0108] In Figures 9 through 12, the hybrid connector is shown to have two slot portions for accommodating a hybrid card: one slot portion for accommodating a signal portion of the hybrid card and another slot portion for accommodating a power portion of the hybrid card. In other embodiments, the hybrid connector may have two or more slot portions for accommodating, for example, a hybrid card having more than one signal portion and / or more than one power portion. However, it should be understood that a one-to-one relationship between the signal portion and / or power portion of a hybrid card and a slot portion in a connector is not required, as more than one power portion having the same thickness and mid-plane can fit into the same slot portion. Similarly, more than one signal portion can fit into the same slot portion.

[0109] As discussed above, the hybrid card can be used with power terminals that carry a large amount of current. Figure 13A depicts a top plan view of a power terminal 1300 that can be used as one of the second conductive terminals 83 and 93 discussed above. The power terminal 1300 may have a plurality of finger groups shown here as a first plurality of first fingers 1312, each first plurality of first fingers 1312 having a first end 1312a spaced apart from each other and a second end 1312b connected to each other via a first joint. The power terminal 1300 may also include a second plurality of second fingers 1313 having a first end 1313a spaced apart from each other and a second end 1313b connected to each other via a second joint (see Figure 13B). The first end 1313a of the second fingers 1313 may be spaced apart from the first end 1312a of the first fingers 1312. The second end 1312b of the first finger 1312 may contact the second end 1313b of the second finger 1313 at a mating region 1340. The first ends 1312a and 1313a may be mating ends or mating portions.

[0110] In two or more groups, the centers of the mating ends of the fingers can be offset relative to each other in a direction perpendicular to one of the finger's elongation directions. In the example of Figure 13A, the center of the first end 1312a can be offset relative to the center of the first end 1313a. This configuration can disperse wear on the mating edges of the conductive blades of a hybrid card. Dispersing wear reduces the likelihood of contact failure after repeated use and is particularly advantageous in configurations where the fingers have pits on their contact surfaces to provide lower contact resistance or a greater ability to remove oxide layers due to the higher contact pressure provided by the pits.

[0111] The first complex number can be greater than the second complex number; that is, the number of first fingers 1312 can be greater than the number of second fingers 1313. For example, there can be three first fingers 1312 and two second fingers 1313, as shown in Figure 13A. Depending on the situation, as shown in Figure 13A', a power terminal 1300' may include four first fingers 1312 and three second fingers 1313. Having more first fingers allows the first fingers to be narrower than the second fingers. This configuration can provide multiple contact fingers with substantially the same contact force, even if the first fingers are shorter than the second fingers.

[0112] However, Figure 13D shows a configuration with two first fingers and two second fingers. Figure 13D shows the mating portions of two power terminals 1300a'' and 1300b'', which are configured to be mounted within a connector housing on opposite surfaces of a slot to receive a conductive blade inserted between them into the slot. The outer fingers 1313a'' and 1313b'' engage with the inner fingers 1312a'' and 1312b'' at connectors 1340a'' and 1340b'', respectively. In this example, the contact surface 1374a'' of the outer finger is aligned with the contact surface 1372a'' of the inner finger in a direction perpendicular to one edge of the hybrid card to which the finger can engage. As will be understood, the first and second prongs may have values ​​different from those shown in Figures 13A, 13D, and 13A'.

[0113] Power terminal 1300 may also include a mounting end 1320 configured for attachment to a substrate 1365 (see FIG. 13C). As will be understood, the mounting end may be configured to support a desired board configuration. For example, the mounting end 1320 of power terminal 1300 or 1300' may have a surface mount solder tail suitable for use with a connector shown in FIG. 2C. For example, the mounting end 1320 of the power terminal in FIG. 13C may have a press-fit solder tail suitable for use with a connector shown in FIG. 2B. For example, the first finger 1312 in FIG. 13B has a first tail and the second finger 1313 has a second tail. Power terminals shown in FIG. 13D are illustrated but their mounting ends are not shown; the mounting ends may have any suitable configuration.

[0114] The first end 1312a of the first finger 1312 may have a first contact point 1312c that can be configured to contact a first side of a card. For example, the contact point 1312c may contact a contact surface of a conductive blade or a power supply portion of a hybrid card. The contact point may be formed on a convex surface in the finger. Such surfaces may be electroplated or treated to reduce the resistance of a contact. In some embodiments, a contact point may extend across the finger. In other embodiments, a recess may be formed in the finger to provide a smaller contact point.

[0115] The first end 1313a of the second finger 1313 may have a second contact point 1313c that can be configured to contact the first side of the card. The first contact point 1312c may contact the first side of the card at a different position than the second contact point 1313c.

[0116] The length of one of the first fingers 1312 may be less than the length of one of the second fingers 1313. This configuration achieves both a large number of contact points and a low body resistance for the power terminals by using multiple metal sheets to form the power terminals. The two metal sheets are shown in FIG13A as being joined at a joining region 1340 and in FIG13D as being joined at joining regions 1340a'' and 1340b''. In the embodiment of FIG13C, two metal sheets are stamped on each of the terminals on opposite sides of a slot, and then the two metal sheets are joined, resulting in four joined metal sheets.

[0117] In some embodiments, the bonded metal sheets may have different thicknesses. For example, the thickness T1 of one of the first fingers 1312 may be less than the thickness T2 of one of the second fingers 1313. For example, T1 may be between 0.15 mm and 0.25 mm smaller than T2.

[0118] As shown in Figure 13B, at least one of the second fingers 1313 may include an elongated straight body and a hook-shaped first end 1313a connected to the straight body, wherein the first end 1313a may be a distal end, and the straight body includes a second intermediate portion. A second contact point 1313c of each of the at least one second finger 1313 may be located on the hook-shaped first end 1313a. For example, the second contact point 1313c may protrude from the hook-shaped first end 1313a.

[0119] Figure 13B illustrates a terminal assembly having two power terminals with mating portions as shown in Figure 13A, but configured for mounting in a right-angle connector. In the illustrated embodiment, one assembly 130 of power terminals 1300, 1301 is held within a substrate 1347 such that when the terminal assembly is inserted into an insulating housing 1350, the power terminals 1300, 1301 are aligned with the opposing walls of a slot 1345. The substrate 1347 may be formed in an embedded molding operation or in another suitable manner. Figure 13B shows a cross-section through one of the two opposing power terminals 1300, 1301 of a terminal assembly 130. It should be understood that a terminal assembly may contain more or fewer than two terminals, or alternative construction techniques may be used, such as inserting power terminals into a connector housing without forming the terminals as a terminal assembly.

[0120] As shown in Figure 13B, at least one of the first fingers 1312 may include an elongated body having at least one bend and a first end 1312a connected to the body, wherein the first end 1312a may be a distal end, and the elongated body includes a first intermediate portion. The first end 1312a is shown to have a bend. A first contact point 1312c of each of the at least one first finger 1312 may be on the bend of the first end 1312a. For example, the first contact point 1312c may protrude from the bend of the first end 1312a. In this example, the bend forms the distal end of the first finger.

[0121] At least one of the second fingers 1313 may have a hook-shaped first end 1313a that is hook-shaped, such that there is an opening 1313e facing one of the engagement regions 1340. As shown in FIG13B, a concave portion of the hook-shaped first end 1313a may be structured such that the opening 1313e faces the engagement region 1340. As will be understood, although the power terminal 1300 may be described herein as having two finger layers stacked one on top of the other, variations of the power terminal 1300 may have three or four or more finger layers.

[0122] Figure 13C is a cross-section through one of the opposing power terminals in a right-angle connector. Therefore, the power terminals of Figure 13C have a mounting portion with a different configuration than those in Figure 13A, but the mating portion can be the same. As shown in Figure 13C, the minimum distance from the straight body of the second finger 1313 to the tip 1313d of the hook-shaped first end 1313a connected to the straight body is greater than the minimum distance from the straight body of the second finger 1313 to the tip 1312d of the curved first end 1312a of at least one of the first fingers 1312. Using this structure, the opening 1313e facing the mating area 1340 faces the tip 1312d of the curved first end 1312a of at least one of the first fingers 1312.

[0123] As shown in Figure 13A, the first finger 1312 can be positioned as a first column in a column direction R, which is parallel to the elongated direction of the slot 1345 into which one edge of a PCB will be inserted. The second finger 1313 can be positioned as a second column in a second direction parallel to the column direction R. That is, the first column can be parallel to the second column. The width W1 of at least one of the first fingers in the direction parallel to the column direction is smaller than the width W2 of at least one of the second fingers in the direction parallel to the column direction.

[0124] A connector incorporated into power terminal 1300 may include an insulating housing 1350 in which first finger 1312 and second finger 1313 are disposed. Housing 1350 may include at least one opening exposing first contact point 1312c and second contact point 1313c, and a groove 1345 configured to receive an edge of a card 1360 therein. Groove 1345 may have a closed end 1346 configured to limit an insertion distance of the card into groove 1345.

[0125] After the card 1360 is inserted into the slot 1345, the contact point of the power terminal 1300 will scrape over a power pad on one surface of the card 1360. For the longer second finger 1313, a scraping length is a distance d1. The distance d1 between the second contact point 1313c and the closed end 1346 of the slot 1345 can be in the range of 7.5 mm to 9.5 mm.

[0126] The shorter inner (first) scratch length of 1312 is shown as d3. The distance d3 between the first contact point 1312c and the closed end 1346 of the groove 1345 can be in the range of 4.5 mm to 6.5 mm.

[0127] The scraping length d3 can be smaller than the scraping length d1 by d2. The distance d2 between the closest of one of the first contact points 1312c and one of the second contact points 1313c can be in the range of 1.5 mm to 3.5 mm. The inventors have recognized and understand that making d2 smaller increases the scraping length of the inner finger 1312, which in turn leads to a smaller contact resistance, because scraping can remove oxides on the contact surface that could otherwise increase the contact resistance.

[0128] As mentioned above, power terminals 1300 and 1301 may be a first power terminal 1300 and a second power terminal 1301 of a power terminal assembly 130, as schematically shown in FIG13B. One or more of these power terminal assemblies may be inserted into the connector housing 1350 or otherwise secured together to form a power portion of a connector. The second power terminal 1301 may have the same structure as the first power terminal 1300, and therefore, details of this structure will not be repeated. The first power terminal 1300 and the second power terminal 1301 may be configured such that the contact point of the first power terminal 1300 faces the contact point of the second power terminal 1301.

[0129] More specifically, for the first power terminal 1300, the first end 1312a of the first finger 1312 may have a first contact point 1312c configured to contact a first side 1360a of a card 1360, and the first end 1313a of the second finger 1313 may have a second contact point 1313c configured to contact the first side 1360a of the card 1360, wherein the first contact point 1312c is different from the second contact point 1313c. For the second power terminal 1301, the first end 1312a of the first finger 1312 may have a first contact point 1312c configured to contact a second side 1360b of the card 1360, and the first end 1313a of the second finger 1313 may have a second contact point 1313c configured to contact the second side 1360b of the card 1360, wherein the first contact point 1312c is different from the second contact point 1313c. A portion of each of the first power terminal 1300 and the second power terminal 1301 can be disposed in the housing 1350, such that the first contact point 1312c and the second contact point 1313c of the second power terminal 1301 face the first contact point 1312c and the second contact point 1313c of the first power terminal 1300 across a gap.

[0130] The first contact point 1312c of the first finger 1312 of the first power terminal 1300 and the first contact point of the first finger of the second power terminal 1301 can be separated by a distance X1. The second contact point 1313c of the second finger 1313 of the first power terminal 1300 and the second contact point of the second finger of the second power terminal 1301 can be separated by a distance X2. X1 can be in the range of 0.75 mm to 0.95 mm, and X2 can be in the range of 0.80 mm to 1.00 mm. Depending on the situation, X1 can be in the range of 0.82 mm to 0.86 mm, and X2 can be in the range of 0.88 mm to 0.92 mm.

[0131] In an alternative embodiment illustrated in the perspective view of Figure 13D, power terminals 1300a'' and 1300b'' may or may not be initially held in a substrate to form an assembly and may be inserted into a housing. Like other power terminals described above, the power terminals 1300a'' and 1300b'' of Figure 13D may be formed from multiple layers. Two such layers are shown here, resulting in power terminals having outer fingers 1313a'' and 1313b'' and inner fingers 1312a'' and 1321b''. In the illustrated embodiment, the same number of inner and outer fingers are present, and the contact points of the inner and outer fingers are aligned in one insertion direction of a clip to be mated with the terminal.

[0132] The power terminals 1300a'' and 1300b'' shown in Figure 13D have a longer finger and a shorter finger. The longer finger has a hook-shaped end, such that the distal tip of the longer finger bends backward toward the distal tip of the shorter finger. The contact point of the longer finger is located on the portion that bends backward toward the shorter finger, so that the scraping distance of the longer and shorter fingers is similar, which is desirable. Furthermore, this configuration resists mechanical removal because the distal tip of the longer finger points away from the insertion direction of a clip, and the distal tip of the shorter finger is protected by the hook-shaped portion of the longer finger.

[0133] Figure 14A is a perspective view of an alternative embodiment of a power terminal 1400, and Figure 14B shows an exploded view of the power terminal 1400 of Figure 14A. Compared to other configurations, the configuration of the power terminal 1400 facilitates the detection of a contact gap between two columns of the finger and also provides a good scraping length. Figures 15A and 15B show a top and bottom plan view of a power terminal assembly 14, which may have a pair of power terminals facing each other, such as the first power terminal 1400 and the second power terminal 1800 discussed below. Figures 15C and 15D show a top and bottom perspective view of the mating portion of the power terminal assembly 14. As with Figures 14A and 14B, the mounting portion of the assembly 14 is not shown for simplicity. Figure 15E shows a side view of the mating portion of the power terminal assembly 14. The three-dimensional representation of the line graphs in Figures 14A' and 15A' to 15D' is shown to more clearly illustrate curvature and other features that may not be easily seen in the line graphs.

[0134] Power terminal 1400 may be constructed from two or more tabs formed by stamping, for example, one of its fingers. The tabs may be stacked one on top of the other such that the contact points on each finger face the same direction to contact a power pad on an edge of a card inserted into a connector containing power terminal 1400. In the illustrated embodiment, power terminal 1400 may include a pair of first fingers 1401, a second finger 1402, and the first and second fingers 1401 and 1402 attached to a base 1403 thereto. First finger 1401 may include a first end 1401a spaced apart from each other and a second end 1401b connected to each other. Second finger 1402 may include a first end 1402a and a second end 1402b. Referring to FIG. 14B, a portion having the second end 1402b has a width greater than a portion having the first end 1402a.

[0135] The substrate 1403 may be configured to hold the second ends 1401b, 1402b of the first finger 1401 and the second finger 1402. For example, the substrate 1403 may be an insulator partially molded around the first finger 1401 and the second finger 1402 of the terminal 140. The second ends 1401b, 1402b of the first finger 1401 and the second finger 1402 may be electrically and / or mechanically connected, such as by welding or soldering, before they are inserted into or molded into the substrate 1403. Alternatively or additionally, the second ends 1401b, 1402b of the first finger 1401 and the second finger 1402 may be electrically connected by being held together in the substrate 1403. Figure 14A does not show a mounting portion of the terminal 1400, but in one of the configurations described above or in any other suitable configuration, a mounting portion may extend from the substrate 1403. A power terminal 1800 may be held opposite to power terminal 1400 in the same substrate 1403 to form a power terminal assembly 14 discussed below (see Figures 14C and 15E). Such assemblies may be inserted into a connector housing to form a power portion of a hybrid connector, or power terminal 1400 may be directly inserted into a connector housing, as described above in conjunction with other embodiments.

[0136] As will be understood from the above discussion, the base 1403 can be molded around the second ends 1401b and 1402b of the first finger 1401 and the second finger 1402, and therefore, the base 1403 and the second ends 1401b and 1402b are schematically depicted in the figure and can be shaped differently from what is depicted in the figure.

[0137] The first ends 1401a and 1402a of the first finger 1401 and the second finger 1402 may each have a contact surface 1401c and 1402c configured to engage and physically contact a PCB or a conductive blade (not shown). The first end 1402a of the second finger 1402 may be positioned in a space between the first ends 1401a of the first finger 1401, such that the contact surfaces 1401c and 1402c of the first finger 1401 and the second finger 1402 may be coplanar and aligned in a column direction R (see FIG. 14C). The second end 1401b of the first finger 1401 may be aligned with the second end 1402b of the second finger 1402 in a second direction S different from the column direction R. For example, the second end 1402b of the second finger 1402 may be stacked on the second end 1401b of the first finger 1401.

[0138] Power terminal 1400 may be a first power terminal 1400 of power terminal assembly 14. In addition to the first power terminal 1400, power terminal assembly 14 may also include a second power terminal 1800, as shown in Figures 15C to 15E. The second power terminal 1800 may have the same structure as the first power terminal 1400, and therefore, details of this structure will not be repeated (the component symbol 18## for the second power terminal 1800 may be used for features similar to the component symbol 14## for the first power terminal 1400). The first power terminal 1400 and the second power terminal 1800 may be attached to substrate 1403 such that the first power terminal 1400 faces the second power terminal 1800. Substrate 1403 may be an electrically insulating substrate or a conductive substrate.

[0139] Similar to a connector formed using a power terminal (such as 1300 as described above), the contact surfaces 1401c and 1402c of the first power terminal 1400 may be configured to face the corresponding contact surfaces 1801c and 1802c of the second power terminal 1800 across a gap 1503. A card receiving slot 1505 may be formed from the portion of the second fingers 1402 and 1802 of the first power terminal 1400 and the second power terminal 1800 facing each other across the gap 1503, the contact surfaces 1401c, 1402c, 1801c, and 1802c of the first power terminal 1400 and the second power terminal 1800 facing each other across the gap 1503, and a lateral portion 1507 of the base 1403 between the first power terminal 1400 and the second power terminal 1800.

[0140] The lateral portion 1507 of the substrate 1403 can be configured to limit the insertion distance of a PCB or a conductive blade into one of the card receiving slots 1505. The contact surfaces 1401c and 1402c of the first power terminal 1400 can be configured to contact a first side of the PCB or conductive blade, and the contact surfaces 1801c and 1802c of the second power terminal 1800 can be configured to contact a second side of the PCB or conductive blade.

[0141] Figure 16A shows a bottom plan view of a first metal sheet stamped to form one of the pair of first fingers 1401 for forming the power terminal 1400. Figure 16B shows a bottom perspective view of one of the pair of first fingers 1401. Figure 16C shows a top perspective view of one of the pair of first fingers 1401. Figure 16D shows a side view of one of the pair of first fingers 1401. As can be seen in Figures 16A to 16D, the first fingers 1401 are stamped to leave a larger gap 1610 between adjacent fingers 1401 in a distal region and a smaller gap 1612 in a proximal region closer to the substrate (not shown). The larger gap 1610 accommodates a distal segment of one of the second fingers 1402. The smaller gap 1612 allows the first fingers 1401 to flex independently of each other.

[0142] Figure 17A shows a bottom plan view of one of the second metal sheets stamped to form one of the second fingers 1402 for forming the power terminal 1400. Figure 17B shows a bottom perspective view of one of the second fingers 1402. Figure 17C shows a side view of one of the second fingers 1402.

[0143] The total width DA of the first finger 1401 at the second end 1401b in a region outside the base 1403 may be within 10% of the width DB of the second finger 1402 at the second end 1402b in a region outside the base 1403. Widths DA and DB may be dimensions parallel to the column direction R.

[0144] The width DC at the first end 1401a of at least one of the first fingers 1401 may be within 10% of the width DD at the first end 1402a of the second finger 1402. Widths DC and DD may be dimensions parallel to the column direction R.

[0145] The second finger 1402 may have a first distal segment 1402t (or 1802t for terminal 1800) adapted to fit into one of the gaps 1610 between the first fingers 1401 (or 1801) of the first piece. The second finger 1402 may have a second proximal segment 1402s (or 1802s for the second power terminal 1800). The first segment 1402t may have a width DD. The average width of one of the second segments 1402s may be greater than the average width of one of the first segments 1402t. This configuration allows the distal end of one of the fingers 1402 to fit into the gap 1610 between the fingers 1401, while providing a lower resistance of one of the fingers 1402 than a second finger 1402 with a uniform width. This shape may also provide a greater scraping length.

[0146] The width DB at the second end 1402b of the second finger 1402 in a region outside the base 1403 (not shown in Figures 17A to 17C) may be greater than the width DD at the first end 1402a of the second finger 1402. The second segment 1402s of the second finger 1402 may have a width increasing from the width DD, wherein the second segment 1402s joins the width DB of the first segment 1402t to the base 1403. The width may monotonically increase along the second segment 1402s. In the illustrated embodiment, for example, the width tapers linearly. However, the second segment 1402s does not need to have the same width as the first segment 1402t at the junction of segments 1402t and 1402s. For example, the second segment 1402s may have a width DB over its entire length or additionally a width greater than the width DB at the junction of the first segment 1402t and the second segment 1402s.

[0147] Example 1

[0148] According to a first embodiment of the present invention, a power terminal for use in a connector is provided. The power terminal may include a first plurality of first fingers and a second plurality of second fingers. The first plurality may be greater in number than the second plurality. The first plurality of first fingers may include first ends spaced apart from each other in a first direction and second ends connected to each other. The second plurality of second fingers may include first ends spaced apart from each other in the first direction and second ends connected to each other. The first ends of the second fingers may be spaced apart from the first ends of the first fingers in a second direction perpendicular to the first direction. The second ends of the first fingers may be electrically connected to the second ends of the second fingers at an engagement region. The first ends of the first fingers may have first contact points configured to contact a first side of a card, and the first ends of the second fingers may have second contact points configured to contact the first side of the card. The first contact points may be different from the second contact points.

[0149] According to one of the first embodiments, a terminal may have one or more of the following characteristics:

[0150] The distance (d2) between one of the first contact points and the closest of the second contact points can be in the range of 1.5 mm to 3.5 mm. Alternatively, the distance (d2) can be less than or equal to 3.5 mm.

[0151] The length of one of the first fingers may be less than the length of one of the second fingers.

[0152] The thickness of one of the first fingers may be less than the thickness of one of the second fingers. For example, the thickness of the first finger may be between 0.15 mm and 0.25 mm less than the thickness of the second finger.

[0153] At least one of the second fingers may include an elongated straight body and a hook-shaped first end connected to the straight body. The second contact point of the at least one of the second fingers may be on the hook-shaped first end.

[0154] The hook-shaped first end may include a convex surface, and the second contact point of at least one of the second fingers may be on the convex surface of the hook-shaped first end.

[0155] At least one of the first fingers may include an elongated body having at least one bend and a bend first end connected to the body. The first contact point of the at least one of the first fingers may be on the bend first end.

[0156] The first curved end may include a convex surface. The first contact point of the at least one of the first fingers may be on the convex surface of the first curved end.

[0157] At least one of the second fingers may include an elongated straight body and a hook-shaped first end connected to the straight body. The hook-shaped first end may have an opening facing one of the engagement areas.

[0158] A minimum distance from the straight body of at least one of the second fingers to the tip of one of the hook-shaped first ends connected to the straight body of at least one of the second fingers may be greater than a minimum distance from the straight body of at least one of the second fingers to the tip of one of the curved first ends of at least one of the first fingers, such that the opening facing the engagement area may face the tip of the curved first end of at least one of the first fingers.

[0159] The first fingers can be arranged in a first column in a column direction, and the second fingers can be arranged in a second column in a second direction parallel to the column direction. The width of at least one of the first fingers in the direction parallel to the column direction may be smaller than the width of at least one of the second fingers in the direction parallel to the column direction.

[0160] According to one of the first embodiments, a terminal can be combined with an insulating shell in which the first fingers and the second fingers are disposed. The combination may have one or more of the following characteristics:

[0161] The insulating housing may include at least one opening exposing the first contact points and the second contact points, and a slot configured to receive the card therein.

[0162] The slot may have a closed end configured to limit the insertion distance of the card into the slot.

[0163] The distance between the second contact point and the closed end of the groove can be in the range of 7.5 mm to 9.5 mm.

[0164] The distance between the second contact point and the closed end of the groove may be one of the scraping lengths of the terminal.

[0165] The distance (d3) between the first contact point and the closed end of the groove can be in the range of 4.5 mm to 6.5 mm.

[0166] Example 2

[0167] According to a second embodiment of the present invention, a power terminal assembly for a snap-fit ​​connector is provided. The terminal assembly may include a first terminal and a second terminal, and an insulating housing supporting the first terminal and the second terminal. Each of the first terminal and the second terminal may include: a first plurality of first fingers, each including a first end spaced apart from each other in a first direction and a second end connected to each other; and a second plurality of second fingers, each including a first end spaced apart from each other in the first direction and a second end connected to each other. For each of the first terminal and the second terminal: the first ends of the second fingers may be spaced apart from the first ends of the first fingers in a second direction perpendicular to the first direction; the first plurality may be greater than the second plurality; and the second ends of the first fingers may be electrically connected to the second ends of the second fingers at a mating region.

[0168] For the first terminal, the first ends of the first fingers may have first contact points configured to contact a first side of a card, and the first ends of the second fingers may have second contact points configured to contact the first side of the card, and the first contact points may be different from the second contact points. For the second terminal, the first ends of the first fingers may have first contact points configured to contact a second side of the card, and the first ends of the second fingers may have second contact points configured to contact the second side of the card, and the first contact points may be different from the second contact points. A portion of each of the first terminal and the second terminal may be disposed in the insulating housing such that the first contact points and the second contact points of the second terminal may face the first contact points and the second contact points of the first terminal across a gap.

[0169] According to one of the second embodiments, the terminal assembly may have one or more of the following characteristics:

[0170] The distance (d2) between one of the first contact points of the first terminal and the closest one of the second contact points of the first terminal may be less than 3.5 mm. For example, the distance (d2) may be in the range of 2.5 mm to 3.5 mm.

[0171] The insulating housing may include openings exposing the first and second contact points of the first and second terminals, and a slot configured to receive the card therein, the slot including the gap.

[0172] The slot may have a closed end configured to limit the insertion distance of the card into the slot.

[0173] The distance (d1) between the second contact points of the first terminal and the second terminal and the closed end of the groove can be in the range of 7.5 mm to 9.5 mm.

[0174] The distance (d1) between the second contact points of the first terminal and the second terminal and the closed end of the groove can be one of the scraping lengths of the terminal.

[0175] The distance (d3) between the first contact points of the first terminal and the second terminal and the closed end of the groove can be in the range of 4.5 mm to 6.5 mm.

[0176] The first fingers of the first terminal and the second terminal may be closer to one of the closed ends of the slot than the second fingers of the first terminal and the second terminal.

[0177] Example 3

[0178] According to a third embodiment of the present invention, a power terminal for a connector is provided. The power terminal may include a first conductive sheet and a second conductive sheet. The first conductive sheet may include at least two first fingers, each first finger including a first end spaced apart from each other and a second end connected to each other. The second conductive sheet may include a second finger, the second finger including a first end and a second end.

[0179] Each of the first ends of the first finger and the second finger may have a contact surface thereon. The first end of the second finger may be positioned in a space between the first ends of adjacent first fingers. The second finger may include: a first segment including the first end of the second finger and having a first average width; and a second segment joined to the first segment and having a second average width greater than the first average width.

[0180] According to one of the third embodiments, the terminal may have one or more of the following characteristics:

[0181] The total width of the first finger at its second end may be within 10% of the width of the second finger at its second end outside the base. Each of the widths at the second ends of the first and second fingers may be a dimension parallel to the column direction.

[0182] The width at the first end of at least one of the first fingers may be within 10% of the width at the first end of the second finger. The widths at the first ends of the at least one first finger and the second finger are each a dimension parallel to the column direction.

[0183] The width of the second segment may increase from the first end of the first segment to the second end opposite to the first end.

[0184] The width of the second segment can be linearly reduced to the width at the first end of the second finger.

[0185] A terminal assembly may include a plurality of terminals according to the third embodiment, combined with an insulating component. The combination may have one or more of the following characteristics:

[0186] The plurality of terminals may include a first terminal and a second terminal. The insulating component may be attached to the first terminal and the second terminal such that the contact surface of the second terminal may face the contact surface of the first terminal across a gap.

[0187] The second terminal may be a copy of one of the first terminals, such that the contact surfaces of the second terminal may directly face the contact surfaces of the first terminal across the gap.

[0188] The second terminal may include a pair of first fingers and a second finger. The second fingers of the first terminal and the second terminal may have a middle portion facing each other across the gap. A card receiving slot may be disposed between the middle portions of the second fingers facing each other across the gap and the contact surfaces of the first terminal and the second terminal facing each other across the gap.

[0189] The insulating component may be configured in one portion between the first insertion portion and the second insertion portion to limit the insertion distance of one of the cards inserted into the card receiving slot.

[0190] The contact surfaces of the first terminal can be configured to contact a first side of the card, and the contact surfaces of the second terminal can be configured to contact a second side of the card.

[0191] Example 4

[0192] According to a fourth embodiment of the present invention, a power terminal for a connector is provided. The terminal may include a first terminal portion comprising a plurality of metal layers stacked in a layer direction. Each metal layer may include fingers arranged in a column direction different from the layer direction. The fingers of the metal layers may form a column of contact surfaces such that a first column of contact surfaces corresponding to a first of the metal layers may be parallel to a second column of contact surfaces corresponding to a second of the metal layers.

[0193] The first type of the metal layers may include distal ends bent into hooks with convex surfaces. The first row of contact surfaces may be disposed on the convex surfaces of the hooks of the first type of the metal layers. The second type of the metal layers may include bent distal ends with convex surfaces. The second row of contact surfaces may be disposed on the convex surfaces of the bent distal ends of the second type of the metal layers. The rows of contact surfaces of the metal layers of the first terminal portion may be configured to contact a similar mating surface.

[0194] According to one of the fourth embodiments, the terminal may have one or more of the following characteristics:

[0195] The fingers of one of the metal layers may have a length different from the length of the fingers of the other metal layer.

[0196] The fingers of one of the metal layers may have the same length as the fingers of the other metal layer.

[0197] The total number of metal layers can be three, four or more.

[0198] The terminal may further include a second terminal portion comprising a plurality of metal layers stacked in the layer direction. Each metal layer of the second terminal portion may include fingers arranged in a direction parallel to the column direction. The fingers of the metal layers of the second terminal portion may form a column of contact surfaces such that a first column of contact surfaces corresponding to a first of the metal layers of the second terminal portion may be parallel to a second column of contact surfaces corresponding to a second of the metal layers of the second terminal portion. The first finger of the metal layers of the second terminal portion may include a distal end bent into a hook with a convex surface. The first column of contact surfaces of the second terminal portion may be disposed on the convex surfaces of the hooks of the first of the metal layers of the second terminal portion. The second finger of the metal layers of the second terminal portion may include a bent distal end with a convex surface. The second column of contact surfaces of the second terminal portion may be disposed on the convex surfaces of the bent distal ends of the fingers of the second of the metal layers of the second terminal portion. The rows of contact surfaces of the metal layers of the second terminal portion can be configured to contact one side of the card opposite to the rows of contact surfaces of the metal layers of the first terminal portion.

[0199] Each of the metal layers can be configured to carry a current up to 30 amps, or up to 35 amps, or up to 40 amps, or up to 45 amps at a maximum temperature 30˚C higher than an ambient temperature.

[0200] in conclusion

[0201] The foregoing features may be used separately or in any combination in any embodiment discussed herein.

[0202] Furthermore, while the advantages of the invention are indicated, it should be understood that not every embodiment of the invention will include every stated advantage. Some embodiments will not implement any features described herein as advantageous. Therefore, the foregoing description and figures are by way of example only.

[0203] Variations of the disclosed embodiments are possible. For example, although power terminals are described as being configured for use in a card edge connector, terminals with mating interfaces as described herein can be used in connectors configured to mate with other types of components. For example, power terminals as described herein can be inserted into a connector housing configured to receive a busbar or a blade-type terminal held in a housing of a mating connector.

[0204] The various forms of this invention can be used individually, in combination, or in various configurations not specifically discussed in the embodiments described above, and therefore their application is not limited to the details and configurations of the components set forth in the foregoing description or illustrated in the drawings. For example, a form described in one embodiment can be combined in any way with forms described in other embodiments.

[0205] The use of ordinal numbers such as "first," "second," and "third" in the description and scope of the invention application to modify an element does not imply any priority, preponderance, or order of one element over another, or the temporal order of actions in performing a method, but is merely used as a marker to distinguish one element or action having a specific name from another element or action having the same name (but using sequential terms).

[0206] All definitions defined and used herein should be understood as being governed by dictionary definitions, definitions incorporated by reference in other documents, and / or by the general meaning of the defined terms.

[0207] The indefinite articles “a” (and “an”) used in this document, in the specification, and in the scope of the invention application should be understood to mean “at least one”, unless clearly indicated to the contrary.

[0208] As used herein in the specification and in the claims of the invention, the phrase "at least one" referring to a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the list, but not necessarily including at least one of each element specifically listed in the list, and does not exclude any combination of elements in the list. This definition also allows for the presence, as appropriate, of elements other than those specifically identified in the list of elements referred to by the term "at least one," whether or not they are related to or unrelated to those specifically identified elements.

[0209] As used herein, in the specification, and within the scope of the invention application, the phrases “equal to” or “identical” referring to two values ​​(e.g., distance, width, etc.) mean that the two values ​​are identical within manufacturing tolerances. Therefore, two values ​​being equal or identical can mean that the two values ​​are different from each other by ±5%.

[0210] The phrase "and / or" as used herein and in the claims of this invention should be understood to mean "any one or both" of the elements so combined (i.e., elements that exist together in some cases and separately in others). The use of "and / or" to list multiple elements, i.e., "one or more" of the elements so combined, should be interpreted in the same manner. Other elements may exist besides those specifically identified by the "and / or" clause, whether or not they are related to or unrelated to those specifically identified elements. Therefore, as a non-limiting example, when used in conjunction with open-ended language such as "including," the reference to "A and / or B" may in one embodiment refer only to A (including elements other than B, as appropriate); in another embodiment, only to B (including elements other than A, as appropriate); in yet another embodiment, both A and B (including other elements, as appropriate), and so on.

[0211] As used herein in the specification and in the claims of the invention, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be interpreted as inclusive, that is, including several elements or a list of elements and, where applicable, at least one of the additional unlisted items, but also including more than one of them. Only when the term explicitly indicates the opposite, such as "only one" or "exact one," or when used in the claims of the invention, "consisting of..." will mean including several elements or exactly one element of a list of elements. Generally speaking, when preceded by an exclusive term (such as "either one," "one," "only one," or "exact one"), the term "or" as used herein should only be interpreted as indicating inclusion of an alternative example (i.e., "one or the other, but not both"). When used in the scope of an invention patent application, "consistent with..." should have its ordinary meaning as it is used in the field of patent law.

[0212] Furthermore, the phrases and terms used herein are for descriptive purposes and should not be considered restrictive. The use of words such as “comprising,” “including,” “consisting of,” “having,” “containing,” and “involving,” and variations thereof, is intended to cover the items listed thereafter, their equivalents, and additional items.

[0213] If used herein, the terms "approximately" and "about" may be interpreted as meaning within ±20% of a target value in some embodiments, within ±10% of a target value in some embodiments, within ±5% of a target value in some embodiments, and within ±2% of a target value in some embodiments. The terms "approximately" and "about" may be equal to the target value.

[0214] If used herein, the term "substantially" may be interpreted as meaning within 95% of a target value in some embodiments, within 98% of a target value in some embodiments, within 99% of a target value in some embodiments, and within 99.5% of a target value in some embodiments. In some embodiments, the term "substantially" may be equal to 100% of the target value.

[0215] 10A: Printed Circuit Board (PCB) 10B: Printed Circuit Board (PCB) 10C: Printed Circuit Board (PCB) 12a: Electrical terminal 12b: Electrical terminal 12c: Electrical terminal 12d: Electrical terminal 14: Power terminal assembly 14A: Main Edge 14B: Marginal protrusion 14C: Marginal protrusion 14D: Main Edge 20a: Card edge connector 20b: Card edge connector 20c: Card edge connector 21a: Power contact pad 21b: Signal contact pad 22a: Printed Circuit Board (PCB) 22b: Printed Circuit Board (PCB) 22c: Printed Circuit Board (PCB) 24: slot 26a:Substrate 26b:Substrate 26c:Substrate 30: Card edge connector 34: slot 34A: Power Supply Section 34B: Signal Section 38a: Power terminal 38b: Signal terminal 40: Mixed Card 40a: Signal Section 40b: Power supply section / conductive blades 40b': Laminated Assembly 41:Substrate 42: Hybrid Connector 44: slot 46: Signal contact pad 52: Edge clip 53: Groove / Recess 54: Resin Board 55: Highly conductive material layer / coating layer 56: Incision / Opening 57: Fixture 58: Metal Plate 59: Area / Incision Area 60: Mixed Card 60a: Signal Section 60b: Power supply section / First conductive blade 60c: Power supply section / second conductive blade 61:Substrate 62: Hybrid Connector 64: slot 65: Insulating clamps 66: Signal contact pad 70a: Signal Section 70A: Hybrid Card 70b: Conductive blade 70B: Mixed Card 70C: Hybrid Card 70D: Hybrid Card 70E: Hybrid Card 72a: Outer surface 72b: Outer surface 72c: Outer surface 72d: Outer surface 80A: Hybrid Connector 80B: Hybrid Connector 81: Insulating outer casing 82: First conductive terminal 83: Second conductive terminal 84: slot 84a: First slot section 84b: Second slot section 90: Hybrid Connector 90': Hybrid connector 91: Insulating outer casing 91a: First outer shell section 91b: Second outer shell section 92: First conductive terminal 93: Second conductive terminal 94: slot 94a: First slot section 94b: Second slot section 95a: First inner surface 95b: Second inner surface 96a: Third inner surface 96b: Fourth inner surface 97a: First Array 97b: Second Array 98a: First Card Acceptance Space 98b: Second card acceptance space 99a: Third Array 99b: Fourth Array 130: Assembly 1300: Power terminal 1300': Power terminal 1300'': Power terminal 1300a'': Power terminal 1300b'': Power terminal 1301: Power Terminal 1312: First finger 1312a: First end 1312a'': Inner finger 1312b: Second end 1312b'': Inner finger 1312c: First contact point 1312d: Top 1313: Second finger 1313a: First end 1313a'': external reference 1313b: Second end 1313b'': External reference 1313c: Second contact point 1313d: Top 1313e: Opening 1320: Installation end 1340: Joining area 1340a'': Connector 1340b'': Connector 1345: slot 1346: Closed end 1347: Base 1350: Insulating casing 1360: Card 1360a: First side 1360b: Second side 1365:Substrate 1372a'': Contact surface 1374a'': Contact surface 1400: Power terminal / First power terminal 1401: First finger 1401a: First end 1401b: Second end 1401c: Contact surface 1402: Second finger 1402a: First end 1402b: Second end 1402c: Contact surface 1402s: Second proximal segment 1402t: First distal fragment 1403: Base 1503: Gap 1505: Card Receiving Slot 1507: Horizontal section 1610: Larger gap 1612: Smaller gap 1800: Second power supply terminal 1801: First finger 1801c: Contact surface 1802: Second finger 1802c: Contact surface 1802s: Second proximal segment 1802t: First distal fragment d1: Distance d2: Distance d3: Distance DA: Width DB: Width DC: Width DD: width DL4: First distance DL5: Second Distance H1: Height H2: Height L1: Insulation layer L2: First surface L3: Second surface L4: First blade L5: Second blade L6: First insertion edge L7: Insert edge L8: Second insertion edge L9: End Cap M1: First midplane M2: Second midplane Ma: Midplane Mb: Midplane P1: Plane P2: Plane P3: Plane P4: Plane R: Column direction S: Second direction T1: Thickness T2: Thickness t1: Thickness t2: thickness t3: thickness t4: Thickness t5: Thickness t6: Thickness t7: Thickness W1: Width W2: Width X1: Distance X2: Distance Y: Total thickness

Claims

1. A power terminal for a connector, the power terminal comprising: A first conductive sheet includes: a first joint; at least two first fingers extending from the first joint, the at least two first fingers having hook-shaped ends connected to the first joint via a first beam, the hook-shaped ends including a first contact surface configured to contact a first side of a card; and a first mounting portion extending from the first joint and configured to be mounted to a substrate; and a second conductive sheet includes: a second joint; at least two second fingers extending from the second joint, the at least two second fingers having bent ends connected to the second joint via a second beam, the bent ends including a second contact surface configured to contact the first side of the card; and a second mounting portion extending from the second joint and configured to mount the substrate, wherein at least one of the first and second mounting portions is composed of at least two mounting tails.

2. The power terminal as claimed in claim 1, wherein the first and second mounting portions are formed by mounting ends configured to be inserted into mounting holes of the substrate.

3. The power terminal as claimed in claim 1, wherein the first and second mounting portions are formed by surface-mount tail portions.

4. The power terminals of claim 1, wherein the length of one of the first fingers is greater than the length of one of the second fingers.

5. The power terminal as claimed in claim 4, wherein the first joint is stacked on the second joint.

6. The power terminals as claimed in claim 5, wherein the first beams are coplanar with the first joint.

7. The power terminals as claimed in claim 5, wherein the second beams extend from the second joint at a non-zero angle.

8. The power terminal as claimed in claim 1, wherein the first and second joints are engaged.

9. The power terminal of claim 1, wherein a distance (d2) between one of the first contact surfaces and the closest of the second contact surfaces is in the range of 1.5 mm to 3.5 mm.

10. The power terminals of claim 1, wherein the distance (d2) between one of the first contact surfaces and the closest of the second contact surfaces is less than or equal to 3.5 mm.

11. The power terminal of claim 1, wherein the thickness of one of the second fingers is between 0.15 mm and 0.25 mm less than the thickness of one of the first fingers.

12. The power supply terminals as requested in item 1, wherein: The first fingers are arranged in a first column in a column direction, and the second fingers are arranged in a second column in a second direction parallel to the column direction, and the width of at least one of the second fingers in the direction parallel to the column direction is less than the width of at least one of the first fingers in the direction parallel to the column direction.

13. The power terminal of claim 1, combined with an insulating housing in which the first finger and the second finger are disposed, wherein the insulating housing comprises: At least one opening that exposes the first contact surfaces and the second contact surfaces, and a groove configured to receive the card therein.

14. The power terminal of claim 13, wherein the slot has a closed end configured to limit one insertion distance of the card into the slot.

15. The power terminals of claim 14, wherein the distance between the first contact surfaces and the closed end of the slot is in the range of 7.5 mm to 9.5 mm.

16. The terminal of claim 14, wherein a distance (d3) between the second contact surfaces and the closed end of the groove is in the range of 4.5 mm to 6.5 mm.

17. The power terminal of claim 13 is further combined with a second terminal disposed in the insulating housing opposite to one of the power terminals.

18. The power supply terminal as claimed in claim 17, wherein the second terminal includes: A third conductive sheet includes: a third joint; at least two third fingers extending from the third joint, the at least two third fingers having hook-shaped ends connected to the third joint via a third beam, the hook-shaped ends including a third contact surface configured to contact a second side of the card; and a third mounting portion extending from the third joint and configured to be mounted to the substrate; and a fourth conductive sheet includes: a fourth joint; at least two fourth fingers extending from the fourth joint, the at least two fourth fingers having bent ends connected to the fourth joint via a fourth beam, the bent ends including a fourth contact surface configured to contact the second side of the card; and a fourth mounting portion extending from the fourth joint and configured to mount the substrate.

19. The power terminal of claim 17, wherein the power terminal is one of a first plurality of terminals disposed on a first side of the slot of the insulating housing, and the second terminal is one of a second plurality of terminals disposed on a second side of the slot of the insulating housing opposite the first side.

20. The power terminal as claimed in claim 13, wherein the slot includes a signal section and the insulating housing has a plurality of signal terminals therein. These signal terminals are exposed in the signal section of the slot.

21. The power terminals of claim 1, wherein the first and second fingers are configured to carry a current of 30 amperes, and a temperature increase is less than or equal to an ambient temperature of 30°C.

22. The power terminals of claim 1, wherein the first and second fingers are configured to carry a current of 35 amperes, and a temperature increase is less than or equal to 30°C above an ambient temperature.

23. The power terminals of claim 1, wherein the first and second fingers are configured to carry a current of 40 amperes, and a maximum temperature increase is less than or equal to 30°C above an ambient temperature.

24. The power terminals of claim 1, wherein the first and second fingers are configured to carry a current of 45 amps, and a maximum temperature increase is less than or equal to 30°C above an ambient temperature.

25. A power terminal for a connector, the power terminal comprising: A first conductive sheet includes: a first bonding portion; at least two first fingers extending from the first bonding portion and having first contact surfaces disposed in a first column; and a first mounting portion extending from the first bonding portion and configured to be mounted to a substrate; and a second conductive sheet includes: a second bonding portion; at least two second fingers extending from the second bonding portion and having second contact surfaces disposed in a second column; and a second mounting portion extending from the second bonding portion and configured to be mounted to the substrate, wherein the first mounting portion is formed by first and second mounting tails disposed on opposite sides of the second mounting portion, such that the second mounting portion is located between the first and second mounting tails of the first mounting portion, and such that the mounting ends of the first mounting portion and the second mounting portion are aligned in a third column.

26. The power terminals of claim 25, wherein the length of one of the first fingers is different from the length of one of the second fingers.

27. The power terminal of claim 25, wherein the first and second mounting portions are composed of surface-mount tail portions.

28. The power terminal of claim 26, wherein the first joint is stacked on the second joint.

29. The power terminal of claim 25, wherein the first and second joints are engaged.

30. The power terminals of claim 28, wherein the contact surfaces of the first fingers and the contact surfaces of the second fingers are configured to contact the same side of a card.

31. The power supply terminal of claim 25, wherein the length of one of the first fingers is greater than the length of one of the second fingers.

32. The power terminals of claim 25, wherein a distance (d2) between one of the first contact surfaces and the closest of the second contact surfaces is in the range of 1.5 mm to 3.5 mm.

33. The power terminals of claim 25, wherein the distance (d2) between one of the first contact surfaces and the closest of the second contact surfaces is less than or equal to 3.5 mm.

34. The power terminals of claim 25, wherein the thickness of one of the second fingers is between 0.15 mm and 0.25 mm less than the thickness of one of the first fingers.

35. The power supply terminals as requested in item 25, wherein: The first fingers are arranged in a first column in a column direction, and the second fingers are arranged in a second column in a second direction parallel to the column direction, and the width of at least one of the second fingers in the direction parallel to the column direction is less than the width of at least one of the first fingers in the direction parallel to the column direction.

36. The power terminal of claim 25, combined with an insulating housing in which the first finger and the second finger are disposed, wherein the insulating housing comprises: At least one opening that exposes the first contact surfaces and the second contact surfaces, and a groove configured to receive a card therein.

37. The power terminal of claim 36, wherein the slot has a closed end configured to limit the insertion distance of the card into the slot.

38. The power terminals of claim 37, wherein the distance between the first contact surfaces and the closed end of the slot is in the range of 7.5 mm to 9.5 mm.

39. The terminal of claim 37, wherein a distance (d3) between the second contact surfaces and the closed end of the groove is in the range of 4.5 mm to 6.5 mm.

40. The power terminal of claim 36 is further combined with a second terminal disposed in the insulating housing opposite to one of the power terminals.

41. The power supply terminal as claimed in claim 40, wherein the second terminal includes: A third conductive sheet includes: a third bonding portion; at least two third fingers extending from the third bonding portion and having third contact surfaces disposed in a third column; and a third mounting portion extending from the third bonding portion and configured to be mounted to a substrate; and a fourth conductive sheet includes: a fourth bonding portion; at least two fourth fingers extending from the fourth bonding portion and having fourth contact surfaces disposed in a fourth column; and a fourth mounting portion extending from the fourth bonding portion and configured to be mounted to the substrate.

42. The power terminal of claim 40, wherein the power terminal is one of a first plurality of terminals disposed on a first side of the slot of the insulating housing, and the second terminal is one of a second plurality of terminals disposed on a second side of the slot of the insulating housing opposite the first side.

43. The power terminal as claimed in claim 36, wherein the slot includes a signal section and the insulating housing has a plurality of signal terminals therein. These signal terminals are exposed in the signal section of the slot.

44. The power terminals of claim 25, wherein the first and second fingers are configured to carry a current of 30 amps, and a temperature increase is less than or equal to an ambient temperature of 30°C.

45. The power terminals of claim 25, wherein the first and second fingers are configured to carry a current of 35 amperes, and a temperature increase is less than or equal to an ambient temperature of 30°C.

46. ​​The power terminals of claim 25, wherein the first and second fingers are configured to carry a current of 40 amps, and a temperature increase is less than or equal to 30°C above an ambient temperature.

47. The power terminals of claim 25, wherein the first and second fingers are configured to carry a current of 45 amperes, and a temperature increase is less than or equal to 30°C above an ambient temperature.

48. A power connector comprising: A housing includes a groove having a first side and a second side facing the first side; a plurality of first power terminals disposed on the first side of the groove; and a plurality of second power terminals disposed on the second side of the groove; wherein each of the plurality of first power terminals and the plurality of second power terminals is composed of: a first conductive sheet including a first joint, at least two first fingers extending from the first joint and having first contact surfaces disposed in a first row, and a first mounting portion extending from the first joint and configured to be mounted to a substrate, the first mounting portion being composed of first and second mounting tails; and a second conductive sheet including: a second joint, at least two second fingers extending from the second joint and having second contact surfaces disposed in a second row, and a second mounting portion extending from the second joint and configured to mount the substrate, the second mounting portion being disposed between the first and second mounting tails of the first mounting portion.

49. The power connector as requested in item 48, wherein, For each of the plurality of first power terminals and the plurality of second power terminals, the length of one of the first fingers is different from the length of one of the second fingers.

50. The power connector as requested in item 48, wherein, For each of the plurality of first power terminals and the plurality of second power terminals, the first joint is stacked on the second joint.

51. The power connector of claim 48, wherein the first and second mating portions are joined together.

52. The power connector of claim 48, wherein the contact surfaces of the plurality of first power terminals face the contact surfaces of the plurality of second power terminals corresponding to the second power terminals.

53. The power connector of claim 48, wherein the slot includes a power section and a signal section, the plurality of first power terminals and the plurality of second power terminals are disposed in the power section, and further includes a plurality of signal terminals disposed in the signal section.

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