Crimping connector

Abstract

An assembly includes a printed circuit board with electroplated holes, the printed circuit board connected by contact pins to a structure having holes formed therein. The contact pin has a longitudinal axis and includes a blade segment extending along the longitudinal axis. The contact pin is provided with a first fastening section and a second fastening section which are connected together through a connecting section. The first fastening section is crimped in a hole of the structure, and the second fastening section is crimped in a plated hole of the printed circuit board. The first fastening structure and the second fastening structure may have the same or different widths.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application No. 63 / 352,778, filed on June 16, 2022, which is incorporated herein by reference. Technical Field

[0003] The present disclosure relates to an electrical contact and, more particularly, to a contact pin suitable for connecting a plurality of substrates together. Background Art

[0004] In electronic systems using one or more PCBs, the PCBs are often electrically connected to other electrical devices (such as other PCBs) via electrical connectors. In many cases, the electrical connectors use one or more contact pins that are fixed in conductive holes in the PCB. Such contact pins can be fixed in the holes of the PCB by welding or by fixing features of the contact pins. In the case where the contact pins are fixed in the holes of the PCB by their fixing features, the contact pins are often referred to as crimp-type contact pins.

[0005] Traditionally, crimp-type contact pins include a compliant fastening segment that undergoes plastic and elastic deformation when inserted into a hole in a PCB. This deformation creates a retention force that holds the fastening segment in the hole in the PCB. The fastening segment has been constructed in a number of different types, one of which is known as an "eye of the needle" (EON) type construction. In this type of construction, a slot or opening is formed in the fastening segment to define a pair of beams that can be elastically moved toward and away from each other to provide a normal force to the PCB hole, thereby providing a reliable electrical connection without the use of solder.

[0006] Conventional crimping contact pins are used to connect a PCB to an electronic device to be mounted on the PCB. Conventional crimping contact pins are not configured to connect two or more structures / devices together. In addition, conventional crimping contact pins are not configured to connect misaligned structures / devices together. Therefore, it is desirable to provide a crimping contact pin that can connect two or more misaligned structures / devices together. Summary of the invention

[0007] According to the disclosure, a component is provided, which has a conductive contact pin (pin) and a printed circuit board, which is arranged adjacent to a structure with a hole. The contact pin includes a blade (knife edge) section and a first fastening section connected to a second fastening section by a connecting section. The first fastening section has a first opening extending through (extending through) in a direction perpendicular to the longitudinal axis to help form a pair of first beams. The first fastening section is crimped (press-fitted) in the hole of the structure so as to be completely disposed therein. The second fastening section is connected to the blade section and has a second opening extending through (extending through) in a direction perpendicular to the longitudinal axis to help form a pair of second beams. The second fastening section is crimped in a plated hole of the printed circuit board. No part of the second fastening structure is disposed in the hole of the structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The features, aspects and advantages of the present invention will become better understood through the following description, appended claims and accompanying drawings:

[0009] Figure 1 shows a perspective view of a contact pin of a first embodiment;

[0010] Figure 2 Shows Figure 1 A side view of a contact pin;

[0011] Figure 3 Shows Figure 1 A front view of a contact pin;

[0012] Figure 4 shows a front view of a contact pin of a second embodiment;

[0013] Figure 5 shows a perspective cutaway view of an assembly having contact pins connecting a printed circuit board and a heat sink together;

[0014] Figure 6 shows a front cross-sectional view of an assembly having contact pins in the process of being connected to a printed circuit board and an adjacent heat sink;

[0015] Figure 7 Shows Figure 6 A front cross-sectional view of an assembly of wherein the contact pins are fully connected to the printed circuit board and the heat sink; and

[0016] Figure 8 A side cross-sectional view of an assembly is shown having contact pins in the process of being mounted to a printed circuit board and an adjacent heat sink. DETAILED DESCRIPTION

[0017] It should be noted that in the following detailed description, the same components have the same reference numerals, regardless of whether they are shown in different embodiments of the present disclosure. It should also be noted that for the sake of clarity and simplicity, the drawings are not necessarily drawn to scale, and some features of the present disclosure may be shown in schematic form.

[0018] The present disclosure relates to a method and apparatus for securing together a pair of structures having holes formed therein. The structures may be a pair of printed circuit boards (PCBs), a PCB and another structure, or a pair of other types of structures. The method and apparatus are applicable to structures having holes that are aligned or substantially aligned with each other. In fact, the method and apparatus are particularly applicable to structures in which the holes in the structures are not perfectly aligned.

[0019] Reference now Figure 1-3 , an embodiment of a contact pin 10 constructed according to the present disclosure is shown in the figure. The contact pin (pin) 10 is an integral structure, made of a conductive metal (such as a tinned copper alloy), is elongated, and has a longitudinal axis L. The contact pin 10 includes a blade segment 14 integrally bonded to a fastening segment 16. The blade segment 14 can have different configurations (constructions). For example, the blade segment 14 can have a shoulder 18 and further include a pin suitable for inserting into a female connector (not shown) to make an electrical connection with the female connector. The free end of the pin can be tapered for easy insertion. Depending on the application, in addition to the shoulder 18, the blade segment 14 can also have one or more additional fixing structures, such as a large star-shaped structure and a smaller elongated star-shaped structure (not shown) arranged on the circumference of the fixing area near the shoulder 18. The diameter of the fixing area can be larger than the diameter of the pin. The shoulder 18 and any additional fixing structures can be used to fix the contact pin 10 to a connector housing or other types of components or parts. The shoulder 18 may also serve as a stop against which a force may be applied in order to insert the fastening segment 16 into a hole in a plurality of base plates (substrates).

[0020] The fastening section 16 includes a top 22 and a neck 24. The top 22 has a flat face and is solid, that is, the axial hole does not extend through the face. The plane in which the face is located is perpendicular to the longitudinal axis L. The top 22 can be chamfered around the entire periphery of the face, or only between the face and the main surface, or only between the face and the side surface. The neck 24 is coupled to the blade segment 14, for example, the neck 24 is coupled to the blade segment 14 at the shoulder 18. There are two or more deformable parts between the top 22 and the neck 24, such as a first deformable part 28 and a second deformable part 30. The first deformable part 28 and the second deformable part 30 are connected together by a connecting (coupling) section 32 and are arranged in sequence along the direction of the longitudinal axis L. As described in more detail below, the first deformable part 28 and the second deformable part 30 can have the same or different configurations and sizes. Therefore, the first deformable part 28 and the second deformable part 30 can have the same or different deformation profiles in the direction of the longitudinal axis L.

[0021] The first deformable portion 28 has opposite main surfaces 34 extending between the top end 22 and the connecting section 32, respectively, along the direction of the longitudinal axis L. Opposite side surfaces 36 also extend between the connecting section 32 and the top end 22, respectively, along the direction of the longitudinal axis L, and are joined between the main surfaces 34. Each side surface 36 is arcuate in the longitudinal direction and the normal direction. The side surface 36 can be completely arcuate (circular) in both the longitudinal direction and the normal direction, or can have straight portions. The main surface 34 can be substantially flat, and the plane in which it lies is parallel to the longitudinal axis L. However, one or both of the main surfaces 34 can be partially flat and partially conical, and the conical portion can be flat or curved. The main surfaces 34 are joined to the side surfaces 36 at rounded edges, respectively.

[0022] like Figure 3 As best shown, the first deformable portion 28 has a maximum width W1 at its center and has a length L1. In certain embodiments, W1 can be in the range of about 1 mm to about 4 mm, more typically in the range of about 1 mm to about 2 mm, and more typically about 1.5 mm. The length L1 can be in the range of about 2 mm to about 8 mm, more typically in the range of about 3 mm to about 6 mm.

[0023] The openings or eyelets 40 extend through the major surface 34 along the normal direction, respectively. The eyelets 40 have an elongated elliptical shape and are defined by an elliptical inner wall extending linearly (straightly) along the normal direction. The eyelets 40 help define a pair of beams 44. The eyelets 40 are substantially symmetrical about the longitudinal axis L and an axis perpendicular to the longitudinal axis extending through the beams 44 at the center of the eyelet 40. The eyelet 40 has a maximum width EW1 at its center and a length EL1 between its longitudinally spaced ends. In certain embodiments, EW1 may be in the range of about 0.2 mm to about 2 mm, more typically in the range of about 0.3 mm to about 1.0 mm. The length EL1 may be in the range of about 2 mm to about 6 mm. The ratio of EL1 / EW1 may be in the range of about 3 to about 6.

[0024] The beams 44 are joined at the top end 22 and the connecting section 32 and separated by the eyelet 40. The beams 44 are resiliently movable toward and away from each other. This resiliency allows the beams 44 to move toward each other when the first deformable portion 28 is inserted into the hole of the substrate, and when the beams 44 are placed in the hole, this resiliency allows the beams 44 to exert an outward force on the inner wall of the hole, thereby fixing the first deformable portion 28 in the hole. The rounded shape of the top end 22, the arcuate profile of the side surface 36, and the rounded edge joining the side surface 36 to the main surface 34 all facilitate the insertion of the first deformable portion 28 into the hole and help prevent damage to the substrate around the hole.

[0025] The connecting section 32 may have an angled structure with an outer cuboid portion connected to a larger inner cuboid portion by oppositely inclined surfaces. The length LL of the connecting section 32 is selected to provide a desired distance between the eyelet 40 and the eyelet 60 of the second deformable portion 30 .

[0026] The second deformable portion 30 has opposite main surfaces 54 extending between the connecting section 32 and the neck 24, respectively, along the direction of the longitudinal axis L. The opposite side surfaces 56 also extend between the connecting section 32 and the neck 24, respectively, along the direction of the longitudinal axis L, and are joined between the main surfaces 54. Each side surface 56 is at least partially arcuate in the longitudinal direction and the normal direction. The side surface 56 can be completely arcuate (rounded) in both the longitudinal direction and the normal direction, or can have straight portions. The main surface 54 can be substantially flat, and the plane in which it lies is parallel to the longitudinal axis L. However, one or both of the main surfaces 54 can be partially flat and partially conical, and the conical portion can be flat or curved. The main surface 54 can be arranged outward from the main surface 34 of the first deformable portion 28, that is, as shown in the figure, the second deformable portion 30 can be thicker than the first deformable portion 28. However, in some embodiments, the thickness of the second deformable portion 30 can be the same as the thickness of the first deformable portion 28. The main surface 54 and the side surface 56 are joined at rounded edges, respectively.

[0027] The second deformable portion 30 has a maximum width W2 at its center and has a length L2. The length L2 may be substantially the same as the length L1, i.e., in the range of about 2 mm to about 8 mm, more typically in the range of about 3 mm to about 6 mm. W2 may be the same as W1 (e.g., Figure 4 ), or can be greater than W1 (as shown Figure 1-3 and Figure 6-7 In some embodiments, W2 may be in the range of about 1 mm to about 4 mm, more typically in the range of about 1 mm to about 2 mm, and more typically about 1.5 mm. The ratio of W2 / W1 may be in the range of about 1.0 to about 1.5.

[0028] An opening or eyelet 60 extends through each of the major surfaces 54 in the normal direction. The eyelets 60 may have an elliptical or irregular elliptical shape. The eyelets 60 help define a pair of beams 64. In embodiments where the eyelets 60 are elliptical, the eyelets 60 are substantially symmetrical in the direction of the longitudinal axis L and in the direction of an axis extending through the beams 64 at the center of the eyelet 60 and perpendicular to the longitudinal axis. In embodiments where the eyelets 60 are irregular elliptical, the eyelets 60 are symmetrical in the longitudinal direction but asymmetrical in the normal direction between the beams 64.

[0029] The beams 64 are joined at the connecting section 32 and the neck 24 and are separated by the eyelet 60. The beams 64 are resiliently movable toward and away from each other. This resiliency allows the beams 64 to move toward each other when the second deformable portion 30 is inserted into the hole of the substrate, and when the beams 64 are placed in the hole, this resiliency allows the beams 64 to exert an outward force on the inner wall of the hole, thereby fixing the second deformable portion 30 in the hole. The arcuate profile of the side surface 56 and the rounded edge joining the side surface 56 to the main surface 54 both facilitate the insertion of the second deformable portion 30 into the hole and help prevent damage to the substrate around the hole.

[0030] like Figure 1-3 As shown, the second deformable portion 30 may be wider than the first deformable portion 28 and the apertures 40 , 60 may have different configurations. Figure 4 The first deformable portion 28 and the second deformable portion 30 are shown to have the same size and aperture configuration. Figure 6-7 The second deformable portion 30 is shown to be wider than the first deformable portion 28, and the apertures 40, 60 have the same oval configuration, but are different sizes.

[0031] Reference now Figure 5-7, one or more contact pins 10 can be used to electrically, thermally and physically connect the PCB 70 and the heat sink 72 together. The PCB 70 has one or more through holes 74, which have an internal metal plating 76. Each through hole 74 has a length HL and a width HW, and the width HW can be less than, equal to or greater than the width W1 of the first deformable portion 28 of the contact pin 10. However, the width HW is less than the width W2 of the second deformable portion 30. The heat sink 72 may include a body 78 and one or more cylindrical supports 80. The support 80 helps to form a space between the PCB 70 and the body 78. The support 80 and the body 78 can be independent components fixed together, or can be integrally combined to be different parts of an integral structure. The body 78 and the support 80 can each be made of steel, brass, copper, aluminum or ceramic aluminum (such as aluminum nitride). If the support 80 is an independent component, the support 80 can have the same or different components. The heat sink 72 has a plurality of holes 82, each hole 82 extending through the support 80. The holes 82 may be straight or stepped, and may be threaded or smooth.

[0032] Figure 6-7 An embodiment is shown in which the hole 82 is stepped so as to have a first hole portion 82a and a second hole portion 82b. The first hole portion 82a has a diameter or width WB1, and the second hole portion 82b has a diameter or width WB2. The width WB2 is greater than the width WB1. The width WB1 is slightly less than the width W1 of the first deformable portion 28. The first hole portion 82a and the second hole portion 82b intersect (connect) at an inclined annular shoulder 86. The first hole portion 82a extends through the interior of the support 80 into the body 78. The support 80 has a length SL, and the body 78 has a thickness X.

[0033] The dimensions of the various components of the heat sink 72 and PCB 70 help determine the size and configuration of the contact pin 10. For example, the length HL of the through hole 74 will help determine the length L2 of the second deformable portion 30. Similarly, the length SL of the standoff 80 and the thickness X of the body 78 help determine the length L1 of the first deformable portion 28. The length LL of the connecting segment 32 (which separates the first deformable portion 28 from the second deformable portion 30) is determined by a number of factors, including the dimensions HL, SL, X, L1, and L2.

[0034] In the embodiment where the hole 82 is stepped, the position of the shoulder 86 can be determined by the timing of the second deformable portion 30 entering the through hole 74 and the first deformable portion 28 entering the first hole portion 82a. Figure 6 As shown, the second deformable portion 30 may engage the plating 76 of the through hole 74 just before the first deformable portion 28 engages the inner wall defining the first hole portion 82a.

[0035] Figure 8 An embodiment is shown in which the inner wall of each hole 82 has a protrusion 75 extending therefrom. The protrusion 75 can be a circle of one or more (one or more) helical threads, spaced annular ridges, or other types of protrusions. The threads can be single-start threads or multiple-start threads. When the contact pin 10 moves into the hole 82 of the heat sink 72, the protrusion 75 engages with the beam 44 of the first deformable portion 28, thereby helping to retain the first deformable portion 28 in the hole 82, respectively.

[0036] exist Figure 8 , the protrusion 75 in each hole 82 is shown as extending over most of the length of the hole 82. In other embodiments, the protrusion 75 may extend along a smaller portion of the hole 82. For example, the hole 82 may be stepped, and the protrusion may be located only in the first hole portion 82a.

[0037] The PCB 70 and the heat sink 72 are connected together by first (substantially) aligning the through hole 74 of the PCB 70 with the hole 82 of the heat sink 72. The PCB 70 and the heat sink 72 are securely held in place when the contact pin 10 is pressed into place so that the first deformable portion 28 of the contact pin 10 moves through the through hole 74 of the PCB 70 into the hole 82 of the heat sink 72. If the width W1 of the first deformable portion 28 is greater than the width HW of the through hole 74 in the PCB 70, the first deformable portion 28 will deform and move through the through hole 74 into the hole 82. If the width W1 of the first deformable portion 28 is less than the width HW of the through hole 74, the first deformable portion 28 will not deform and will smoothly move through the through hole 74 into the hole 82.

[0038] If the beams 44 have not been pressed together after passing through the through holes 74 in the PCB 70, the beams 44 will be pressed together when the first deformable portions 28 are moved into the holes 82, respectively. Within the holes 82, the beams 44 apply a lateral outward force to the inner wall, which secures the first deformable portion 28 within the holes 82 through friction. Similarly, when the second deformable portion 30 moves into the through holes 74 of the PCB 70, the plating 76 that defines the through holes 74 causes the beams 64 to move laterally inward toward each other. Within the through holes 74, the beams 64 apply a lateral outward force to the plating 76 to secure the second deformable portion 30 within the through holes 74 through friction. In this way, the first deformable portion 28 is secured within the heat sink 72 and the second deformable portion 30 is secured within the PCB 70, thereby securing the heat sink 72 and the PCB 70 together so that they are adjacent to each other. As shown in FIG. Figure 5 and Figure 7As shown, most or all of each second deformable portion 30 is arranged in a corresponding through hole 74 in the PCB 70, and each first deformable portion 28 is arranged in a corresponding hole 82 in the heat sink 72. The blade segment 14 can be fixed to another device or structure, thereby realizing the interconnection of three structures / devices. The connection between the blade segment 14 and another device can be an electrical (and mechanical) connection, for example, for transmitting electrical signals. In contrast, the connection between the PCB 70 and the heat sink 72 through the contact pin 10 is a thermal connection (and mechanical connection). Therefore, the contact pin 10 can be mechanically connected, electrically connected, and thermally connected.

[0039] When the PCB 70 and the heat sink 72 are connected together, when the contact pin 10 is inserted into the through hole 74 and the hole 82, the center line of the through hole 74 in the PCB 70 may be slightly offset relative to the center line of the hole 82 in the heat sink 72. The construction of the contact pin 10 allows the contact pin 10 to bend slightly to accommodate this offset and still be securely connected to the PCB 70 and the heat sink 72.

[0040] It should be understood that the description of the foregoing exemplary embodiments is for illustration only and not exhaustive. A person of ordinary skill may make certain additions, deletions and / or modifications to the embodiments of the disclosed subject matter without departing from the spirit or scope of the present disclosure.

Claims

1. A component comprising: a printed circuit board having a hole; a structure having a hole, the structure being disposed adjacent to the printed circuit board; An electrically conductive contact pin having a longitudinal axis and comprising: a blade segment extending along the longitudinal axis; a first fastening segment having a first opening extending therethrough in a direction perpendicular to the longitudinal axis to help form a pair of first beams, the first fastening segment being crimped into the hole of the structure so as to be fully disposed therein; a second fastening segment connected to the blade segment and having a second opening extending therethrough in a direction perpendicular to the longitudinal axis to help form a pair of second beams, the second fastening segment being crimped into the plated hole of the printed circuit board; and a connecting section connecting the first fastening section to the second fastening section; and Wherein, no part of the second fastening structure is arranged in the hole of the structure.

2. The assembly according to claim 1, wherein An inner wall of the structure forms the aperture, and wherein the inner wall has a protrusion extending therefrom.

3. The assembly according to claim 2, wherein: The first fastening section engages a protrusion in the hole.

4. The assembly according to claim 3, wherein: The protrusion in the hole is a coil of one or more helical threads.

5. The assembly according to claim 1, wherein: The structure and the printed circuit board are in physical contact with each other.

6. The assembly according to claim 1, wherein: The second fastening section is crimped into the plated hole of the printed circuit board so as to be completely disposed in the plated hole.

7. The assembly according to claim 1, wherein: The hole of the structure is stepped so as to have a first hole portion and a second hole portion, wherein the diameter of the first hole portion is smaller than the diameter of the second hole portion.

8. The assembly according to claim 7, wherein: A majority of the first fastening section of the contact pin is disposed in the first hole portion.

9. The assembly according to claim 8, wherein: The structure has an inner wall that helps define the aperture, and wherein the inner wall has a protrusion extending therefrom, the protrusion being located in the first aperture portion; wherein the first fastening section engages with a protrusion in the hole; and Wherein, the protrusion is one or more spiral threads in a loop.

10. The assembly of claim 1, wherein: The second fastening section is thicker than the first fastening section in a direction perpendicular to the longitudinal axis.

11. The assembly according to claim 1, wherein: The structure is a heat sink.

12. The assembly according to claim 11, wherein The heat sink comprises aluminum.

13. The assembly of claim 1, wherein: The printed circuit board has a plurality of holes; wherein the structure has a plurality of inner walls, each of the inner walls forming an aperture, each of the inner walls having a protrusion extending therefrom; and Wherein the assembly comprises a plurality of electrically conductive contact pins, each contact pin having a longitudinal axis, and comprising: a blade segment extending along the longitudinal axis; a first fastening segment having a first opening extending therethrough in a direction perpendicular to the longitudinal axis to help form a pair of first beams; a second fastening segment connected to the blade segment and having a second opening extending therethrough in a direction perpendicular to the longitudinal axis to help form a pair of second beams; and a connecting section, the connecting section connecting the first fastening section to the second fastening section; wherein the first fastening sections are respectively crimped into the holes of the structure so as to be completely disposed in the holes and engage with the protrusions in the holes; wherein the second fastening sections are respectively crimped into the plated holes of the printed circuit board; and Wherein, no part of the second fastening structure is arranged in the hole of the structure.

14. The assembly of claim 13, wherein: The structure is a heat sink and includes a body with a plurality of standoffs extending therefrom and wherein each of the apertures extends through one of the standoffs.

15. The assembly of claim 14, wherein: The standoff spaces the body of the heat sink apart from the printed circuit board.

16. A method of forming an assembly, comprising: (a.) providing a printed circuit board having a hole; (b.) providing a structure having a hole; (c.) providing an electrically conductive contact pin having a longitudinal axis and comprising: a blade segment extending along the longitudinal axis; a first fastening segment having a first opening extending therethrough in a direction perpendicular to the longitudinal axis to help form a pair of first beams; a second fastening segment connected to the blade segment and having a second opening extending therethrough in a direction perpendicular to the longitudinal axis to help form a pair of second beams; and a connecting section, the connecting section connecting the first fastening section to the second fastening section; (d.) positioning the structure and the printed circuit board so as to be disposed adjacent to each other and so that the holes of the printed circuit board are at least partially aligned with the holes of the structure; (e.) inserting the contact pin into the hole of the printed circuit board and the hole of the structure until the first fastening section is crimped into the hole of the structure so as to be fully disposed in the hole, and the second fastening section is crimped into the plated hole of the printed circuit board without any portion of the second fastening structure being disposed in the hole of the structure, thereby completing the insertion.

17. The method according to claim 16, wherein: The hole is lined with a metal coating; wherein the hole of the structure is stepped so as to have a first hole portion and a second hole portion, wherein the first hole portion is defined by an inner wall and the diameter of the first hole portion is smaller than the diameter of the second hole portion; and Wherein, when the contact pin is inserted into the hole of the printed circuit board and the hole of the structure, the second fastening structure engages with the plating of the hole before the first fastening section engages with the inner wall defining the first hole portion.

18. The method according to claim 17, wherein: When the insertion of the contact pin is completed, a majority of the first fastening section of the contact pin is disposed in the first hole portion.

19. The method according to claim 16, wherein: The structure has an inner wall that helps define the aperture, and wherein the inner wall has one or more helical threads formed therein; and Therein, during insertion of the contact pin, the first fastening section engages with one or more helical threads in the hole.

20. The method according to claim 19, wherein: Positioning of the structure and the printed circuit board is performed so that the structure and the printed circuit board are in physical contact with each other.

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