Electrical contact with textured contact interface

Abstract

An electrical contact having at least one textured contact interface. The at least one textured contact interface includes a rounded portion having a plurality of raised contact regions. A void is positioned between the plurality of raised contact regions. The rounded portion of the at least one textured contact interface provides more than one contact point when the rounded portion of the at least one textured contact interface is positioned in electrical engagement with a mating electrical contact.

Description

Technical Field

[0001] The present invention relates to an electrical contact with a textured contact interface to improve the reliability of the connector under harsh environmental conditions. In particular, the textured contact interface provides more than one possible contact point within a wider range of tolerances and alignments. Background Art

[0002] An electrical connector is plugged into a mating connector to create an electrical connection. Electrical connectors are typically used for signal transmission or for power transmission and can be defined as an electromechanical system that provides a separable interface between two electronic subsystems. To this end, electrical connectors typically have conductive contacts or terminals that, when plugged together, engage the conductive contacts or terminals of the mating connector to form an electrical and mechanical connection between them. In many applications, when the connector and mating connector are plugged together, one or both of the conductive contacts of the connector and the conductive contacts of the mating connector exert a force on the other to ensure a reliable conductive connection.

[0003] In many applications, connectors and contacts are exposed to harsh environmental conditions such as moisture, temperature changes, vibrations, and corrosive media. Exposure to such an environment can lead to the formation of an insulating oxide layer in the contact area and, consequently, to connector failure. Summary of the Invention

[0004] Therefore, it would be beneficial to provide a contact having a textured contact surface that improves the reliability of the electrical connection between the contact and a mating contact, improving contact reliability overall and also improving contact reliability under harsh environmental conditions. In particular, it would be beneficial to provide a textured contact surface that provides two or more contact points to improve contact reliability under high vibration conditions and that can vary with changes in contact tolerance / alignment.

[0005] The solution is provided by a connector system that includes a textured contact interface to improve connector reliability under harsh environmental conditions. The textured beam can provide two or more contact points over a wide range of connector tolerance stackups. The textured contact surface can provide a reservoir of contact lubricant that can be drawn into the mating contact points over time / mating cycles. The two contact points improve the reliability of the connector under high vibration conditions. This approach to obtaining two contact points works over a wider range of connector tolerance stackups than previous designs. In addition, the lubricant reservoir can provide better reliability over more mating cycles. The texture can be achieved through various manufacturing methods and can have different geometries. For example, the texture pattern can be stamped into the contact surface using a progressive die tooling process. In one embodiment, the texture can be applied by a laser or other method. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0007] Figure 1 is a perspective view of a first illustrative embodiment of an electrical contact according to the present invention having a single beam construction with a textured contact interface in the contact area.

[0008] Figure 2 is a perspective view of a second illustrative embodiment of an electrical contact according to the present invention having a bifurcated beam configuration with a textured contact interface in the contact area.

[0009] Figure 3 is a perspective view of a third illustrative embodiment of an electrical contact having a bifurcated creeping beam configuration with a textured contact interface in the contact area in accordance with the present invention.

[0010] Figure 4 is an illustration of a textured contact area of ​​a beam of a contact electrically engaged with a mating contact or mating area of ​​a wafer, the textured contact area of ​​the beam of the contact shown in a first orientation relative to the mating area of ​​the wafer.

[0011] Figure 5 is an illustration of a textured contact area of ​​a beam of a contact electrically engaged with a mating contact or mating area of ​​a wafer, the textured contact area of ​​the beam of the contact shown in a second orientation relative to the mating area of ​​the wafer.

[0012] Figure 6 is an illustration of a textured contact area of ​​a beam of a contact electrically engaged with a mating contact or mating area of ​​a wafer, the textured contact area of ​​the beam of the contact shown in a third orientation relative to the mating area of ​​the wafer.

[0013] Figure 7 is an enlarged view of the textured contact area of ​​the contact's beam, showing that the texturing is applied at an angle relative to the longitudinal axis of the contact, the texturing being applied on the surface of the contact area of ​​the contact's beam so that when contact is made to a flat mating area of ​​a wafer, at least two points of contact exist between the textured contact area of ​​the contact's beam and the mating area of ​​the wafer.

[0014] Figure 8 is an enlarged view of the textured contact area of ​​the contact beam showing the contact lubricant disposed in the spaces between the raised areas.

[0015] Figure 9 is a schematic diagram showing the textured contact area of ​​a beam of a contact mating with a mating area of ​​a wafer.

[0016] Figure 9A yes Figure 9 An enlarged portion of the area marked 9A in the figure shows the contact line between the textured contact area of ​​the beam of the mating contact and the mating area of ​​the wafer, where the contact line between the textured contact area of ​​the beam of the mating contact and the mating area of ​​the wafer is set on two raised areas of the textured contact area to provide two contact points, which vary according to the tolerance and alignment of the textured contact area of ​​the beam of the mating contact and the mating area of ​​the wafer.

[0017] Figure 9B yes Figure 9 An enlarged portion of the area marked 9B in the figure shows the contact line between the textured contact area of ​​the beam of the mating contact and the mating area of ​​the wafer, where the contact line between the textured contact area of ​​the beam of the mating contact and the mating area of ​​the wafer is set on two raised areas of the textured contact area to provide two contact points, which vary according to the tolerance and alignment of the textured contact area of ​​the beam of the mating contact and the mating area of ​​the wafer.

[0018] Figure 10 is a cross-section of a textured contact area showing a first alternative exemplary configuration of raised contact areas and voids.

[0019] Figure 11 is a portion of a textured contact area showing a second alternative exemplary configuration of raised contact areas and voids. DETAILED DESCRIPTION

[0020] The connector system includes a textured contact interface to improve connector reliability in harsh environmental conditions. The textured beam can provide two or more contact points over a wide range of connector tolerance stack-ups. The textured contact surface can provide a reservoir for contact lubricant that can be drawn into the mating contact points over time / mating cycles.

[0021] Two points of contact improve connector reliability under high-vibration conditions. This approach to achieving two points of contact operates within a wider connector tolerance stackup than previous designs. Additionally, a lubricant reservoir provides improved reliability over a greater number of mating cycles.

[0022] The texture can be achieved through various manufacturing methods and can have different geometries. For example, a texture pattern can be stamped into the contact surface using a progressive die process. In one embodiment, the texture can be applied by laser or other methods.

[0023] One embodiment relates to an electrical contact having at least one textured contact interface. The at least one textured contact interface has a plurality of raised contact areas with voids positioned between the plurality of raised contact areas. When the at least one textured contact interface is positioned in electrical engagement with a mating electrical contact, the at least one textured contact interface provides more than one point of contact.

[0024] One embodiment relates to an electrical contact having at least one textured contact interface. The at least one textured contact interface includes a rounded portion having a plurality of raised contact areas. A gap is positioned between the plurality of raised contact areas. When the rounded portion of the at least one textured contact interface is positioned to electrically engage a mating electrical contact, the rounded portion of the at least one textured contact interface provides more than one contact point.

[0025] One embodiment relates to an electrical contact having at least one textured contact interface. The at least one textured contact interface has a plurality of raised contact areas, wherein voids are positioned between the plurality of raised contact areas. A lubricant is disposed in the voids. When the raised contact areas of the at least one textured contact interface are positioned to electrically engage a mating electrical contact, the raised contact areas of the at least one textured contact interface provide more than one contact point.

[0026] The description of illustrative embodiments according to the principles of the present invention is intended to be read in conjunction with the accompanying drawings, which are to be considered a part of the entire written description. In the description of the embodiments of the present invention disclosed herein, any reference to direction or orientation is intended solely for ease of description and is not intended to limit the scope of the invention in any way. Relative terms such as "lower," "upper," "horizontal," "vertical," "above," "below," "upward," "downward," "top," and "bottom," and their derivatives (e.g., "horizontally," "downwardly," "upwardly," etc.) should be interpreted as referring to orientations as described subsequently or as shown in the accompanying drawings. These relative terms are for ease of description only and do not require that a device be constructed or operated in a particular orientation unless expressly so indicated. Unless expressly stated otherwise, terms such as "attach," "attach," "connect," "couple," and "interconnect" refer to relationships in which structures are fixed or attached to each other, directly or indirectly, through intermediate structures, as well as removable or rigid attachment relationships. Furthermore, the features and benefits of the present invention are illustrated by reference to preferred embodiments. Therefore, the present invention expressly should not be limited to such preferred embodiments illustrating some possible non-limiting combinations of features that may exist alone or in other combinations of features, the scope of the invention being defined by the appended claims.

[0027] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. Reference numerals are used throughout the detailed description to refer to various elements and structures. Although the following detailed description contains many details for illustrative purposes, it will be understood by those skilled in the art that many variations and modifications to the following details are within the scope of the present invention. Therefore, the following embodiments of the present invention are set forth without loss of generality and without imposing limitations on the claimed invention.

[0028] refer to Figure 1 , shows an illustrative embodiment of an electrical contact 10. The contact 10 has a circuit board mounting section 12, a housing-securing section 14, and a mating section 16. In the illustrated embodiment, the circuit board mating section 12 has an eye-of-the-needle configuration, although other configurations may be used. The circuit board mating section 12 is configured to mechanically and electrically connect to a circuit board (not shown). Alternative types of mounting sections 12 may be used.

[0029] In the illustrated embodiment, the securing segment 14 has a barb 18 and a lance 20. The barb 18 and lance 20 are configured to mate with a housing (not shown) of an electrical connector (not shown) to maintain the position of the contact 10 relative to the housing of the electrical connector. Alternative configurations of the securing segment 14 may be used.

[0030] In the illustrated embodiment, the mating segment 16 extends from the fixed segment 14 in a direction away from the mounting segment 12. The mating segment 16 has a single contact arm 30 extending from a free end 32 of the mating segment 16. Other configurations of the contact arm 30 may be used.

[0031] Each contact arm 30 has a radiused contact portion 34 disposed between a free end 32 of the mating segment 16 and the fixed segment 14. The mating segment 16 extends at an angle from the fixed segment 14, with the radiused contact portion 34 of each contact arm offset from the plane of the fixed segment 14.

[0032] Each rounded contact portion 34 has a textured contact interface 36. Figure 7 As shown, the textured contact interface 36 has a plurality of raised contact areas 38. The raised contact areas 38 are separated by voids or valleys 40.

[0033] The raised contact area 38 and the void 40 are applied to the face of the textured contact interface 36 of the radiused contact portion 34 at an angle 41. In various illustrative embodiments, the raised contact area 38 extends at an angle 41 between 0 and 90 degrees relative to a line perpendicular to the longitudinal axis of the contact arm 30 of the mating segment 16 of the electrical contact 10. In various other illustrative embodiments, the raised contact area 38 extends at an angle 41 between 20 and 70 degrees relative to the longitudinal axis of the contact arm 30 of the mating segment 16 of the electrical contact 10. The void 40 extends at the same angle 41 relative to the longitudinal axis of the electrical contact 10 as the raised contact area 38.

[0034] Figure 1-8 The configuration of the textured contact interface 36 shown in FIG is intended to be illustrative. The raised contact areas 38 and voids 40 of the textured contact interface 36 may take many configurations, such as, but not limited to, Figure 10 and 11 The configuration shown in . The raised contact areas 38 and voids 40 can be fabricated by laser or other known methods.

[0035] like Figure 7 As shown, lubricant 42 may be provided in the gap 40. Figures 4 to 6 During mating, the lubricant can migrate from the void 40 to the raised contact area 38. The lubricant can be any lubricant that provides lubricity to protect the surface to which it is applied and allows for multiple mating cycles. The lubricant can be, but is not limited to, a solid lubricant (e.g., graphite) or a liquid lubricant.

[0036] As the contact interface 36 of the contact 10 mates with the mating contact or mating substrate 44, the lubricant 42 is transferred, deposited, or applied to the raised contact area 38 by a wiping action or the like. Continued mating causes the mating contact or mating substrate 44 to move into engagement with the void 40 and the lubricant 42. As this occurs, the lubricant 42 from the void 40 is transferred, deposited, or applied to the raised contact area 38 by a wiping action or the like.

[0037] The textured contact interface 36 improves the reliability of the contact 10 in harsh environmental conditions because the angled raised contact areas 38 provide two or more contact points 46, 48 over a wide range of connector tolerance stack-ups. Figure 7 ). Two or more contact points improve contact reliability under high vibration conditions. The contact points 46, 48 can vary with tolerance / alignment, such as Figures 4 to 6 as well as Figure 9A and Figure 9B shown.

[0038] The textured contact surface can provide a reservoir of contact lubricant that can be drawn into the mating contact points over time / mating cycles. Furthermore, the lubricant reservoir can provide better reliability over more mating cycles.

[0039] The raised contact areas 38 and voids 40 of the textured contact interface 36 can be achieved by various manufacturing methods and can have different geometries. For example, the textured contact interface 36 can be stamped into the contact surface using a progressive die process, or the textured contact interface 36 can be applied by a laser or other method.

[0040] refer to Figure 2 , shows an alternative embodiment of the contact 10. The mating segment 16 has a bifurcated contact arm 30 extending from a free end 32 of the mating segment 16. In the illustrated embodiment, the bifurcated contact arm 30 has a similar configuration, however, the bifurcated contact arm 30 may have a different configuration.

[0041] Each contact arm 30 has a radiused contact portion 34. Each radiused contact portion 34 has a textured contact interface 36. Textured contact interface 36 has a plurality of raised contact areas 38. Raised contact areas 38 are separated by voids or valleys 40. Raised contact areas 38 and voids 40 are applied at angles 41 to the face of textured contact interface 36 of radiused contact portion 34.

[0042] Figure 2 Other features and operation of the illustrated contact 10 are similar to those described above.

[0043] refer to Figure 3, shows another alternative embodiment of the contact 10 . The mating segment 16 has a bifurcated creeping beam contact arm 30 extending from a free end 32 of the mating segment 16 .

[0044] Each contact arm 30 has two rounded contact portions 34. Each rounded contact portion 34 has a textured contact interface 36. The textured contact interface 36 has a plurality of raised contact areas 38. The raised contact areas 38 are separated by voids or valleys 40. The raised contact areas 38 and voids 40 are applied at an angle 41 on the face of the textured contact interface 36 of the rounded contact portion 34.

[0045] Figure 3 Other features and operation of the illustrated contact 10 are similar to those described above.

[0046] The textured contact surface can be applied to any type of contact tip design, including bifurcated tips, single tips, or other known designs. The textured contact surface provides more than one contact point within a wider tolerance and alignment range than known contacts.

Claims

1. An electrical contact, comprising: At least one textured contact interface, the at least one textured contact interface comprising: multiple raised contact areas; a void positioned between the plurality of raised contact areas; Wherein, the at least one textured contact interface provides more than one point of contact when the at least one textured contact interface is positioned in electrical engagement with a mating electrical contact. 2 . The electrical contact of claim 1 , wherein the at least one textured contact interface is positioned on at least one rounded corner portion of the electrical contact. 3 . The electrical contact of claim 1 , wherein the electrical contact has a single contact beam, the at least one textured contact interface being positioned on the single contact beam. 4 . The electrical contact of claim 1 , wherein the electrical contact has a plurality of contact beams, at least one of the at least one textured contact interface being positioned on each of the plurality of contact beams. 5 . The electrical contact of claim 4 , wherein each of the plurality of contact beams has one of the at least one textured contact interface located on a rounded portion of each of the plurality of contact beams. 6 . The electrical contact of claim 4 , wherein each of the plurality of contact beams has a plurality of textured contact interfaces among the at least one textured contact interface located on a rounded portion of each of the plurality of contact beams.

7. The electrical contact of claim 1, wherein the raised contact area extends at an angle between 0 degrees and 90 degrees relative to a longitudinal axis of the electrical contact.

8. The electrical contact of claim 7, wherein the void extends at the same angle as the raised contact area relative to a longitudinal axis of the electrical contact.

9. The electrical contact of claim 1, wherein the raised contact area extends at an angle of between 20 degrees and 70 degrees relative to a longitudinal axis of the electrical contact.

10. The electrical contact of claim 9, wherein the void extends at the same angle as the raised contact area relative to a longitudinal axis of the electrical contact.

11. The electrical contact of claim 1 , wherein a lubricant is disposed in the void, wherein the lubricant is capable of migrating from the void to the raised contact area when the at least one textured contact interface is positioned in electrical engagement with the mating electrical contact.

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