Electrical connector having terminals incorporating passive electronic components

Abstract

An electrical connector assembly (100) includes a flat flexible cable (FFC) (106) having a substrate that holds a conductor (104). The conductor has an end at an end (124) of the FFC. The electrical connector assembly includes an electrical connector (110) terminated to an end of the FFC. The electrical connector includes a housing (120) that holds a terminal (150). The terminals are terminated to the ends of the corresponding conductors. At least one of the terminals includes a passive electronic component (200) in line with the terminal.

Description

Technical Field

[0001] This article mainly deals with electrical connectors. Background Technology

[0002] Electrical connectors are used in a variety of systems and applications to electrically connect components or devices. An electrical connector includes a housing that holds contacts or terminals. The terminals are electrically connected to a circuit board or cable assembly. In some applications, it may be desirable to control transmission lines, such as providing active or passive functionality to the transmission lines. For example, passive electrical components can be added to a system to handle or control transmission lines. For instance, terminals may be electrically connected to a circuit board, and passive electrical components may be mounted to the circuit board to control a transmission. However, providing a circuit board and passive electrical components on the board increases the cost of the overall system. Additionally, the use of a circuit board increases the overall size of the electrical connector. Some systems do not include a circuit board, therefore passive electronic components cannot be incorporated into the connector in this way.

[0003] There is still a need for an electrical connector with terminals that integrate passive electronic components. Summary of the Invention

[0004] In one embodiment, an electrical connector assembly is provided, and the electrical connector assembly includes a cable assembly having conductors. The conductors have ends at the ends of the cable assembly. The electrical connector assembly includes an electrical connector terminated to the ends of the cable assembly. The electrical connector includes a housing that retains terminals. The housing extends between a mating end and a cable end. The cable assembly extends from the cable end. The housing includes a wall forming a terminal channel that receives a corresponding terminal. Each terminal includes a mating end and a termination end opposite to the mating end. The termination end is configured to terminate to a corresponding conductor of the cable assembly. The terminal includes a body between the mating end and the termination end. The body includes a first pad, a second pad, and a sacrificial portion between the first pad and the second pad. The sacrificial portion is configured to be removed to separate the first pad and the second pad. The terminal is configured to receive passive electronic components. Attached Figure Description

[0005] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0006] Figure 1 An electrical connector assembly according to an exemplary embodiment is shown.

[0007] Figure 2 This is a cross-sectional view of an electrical connector assembly according to an exemplary embodiment.

[0008] Figure 3 This is a perspective view of one of the terminals according to an exemplary embodiment.

[0009] Figure 4This is a top view of a portion of an electrical connector according to an exemplary embodiment, showing multiple terminals loaded into terminal channels in a housing.

[0010] Figure 5 This is an enlarged top view of a portion of an electrical connector according to an exemplary embodiment, showing one of the terminals loaded into a corresponding terminal channel in the housing.

[0011] Figure 6 This is a cross-sectional view of a portion of an electrical connector according to an exemplary embodiment, showing one of the terminals in the housing, without any passive electronic components.

[0012] Figure 7 This is a cross-sectional view of a portion of an electrical connector according to an exemplary embodiment, showing one of the terminals in the housing to which a passive electronic component is coupled.

[0013] Figure 8 This is a top view of a portion of an electrical connector according to an exemplary embodiment, showing a plurality of passive electronic components connected in series with corresponding terminals. Detailed Implementation

[0014] Figure 1 An electrical connector assembly 100 according to an exemplary embodiment is shown. The electrical connector assembly 100 includes an electrical connector 110 terminated at an end of a cable assembly 102. In an exemplary embodiment, the electrical connector 110 is configured to mate with a mating electrical connector (not shown), the electrical connector 110 being incorporated along a transmission line with one or more passive electronic components 200 to provide passive electronic components 200 between the cable assemblies 102 in the mating electrical connector.

[0015] The electrical connector assembly 100 can be used in various types of electrical systems. For example, the electrical connector assembly 100 can be used in power systems, such as vehicle battery systems, such as battery packs, to connect battery cells together or to another component of the battery system. The electrical connector assembly 100 can be used in communication systems, such as network devices, servers, computers, or other types of data communication systems.

[0016] Cable assembly 102 includes a plurality of conductors 104 electrically connected to electrical connector 110. In an exemplary embodiment, cable assembly 102 includes a flat flexible cable 106 (FFC 106) having a substrate 108 holding the conductors 104. However, cable assembly 102 is not limited to FFC. Instead, cable assembly 102 may include individual cables or wires, such as single-ended wires, coaxial cables, biaxial cables, ribbon cables, etc. In various other embodiments, cable assembly 102 may include flexible printed circuitry.

[0017] Electrical connector 110 terminates at the end of a cable assembly and is electrically connected to conductor 104 of cable assembly 102. Electrical connector 110 includes a housing 120 holding a plurality of terminals 150. Terminals 150 are configured to be electrically connected to corresponding conductors 104 of cable assembly 102. Terminals 150 may be power terminals, signal terminals, ground terminals, or other types of terminals. In an exemplary embodiment, one or more of terminals 150 are incorporated into passive electronic component 200. For example, passive electronic component 200 is electrically connected in series with terminals 150. Passive electronic component 200 may include protective devices such as fuses, resistors, or other passive protective devices. Passive electronic component 200 may include electronic devices that perform passive operations such as consuming, storing, or releasing electrical energy. For example, passive electronic component 200 may include capacitors, resistors, inductors, etc. Passive electronic component 200 may store energy in an electric or magnetic field, absorb energy, dissipate energy, control complex circuits or signals, generate phase shifts in signals, provide some form of feedback, or perform other passive functions.

[0018] The housing 120 extends between a mating end 122 and a cable end 124. In the illustrated embodiment, the cable end 124 is opposite to the mating end 122. For example, the mating end 122 is located at the front of the housing 120, and the cable end 124 is located at the rear of the housing 120. In alternative embodiments, other orientations are possible. For example, the housing 120 may be a right-angled housing having a cable end 124 perpendicular to the mating end 122. In an exemplary embodiment, an end of the cable assembly 102 extends into the housing 120 for electrical connection to a terminal 150. The housing 120 may have any desired shape, such as rectangular, elliptical, or other shapes. In various embodiments, the mating end 122 may define a plug end of an electrical connector 110 configured to insert into a receptacle of a mating electrical connector. Alternatively, the mating end 122 may define a receptacle of an electrical connector 110 configured to receive a plug end of a mating electrical connector.

[0019] Figure 2 This is a cross-sectional view of an electrical connector assembly 100 according to an exemplary embodiment. Figure 2 The diagram shows a terminal 150 received in the housing 120 and a conductor 104 of a cable assembly 102 terminated at the end of the terminal 150. Figure 2 A passive electronic component 200 is also shown that is electrically connected to terminal 150 in a straight line.

[0020] The housing 120 includes a wall 126 forming a terminal channel 128 that receives terminals 150. For example, the wall 126 may include an upper wall, lower wall, side wall, front wall, rear wall, etc., surrounding and defining the terminal channel 128. The housing 120 is made of a dielectric material such as a plastic material to provide electrical insulation between the terminals 150. The housing 120 may be manufactured by a molding process, such as injection molding. In various embodiments, the housing 120 is a multi-piece housing having separate, discrete molded housing portions joined together to form the housing 120. In alternative embodiments, the housing 120 may be a single-piece housing manufactured by a single molding process.

[0021] In an exemplary embodiment, housing 120 includes an opening 130 providing access to terminal 150. For example, housing 120 may be open at the front to allow terminal 150 to mate with mating terminals of a mating electrical connector. Housing 120 may be open at the rear to allow cable assembly 102 to enter housing 120.

[0022] In an exemplary embodiment, opening 130 includes terminal access opening 132, which allows manipulation of terminal 150 to prepare terminal 150 for connection of passive electronic component 200 to terminal 150. For example, terminal access opening 132 allows manipulation of terminal 150 to remove a portion of terminal 150 to create a discontinuity along terminal 150 for connection of passive electronic component 200 at the discontinuity.

[0023] In the illustrated embodiment, the access opening 132 is located at the bottom of the housing 120. In alternative embodiments, other locations are also possible. In an exemplary embodiment, opening 130 includes a cable access opening 134 that allows the interface between the end of the operating terminal 150 and the end of the conductor 104 of the cable assembly 102 to terminate the terminal 150 to the conductor 104. For example, the terminal 150 can be soldered or brazed to the conductor 104 through the cable access opening 134.

[0024] For further reference Figure 3 , Figure 3 This is a perspective view of one of the terminals 150 according to an exemplary embodiment. The terminal 150 includes a metal body 152 extending between a mating end 154 and a terminating end 156. The terminal 150 includes a body 160 between the mating end 154 and the terminating end 156. The terminal 150 generally extends along a longitudinal terminal axis 158. For example, the mating end 154, the terminating end 156, and the body 160 may extend generally parallel to each other. However, in an alternative embodiment, the terminating end 156 may extend at an angle relative to the mating end 154, for example, perpendicular to the mating end 154.

[0025] In an exemplary embodiment, the metal body 152 is a stamped body configured to be stamped and formed from a sheet of metal into a predetermined shape. The metal body 152 forms an integral structure, wherein the mating end 154, the body 160, and the terminating end 156 are integral during stamping and forming. In an exemplary embodiment, a portion of the body 160 is configured to be removed after the terminal 150 is located in the housing 120 for connecting a passive electronic component 200 in a straight line with the body 160 to connect a separated portion of the terminal 150 via the passive electronic component 200.

[0026] The mating end 154 is located at the front of the terminal 150. The mating end 154 is configured to mate with the mating terminals of the mating electrical connector. The mating end 154 may take different forms depending on the specific application. In the illustrated embodiment, the mating end 154 includes a receptacle configured to receive a pin of the mating terminal. In alternative embodiments, the mating end 154 may have other forms, such as a pin, spring beam, blade, tulip receptacle, or another type of mating interface.

[0027] Termination terminal 156 is located at the rear of terminal 150. Termination terminal 156 is configured to terminate to the corresponding conductor 104 of cable assembly 102. Depending on the specific application, termination terminal 156 may take different forms. In the illustrated embodiment, termination terminal 156 includes a solder pad 157 configured to be soldered to conductor 104. Pad 157 may be planar. In alternative embodiments, termination terminal 156 may have other forms, such as crimp sleeves and insulated displacement contacts, or another type of termination interface.

[0028] The body 160 transitions between a mating end 154 and a terminating end 156. In an exemplary embodiment, the body 160 includes a first pad 164 extending from the mating end 154 and a second pad 166 extending from the terminating end 156. In an exemplary embodiment, the body 160 includes a sacrificial portion 162 between the first pad 164 and the second pad 166. The sacrificial portion 162 is configured to be removed during the assembly process to separate the first pad 164 from the second pad 166. The sacrificial portion 162 may be a region with a reduced cross-section. For example, the body 160 may form a neck 168 between the first pad 164 and the second pad 166, the neck 168 having a width narrower than other segments of the body 160. Passive electronic components 200 are configured to bridge between the first pad 164 and the second pad 166 after the sacrificial portion 162 is removed. In an exemplary embodiment, some terminals 150 within the electrical connector 110 may remain intact, with the sacrificial portion 162 remaining between the first pad 164 and the second pad 166. Such terminals do not receive passive electronic components 200. Instead, passive electronic components 200 are used with terminals 150 with the sacrificial portion 162 removed.

[0029] In an exemplary embodiment, the terminal includes a first passive component connector 170 extending from a first pad 164. The first passive component connector 170 is configured for electrical connection to a passive electronic component 200. The first passive component connector 170 includes a first contact spring 172 extending from the first pad 164 for mating with the passive electronic component 200. In the illustrated embodiment, the first contact spring 172 extends upward from and above the first pad 164. The first contact spring 172 includes opposing first spring arms 174 on opposite sides of the first pad 164. The first spring arms 174 are deflectable relative to each other. The first spring arms 174 form a first pocket 176 configured to receive the passive electronic component 200. The first spring arms 174 may form a clamp configured to clamp against opposite sides of the passive electronic component 200 for mechanical and electrical connection to the passive electronic component 200. The first spring arms 174 may be bent, such as bent inward toward each other to form the first pocket 176. Optionally, the distal end of the first spring arm 174 may flare outward to provide access to the first pocket 176, allowing the passive electronic component 200 to be loaded into the first pocket 176. For example, the passive electronic component 200 may be loaded from above into the first pocket 176 through a gap or opening between the first spring arms 174. In an alternative embodiment, the first contact spring 172 may have other shapes. In an alternative embodiment, the first contact spring 172 may be located in other positions. Other types of passive component connectors may be provided to electrically connect the first pad 164 to the passive electronic component 200. For example, the passive component connector may include a solder pad or brazed pad configured to be fused or brazed to the ends or leads of the passive electronic component 200.

[0030] In an exemplary embodiment, the terminal includes a second passive component connector 180 extending from a second pad 166. The second passive component connector 180 is configured for electrical connection to a passive electronic component 200. The second passive component connector 180 includes a second contact spring 182 extending from the second pad 166 for mating with the passive electronic component 200. In the illustrated embodiment, the second contact spring 182 extends upward from and above the second pad 166. The second contact spring 182 includes opposing second spring arms 184 on opposite sides of the second pad 166. The second spring arms 184 are deflectable relative to each other. The second spring arms 184 form a second pocket 186 configured to receive the passive electronic component 200. The second spring arms 184 may form a clamp configured to clamp against opposite sides of the passive electronic component 200 for mechanical and electrical connection to the passive electronic component 200. The second spring arms 184 may be bent, for example, bent inward toward each other to form the second pocket 186. Optionally, the distal end of the second spring arm 184 may flare outward to provide access to the second pocket 186, allowing the passive electronic component 200 to be loaded into the second pocket 186. For example, the passive electronic component 200 may be loaded from above into the second pocket 186 through a gap or opening between the second spring arms 184. In an alternative embodiment, the second contact spring 182 may have other shapes. In an alternative embodiment, the second contact spring 182 may be located in other positions. Other types of passive component connectors may be provided to electrically connect the second pad 166 to the passive electronic component 200. For example, the passive component connector may include a solder pad or brazed pad configured to be fused or brazed to the ends or leads of the passive electronic component 200.

[0031] In an exemplary embodiment, terminal 150 includes a terminal positioning element 190 for positioning terminal 150 relative to housing 120. For example, positioning element 190 may be disposed along body 160. In an exemplary embodiment, positioning element 190 includes positioning shoulder 192, which provides a surface for longitudinally and / or laterally positioning terminal 150 in terminal channel 128 of housing 120. Positioning element 190 may include a protrusion projecting outward from body 160 and / or a recess extending inward into body 160, the recess defining positioning shoulder 192. In various embodiments, positioning shoulder 192 may be oriented substantially perpendicular to longitudinal terminal axis 158 of terminal 150. In alternative embodiments, other orientations are possible.

[0032] Figure 4 This is a top view of a portion of an electrical connector 110 according to an exemplary embodiment, showing a plurality of terminals 150 loaded into a terminal channel 128 of a housing 120. Figure 5This is an enlarged top view of a portion of an electrical connector 110 according to an exemplary embodiment, showing one of the terminals 150 being loaded into a corresponding terminal channel 128 of the housing 120.

[0033] In an exemplary embodiment, terminals 150 are arranged in a row within respective terminal channels 128. Terminals 150 may be aligned with each other, for example, by aligning the mating end 154 and terminating end 156 of each terminal 150 with each other within the row. Wall 126 defines the terminal channel 128 and is located between the terminals 150 to electrically insulate the terminals 150 from each other. Alternatively, the terminal channel 128 may be open from above to receive terminals 150. The terminal channel 128 may later be closed by a cover (not shown) or another portion of the housing 120 to retain the terminals 150 within the terminal channel 128.

[0034] In an exemplary embodiment, housing 120 includes a positioning element 140 for positioning a terminal 150 in a terminal channel 128. For example, positioning element 140 may be disposed along wall 126. Positioning element 140 is configured to mate with positioning element 190 of terminal 150 to position terminal 150 relative to housing 120. In an exemplary embodiment, positioning element 140 includes a positioning tab 142 that provides a surface for longitudinally and / or laterally positioning terminal 150 in the terminal channel 128 of housing 120. Positioning shoulder 192 of terminal 150 is configured to mate with positioning tab 142 to axially position terminal 150 in terminal channel 128. Other types of positioning elements may be used in alternative embodiments. In an exemplary embodiment, positioning element 140 is configured to position both a forward portion (e.g., a first pad 164 and mating end 154) and a rearward portion (e.g., a second pad 166 and terminating end 156) of terminal 150. In this way, when the sacrificial portion 162 is removed, both the front and rear portions remain independently within the housing 120.

[0035] Figure 6 This is a cross-sectional view of a portion of an electrical connector 110 according to an exemplary embodiment, showing one of the terminals 150 in the housing 120 without the passive electronic components 200. Figure 7 This is a cross-sectional view of a portion of an electrical connector 110 according to an exemplary embodiment, showing one of the terminals 150 in the housing 120 to which a passive electronic component 200 is coupled.

[0036] Terminal 150 is positioned in terminal channel 128 of housing 120. Body 160 rests along the bottom of terminal channel 128 and is supported by bottom wall 126 of housing 120. Contact spring 172 extends upward from body 160. Spring arm 174 is located on the opposite side of pocket 176. Spring arm 174 bends inward into pocket 176 to create a space configured to receive passive electronic component 200. When passive electronic component 200 is loaded into pocket 176, spring arm 174 deflects outward, causing spring arm 174 to press inward to maintain a reliable electrical connection with passive electronic component 200.

[0037] Figure 8 This is a top view of a portion of an electrical connector 110 according to an exemplary embodiment, showing a plurality of passive electronic components 200 connected in series with corresponding terminals 150. In various embodiments, a subset of terminals 150 receives a corresponding passive electronic component 200, while some of the terminals 150 do not receive any passive electronic component 200. Depending on the specific application and the transmission line requiring the passive electronic component 200, any one of the terminals 150 may receive a passive electronic component 200. Terminals 150 that do not receive passive electronic components 200 leave the sacrificial portion 162 intact to define an electrical path between the first pad 164 and the second pad 166. Terminals 150 that receive passive electronic components 200 route the transmission line between the first pad 164 (and mating end 154) and the second pad 166 (and terminating end 156) via the passive electronic components 200.

Claims

1. An electrical connector assembly (100), comprising: A cable assembly (102) having a conductor (104) having an end at an end of the cable assembly; An electrical connector (110) terminates at the end of the cable assembly, the electrical connector including a housing (120) for retaining a terminal (150). The housing extends between a mating end (122) and a cable end (124), the cable assembly extends from the cable end, and the housing includes a wall (126) that forms a terminal channel (128) for receiving a corresponding terminal. Each terminal includes a mating end (154) and a terminating end (156) opposite to the mating end, the terminating end being configured to terminate to a corresponding conductor of the cable assembly. The terminal includes a body (160) between the mating end and the terminating end, the body including a first pad (164), a second pad (166), and a sacrificial portion (162) between the first pad and the second pad, the sacrificial portion being configured to be removed to separate the first pad and the second pad. The terminal is configured to receive a passive electronic component (200).

2. The electrical connector assembly (100) according to claim 1, wherein when the sacrificial portion (162) is removed, the first pad (164) is electrically connected to the second pad (166) via the passive electronic component (200).

3. The electrical connector assembly (100) according to claim 1, wherein, The cable assembly (102) includes a flat flexible cable (106) having a substrate that holds the conductor (104).

4. The electrical connector assembly (100) according to claim 1, wherein, The housing (120) includes an intervention opening (130) leading to the terminal channel (128), the terminal (150) being positioned in the terminal channel of the housing, wherein the sacrificial portion (162) is aligned with the intervention opening.

5. The electrical connector assembly (100) according to claim 1, wherein, The housing (120) includes a positioning element (140), and the terminal (150) includes a positioning element that interacts with the positioning element of the housing to axially position the terminal in the terminal channel (128).

6. The electrical connector assembly (100) according to claim 5, wherein, The positioning element (140) of the housing (120) includes a positioning tab (142) extending into the terminal channel (128), and the positioning element of the terminal (150) includes a positioning shoulder (192) configured to engage the positioning tab to position the terminal relative to the housing.

7. The electrical connector assembly (100) of claim 1, wherein the terminal (150) includes a first passive electronic component connector (170) extending from the first pad (164) and a second passive electronic component connector (180) extending from the second pad (166), the passive electronic component (200) being connected between the first and second passive electronic component connectors.

8. The electrical connector assembly (100) according to claim 7, wherein the first passive electronic component connector (170) includes a first contact spring (172) mating with the passive electronic component, and the second passive electronic component connector (180) includes a second contact spring (182) mating with the passive electronic component (200).

9. The electrical connector assembly (100) of claim 8, wherein the first contact spring (172) comprises opposing first spring arms (174) on opposite sides of the first pocket (176), the passive electronic component (170) being received in the first pocket between the opposing first spring arms, and the second contact spring (182) comprises opposing second spring arms (184) on opposite sides of the second pocket (186), the passive electronic component (180) being received in the second pocket between the opposing second spring arms.

10. The electrical connector assembly (100) of claim 1, wherein the terminal (150) is configured to receive the passive electronic component (200) aligned with the body (160) to connect the first pad (164) and the second pad (166) after the sacrificial portion (162) is removed.

11. The electrical connector assembly (100) according to claim 1, wherein, The housing (120) includes a cover attached to the housing to retain the terminal (150) in the terminal channel (128).

12. The electrical connector assembly (100) according to claim 1, wherein, The passive electronic component (200) includes one of a fuse, resistor, capacitor, or noise filter.

13. The electrical connector assembly (100) according to claim 1, wherein, The termination end (156) includes a solder pad (157) configured to be soldered to the conductor (104), and wherein the mating end (154) includes one of a socket, a pin, a spring beam, or a blade.

14. The electrical connector assembly (100) of claim 1, wherein the first gasket (164), the second gasket (166), and the sacrificial portion (162) are coplanar.

15. The electrical connector assembly (100) according to claim 1, wherein, The terminal (150) includes a stamped body having the mating end (154), the body (160), and the terminating end (156), the mating end (154), the body (160), and the terminating end (156) forming an integral structure until the sacrificial portion (162) of the body is removed to physically separate the second pad (166) and the terminating end from the first pad (164) and the mating end.

16. An electrical connector assembly (100), comprising: A flat flexible cable (106), namely FFC (106), the FFC (106) having a substrate holding a conductor (104) having an end at an end (124) of the FFC; An electrical connector (110) terminates at the end of the FFC, the electrical connector including a housing (120) holding a terminal (150) terminated at the end of the corresponding conductor, at least one of the terminals including a passive electronic component (200) aligned with the terminal.

17. The electrical connector assembly (100) of claim 16, wherein each terminal (150) includes a mating end (154) and a terminating end (156) opposite to the mating end, the terminating end (156) being configured to terminate to the corresponding conductor (104), the terminal including a body (160) between the mating end and the terminating end, the body including a first pad (164), a second pad (166) and a sacrificial portion (162) between the first pad and the second pad, the sacrificial portion being configured to be removed to separate the first pad and the second pad, wherein the terminal is configured to receive the passive electronic component (200) aligned with the body to connect the first pad and the second pad after the sacrificial portion is removed.

18. A terminal (150) for an electrical connector (110), said terminal comprising: The mating end (154) is configured to mate with the mating contact of the mating electrical connector; The termination end (156) opposite to the mating end is configured to terminate to the conductor (104) of the cable assembly (102). The terminal includes a body (160) between the mating end and the terminating end, the body including a first pad (164), a second pad (166), and a sacrificial portion (162) between the first pad and the second pad, the sacrificial portion being configured to be removed to separate the first pad and the second pad. A passive electronic component (200) is coupled in series to the body between the mating end and the terminating end, and the passive electronic component is electrically connected to the first pad and the second pad after the sacrificial portion is removed.

19. The terminal (150) according to claim 18, wherein when the sacrificial portion (162) is removed, the first pad (164) is electrically connected to the second pad (166) via the passive electronic component (200).

20. The terminal (150) of claim 18, wherein the terminal includes a first passive electronic component connector (170) extending from the first pad (164) and a second passive electronic component connector (180) extending from the second pad (166), the first passive electronic component connector including a first contact spring (172) mating with the passive electronic component, and the second passive electronic component connector including a second contact spring (182) mating with the passive electronic component, the passive electronic component being connected between the first and second passive electronic component connectors.

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