Single-element wire / plate connector

Abstract

Electrical single-element connector (10) designed for connecting wires (12) to components, wherein said connector (10) comprises: a conductive contact element (18) which is formed into a cage structure (20) with a wire insertion end (22) and a wire contact end (24) along a longitudinal central axis (26) of said connector (10), wherein said cage structure (20) comprises a wall structure (30) at said insertion end (22) which defines an inlet opening (28) for a wire (12), wherein said cage structure (20) further downstream of said wall structure (30) in an insertion direction of the wire (12) into said connector (10) towards said central axis (26) includes pre-tensioned contact prongs (34), wherein said contact prongs (34) define a contact clamping point (36) for an exposed core (14) of the wire (12); and the connector further includes: a contact surface (38) defined by an element of said cage structure (20) for electrical mating contact with a corresponding contact element on the component; and Release tabs (52) designed for coupling by a tool for separating said contact prongs (34) in order to remove a wire (12) inserted into said connector (10), characterized in that the release tabs (52) extend from a foremost area of ​​said contact prongs (34) substantially in a direction parallel to the longitudinal central axis (26).

Description

Field of invention

[0001] The present invention relates generally to the field of electrical connectors and in particular to a type of connector used to connect an insulated wire to a component, such as a printed circuit board. background

[0002] Various types of connectors are known in engineering for making connections between an insulated wire and any type of electronic component. These connectors are typically available as sockets, plugs, and pin headers in a wide range of sizes, pitches, and metallization options. Many of these conventional connectors are referred to as insulation displacement connectors (IDCs) because they contain one or more contact elements that include a set of cutting blades or jaws. These blades cut through the insulation around the wire in a single step, making electrical contact with the conductive core and thus eliminating the need for stripping and crimping or other wire preparation. Insulation displacement connectors are widely used in the telecommunications industry and are finding increasingly broader application in printed circuit board (PCB) applications.

[0003] Several approaches have been taken to design insulation displacement connectors (IDCs) for surface mount applications. For example, US Patent 7,320,616 B1 describes an IDC connector specifically designed for surface mounting on a printed circuit board (PCB). The connector assembly has at least one contact element with a piercing, cutting, or slotting end that slides within a main body and a mounting end extending from the main body that attaches to a PCB using conventional SMT techniques. An insulated conductor, such as a wire, cable, and / or tape, is inserted into a channel in the main body without being pierced by the piercing end of the contact. When a user presses down on the top of the main body, the contact slides into the channel and pierces the insulated conductor.The upper part of the main body also provides a surface for a vacuum intake nozzle in an automated assembly process.

[0004] AVX Corporation, based in South Carolina, USA, offers a range of low-profile wire-to-board insulation displacement connectors (IDCs) (series 9175-9177) that are surface-mounted (SMT) on a printed circuit board before wires are inserted into contact slots using a hand tool. This process cuts the wire insulation, allowing the conductive wire cores to form a secure conductive connection with the connector.

[0005] Wire-to-board insulation displacement connectors (IDCs) are not suitable for all applications where it is desired to connect one or more wires to a component. For example, the IDCs in the reference documents cited above are relatively complex in that they require multiple parts that are movable relative to each other. An insulating main body is a separate component from the contact element, and all or part of the main body must be movable or shiftable relative to the contacts to make the final connection with the wires after the contact ends have been inserted into through-holes in the printed circuit board (PCB) or surface-mounted on the PCB. The insulating main body of conventional IDCs can also occupy valuable space (area) on the PCB. In this respect, IDCs are relatively complex, large, and can be too expensive for certain applications.

[0006] DE 10 2010 014 143 A1 discloses an actuating device for an electrical terminal block, wherein the electrical terminal block comprises a contact frame arranged in an insulating housing with a conductor clamping connection for an electrical conductor, and the actuating device comprises an actuating element designed as a push button. The conductor clamping connection on the contact frame is formed by at least one spring element, the free end of which forms a clamping edge directed towards the electrical conductor and subjected to a clamping force. The spring elements have vertically upward-facing, funnel-shaped ramps that can be opened by actuating the push button to release the clamped wire. DE 10 2010 014 144 A1 and DE 10 2011 015 968 A1 disclose nearly identical devices.

[0007] DE 197 35 835 A1 describes a connector design in the form of a tunnel with a symmetrical arrangement of the conductor terminals located at the tunnel entrance and, if applicable, also at the tunnel exit. These terminals are each formed by leaf springs punched out of the tunnel side walls in a mirror-symmetrical manner. Upwardly projecting ramps are arranged on the leaf springs, against which a push-button integrated into the electrical connector can act to spread the leaf springs for the purpose of removing the wire.

[0008] The present invention provides an alternative to wire / plate insulation displacement connectors that is robust, reliable and simply constructed. Summary

[0009] The aims and advantages of the invention are partly set out in the following description, or they are obvious from the description, or they can be seen from the application of the invention.

[0010] According to aspects of the invention, an electrical connector is provided that is particularly well suited for connecting at least one insulated wire with a conductive core to an electrical component, such as a printed circuit board. It should be clear that connectors according to the invention are not limited to use with circuit boards, but can be used in any application where a reliable electrical connection between wires and any other type of component is desired. The connectors are described here only for illustrative purposes when used to connect wires to printed circuit boards.

[0011] According to aspects of the invention, the connector is a single-element connector, since it is formed from a single conductive contact element and contains no insulating main part or molded part. The connector is particularly suitable for a placement method in which a vacuum transfer device places the connector onto a printed circuit board for subsequent surface mounting, as is understood by those skilled in the art. However, the connectors are not limited to this placement technique.

[0012] One embodiment of an electrical single-element connector according to aspects of the invention comprises a single conductive contact element formed into a cage structure, wherein this cage structure defines a wire entry end and a wire contact end arranged along a longitudinal central axis of the connector. The cage structure includes a wall structure at the entry end, which defines an inlet opening for a wire at the entry end. For example, in one embodiment, the wall structure can comprise a plurality of walls formed into a box-like structure at the entry end, wherein one of the walls defines an upper receiving surface with a surface area suitable for mounting a suction nozzle of a vacuum transfer device.The cage structure further downstream of the wall structure at the insertion end, in one insertion direction of the wire into the connector, includes a pair of contact prongs pre-tensioned towards the central axis of the connector, whereby the contact prongs define a contact clamping point for an exposed core of the wire. A component of the cage structure defines a contact surface for the electrically mating contact with a corresponding contact element or a terminal on the component to which the connector is mounted, such as a printed circuit board.

[0013] The contact prongs can be designed differently depending on the cage structure. In one embodiment, the contact prongs are front parts of the side walls, angled towards the central axis at the wire contact end of the connector. According to the invention, the prongs include release tabs extending from a frontal region of the contact prongs, the release tabs being designed for coupling by a tool for separating the contact prongs in order to remove a wire inserted into the connector. According to the invention, these release tabs generally extend parallel to the central axis.

[0014] In a particular embodiment, the connector is formed from a single stamped metal sheet, which is bent or otherwise shaped to form the cage structure. Incisions, reliefs, and the like, in any number and design, can be formed in the metal sheet to facilitate bending or otherwise shaping it into the cage structure with the features described herein.

[0015] As mentioned, in one embodiment, the cage structure comprises a plurality of walls bent into a box-like structure with a top wall, a bottom wall, and side walls at the insertion end of the connector, the top wall defining the receiving surface. In this embodiment, the top wall can be a bent extension of one of the side walls that extends to the opposite side wall.

[0016] In one embodiment, the upper and lower walls can generally be parallel, with one or both of the upper and lower walls including a front part that is angled to the central axis of the connector to define an upper wire guide (upper wall) and / or lower wire guide (lower wall).

[0017] In another embodiment, the cage structure can include a wire end stop wall defined in front of the contact prongs in the insertion direction of a wire into the connector, with this wall defining the outermost end position of the conductive core of the wire in the connector. The stop wall can be shaped differently by the cage structure. For example, in one embodiment, the lower wall can extend below the contact prongs, with the stop wall defined by a front portion of the lower wall that is bent upwards towards the central axis.

[0018] As mentioned, the connector's mounting technique is not limited to a printed circuit board or other component. In one embodiment, the contact surface is defined by a portion of the lower wall of the cage structure such that the connector can be surface-mounted to a contact area on a printed circuit board, with the central axis generally parallel to the circuit board. In another embodiment, the connector can be designed for through-hole or top-side mounting, where the connector generally extends perpendicular to the circuit board. In this arrangement, the contact surface can be defined by contact feet that generally extend transversely from the walls (lower, upper, or side walls).

[0019] The present invention also encompasses any type of electrical component assembly comprising the unique connector element introduced above and described in detail below for electrically connecting one or more wires to an electrical component. For example, the component assembly may include a printed circuit board in electrically paired contact with one or more conductive wires via the electrical connector.

[0020] Special embodiments of the unique insulation displacement connectors are described in more detail below with reference to the examples illustrated in the drawing. Brief description of the drawings Fig. Figure 1 is a perspective view of an embodiment of a connector according to aspects of the invention. Fig. Figure 2 is a side cutaway view showing the connector embodiment of Fig. 1 shows. Fig. Figure 3 is a perspective view of a connector from above and from the insertion end according to aspects of the invention. Fig. Figure 4 is a perspective side view of the connector embodiment of Fig. 3. Fig. Figure 5 is a top view of the connector embodiment of Fig. 3. Fig. 6 is a side view of the connector embodiment of Fig. 3. Fig. 7 is an end view of the connector embodiment of Fig. 3. Fig. Figure 8 is a perspective view of an alternative embodiment of a connector according to aspects of the invention. Detailed description

[0021] Reference is now made to embodiments of the invention, one or more examples of which are illustrated in the figures. These embodiments are intended to illustrate the invention and not to limit it. For example, features shown or described as part of one embodiment may be used in another embodiment to create yet another embodiment. It is intended that the present invention includes these and other modifications and variations that fall within the scope and conception of the invention.

[0022] Exemplary embodiments of an electrical connector 10 according to aspects of the invention are described in the Fig. Figures 1 to 8 illustrate this. The electrical connector 10 is designed to connect the conductive core of an insulated wire to any type of electrical component, such as a printed circuit board. For the sake of clarity and illustration, the connector 10 is shown here in the context of connecting wires to a printed circuit board. Furthermore, the connector 10 is depicted in the figures as a "one-way" connector, containing only a single wire position. It should be understood that the connector 10 is not limited by the number of wire positions, and multi-way embodiments are considered within the scope and spirit of the invention. For example, in addition to the one-way connector shown, the invention includes embodiments in which the cage structure is configured as a two-way or three-way connector.

[0023] With reference to the figures in general, an embodiment 10 of an electrical single-element connector according to aspects of the invention is shown. The connector 10 is particularly suitable for connecting a wire 12 to any type of electrical component, such as a printed circuit board. The wire 12 can be a wire with a stranded or solid core, in which a core 14 is surrounded by insulating material 16. Before inserting the wire 12 into the connector 10, a section of the insulating material 16 adjacent to the end of the wire 12 is stripped from the core 14, as shown in particular in the figures. Fig. 1 and Fig. 2 shown.

[0024] As mentioned above, the connector 10 is a "single-element" connector, since it is formed from a single conductive contact element 18. This element 18 can be made of any conductive metal material that has a thickness and other physical properties suitable for maintaining the shape of the connector 10 during the assembly process and in the operating environment of the electrical component to which the connector 10 is mounted.

[0025] The single conductive element 18 is formed into a cage-like structure, which is generally referred to as element 20 in Fig. Figure 1 shows the cage assembly 20, which includes a wire entry end 22 that defines an inlet opening 28 for inserting the wire 12 with a conductive core into the connector 10. The cage assembly 20 also defines a wire contact end 24 ( Fig. 1), which is the end of the cage assembly where the contact element 18 makes contact with the exposed conductive core 14 of the wire 12. The insertion end 22 and the wire contact end 24 are aligned along a longitudinal central axis 26 of the connector 10, as shown in the Fig. 1 and Fig. 2 shown.

[0026] In the illustrated embodiment, the cage structure 20 includes a wall structure 30 that essentially surrounds the wire 12. The wall structure 30 can contain walls of any number and shape, such as a circular wall, semicircular wall components, and so on. At least a portion of the wall structure 30 defines an upper receiving surface 32. This surface 32 has a surface area suitable for mounting a suction nozzle of a vacuum transfer device, so that the connector 10 can be conveyed to an electrical component, such as a printed circuit board, in a conventional placement process, as those skilled in the art understand. In a desirable embodiment, the connectors 10 are supplied in the form of a belt, which is fed to a conventional vacuum transfer device during the placement process.

[0027] The cage structure 20 contains, downstream of the wall structure 30 in the insertion direction of the wire 12 into the connector 10, a pair of contact prongs 34 which are pre-tensioned towards the central axis 26 of the connector 10. These contact prongs 34 are defined by sections or cutouts of the individual contact element 18 and define a contact clamping point 36 ( Fig. 3) to contact the exposed core 14 of the wire 12. The clamping point 36 also serves as a clamping point to prevent unintentional removal of the wire 12 from the connector 10.

[0028] The connector 10 includes a contact surface 38, which can be defined by any element or section of the cage structure 20. The contact surface 38 is intended for electrical mating contact with a corresponding contact element on the electronic component. For example, the contact surface 38 can be defined by any section of the lower area or the lower wall of the cage structure 30, which mats with a corresponding contact surface on the printed circuit board (PCB), and the connector 10 can be surface-mounted directly onto the contact surface of the PCB.

[0029] In the illustrated embodiment, the connector 10, in particular the contact element 18, is formed from a single sheet of metal material, which is bent or otherwise shaped to form the cage structure 30. Any type of incisions, reliefs, or other structures can be cut or punched into the single contact element 18 to facilitate its formation into the overall design of the connector 10 as described herein.

[0030] In the illustrated embodiment, the wall structure 30 comprises a plurality of walls bent to form a box-like structure 40 with an upper wall 42, a lower wall 44, and opposing side walls 46. The upper wall 42 defines the receiving surface 32 described above. It should also be apparent that any of the other walls can define the receiving surface 32. The box-like structure 40 can be defined by the walls in various ways. For example, in the illustrated embodiment, the side walls 46 are components bent upwards with respect to the lower wall 44, while the upper wall 42 is defined by an extension of one of the side walls 46 that is bent towards the opposite side wall 46.

[0031] Certain embodiments of the connector 10 may also include guide surfaces within the cage structure 20, which serve to establish physical contact with the wire 12 and to align it within the structure 20. In the illustrated embodiment, for example, an upper wire guide 48 is defined by an angled portion of the upper wall 42. This upper wire guide 48 is angled from the generally parallel upper wall (parallel to the lower wall 44) towards the central axis 26, as shown in particular in the Fig. 2 and Fig. 3 shown. Similarly, the lower wall 44, which may be parallel to the upper wall 42, may have a front part that is angled towards the central axis 26 to define a lower wire guide 50, as shown in particular in the Fig. 2, Fig. 6 and Fig. 7 can be seen.

[0032] As mentioned, the contact prongs 34 in the cage structure 20 can be designed differently. In the illustrated embodiment, the prongs 30 are defined by front parts of each of the side walls 46, which are bent or angled towards the central axis 26 and the clamping point 36. In this way, the prongs 34 are pre-tensioned relative to each other (and towards the central axis 26). The prongs 34 separate and couple with the conductive core 14 of the wire when the wire is inserted through the prongs 34.

[0033] Especially with regard to the Fig. 3 and Fig. In certain embodiments, it may be desirable to include a release tab 52, which is generally defined on each of the contact prongs 34 in front of the clamping point 36. These release tabs 52 provide a point for inserting a tool between the prongs 34 in order to open the prongs 34 for removing the wire 12, if necessary. The release tabs 52 can be designed differently. In the illustrated embodiment, the release tabs 52 are defined by tabs that generally extend forward and are substantially parallel to the central axis 26 when the wire 12 is removed from the connector 10, as is particularly evident in Fig. 5 shown.

[0034] In certain embodiments, as shown in the figures, it may also be desirable to include a wire stop wall 54 at the end of the wire contact end 24 of the cage assembly 20. This contact wall 54 provides a surface against which the conductive core 14 of the wire 12 abuts in the fully inserted position of the wire 12, as shown in Fig. Figure 2 shows the contact wall 54 in different configurations. In the illustrated embodiment, the contact wall 54 is formed from an upwardly bent portion of the lower wall 44. The wall 54 may further include a lip or overhang 58 extending back towards the clamping point 36 of the contact prongs 34. This overhang 58 can serve to prevent unintentional removal of the wire 12 in a vertical direction relative to the connector 10.

[0035] As mentioned, the contact surface 38 can be defined by any part of the lower wall 44 (or any other wall) that is oriented towards a mating contact surface on a printed circuit board. In this embodiment, the connector 10 is particularly suitable for conventional surface mount methods.

[0036] In an alternative, in Fig. In the embodiment shown in Figure 8, the connector 10 can be designed for a through-hole connection, with the connector extending through a hole in a printed circuit board. Contact feet 56 are provided for mating with a contact surface on both sides of the through-hole in the printed circuit board. Similarly, the contact feet 56 can serve for surface mounting of the connector 10 on a printed circuit board, with the connector 10 assuming a relatively vertical (i.e., perpendicular) orientation with respect to the printed circuit board. In the embodiment shown in Fig.In the embodiment shown in Figure 8, the contact feet 56 are defined by outwardly bent portions of each side wall 46. In an alternative embodiment, the contact feet 56 can also be defined by outwardly bent portions of the lower wall 44 and the upper wall 42.

Claims

[1] Electrical single-element connector (10) designed for connecting wires (12) to components, the connector (10) comprising: a conductive contact element (18) which is formed into a cage structure (20) with a wire insertion end (22) and a wire contact end (24) along a longitudinal central axis (26) of said connector (10), wherein said cage structure (20) comprises a wall structure (30) at said insertion end (22) which defines an inlet opening (28) for a wire (12), wherein said cage structure (20) further downstream of said wall structure (30) in an insertion direction of the wire (12) into said connector (10) towards said central axis (26) includes pre-tensioned contact prongs (34), wherein said contact prongs (34) define a contact clamping point (36) for an exposed core (14) of the wire (12); and the connector further includes: a contact surface (38) defined by an element of said cage structure (20) for electrical mating contact with a corresponding contact element on the component; and Release tabs (52) designed for coupling by a tool for separating said contact prongs (34) in order to remove a wire (12) inserted into said connector (10), characterized by that the release tabs (52) extend from a foremost area of ​​said contact prongs (34) essentially in a direction parallel to the longitudinal central axis (26). [2] Connector according to claim 1, wherein said connector (10) is formed from a single stamped metal sheet which is bent to form said cage structure (20). [3] Connector according to claim 2, wherein said wall structure (20) comprises a plurality of walls (42, 44, 46) which are bent into a box-like structure with an upper wall (42), a lower wall (44) and side walls (46) at said insertion end (22), wherein said upper wall (42) defines a receiving surface. [4] Connector according to claim 3, wherein said upper wall (42) is a bent extension of one of said side walls (46) and extends to the opposite said side wall (46). [5] Connector according to claim 3 or 4, wherein said upper wall (42) is generally parallel to said lower wall (44) and further includes a front part which is angled towards said central axis (26) to define an upper wire guide (48). [6] Connector according to one of claims 3-5, wherein said lower wall (44) is generally parallel to said upper wall (42) and further includes a front part which is angled towards said central axis (26) to define a lower wire guide (50). [7] Connector according to one of claims 3-6, wherein said contact prongs (34) are front parts of said side walls (46) which are angled towards said central axis (26). [8] Connector according to one of claims 3-7, wherein said cage structure (20) further includes a wire end stop wall (54) which is defined in front of said contact prongs (34) in an insertion direction of a wire (12) into said connector (10). [9] Connector according to claim 8, wherein said lower wall (44) extends below said contact prongs (34), wherein said stop wall (54) is defined by a front part of said lower wall (44) which is bent upwards towards said central axis (26). [10] Connector according to one of claims 3-9, wherein said contact surface (38) is defined by a part of said lower wall (44) such that said connector (10) is surface-mounted to a component such that said central axis (26) is generally parallel to the component. [11] Connector according to one of claims 3-10, wherein said contact surface (38) is defined by contact feet (56) which generally extend transversely from any combination of said walls (42, 44, 46) such that said connector (10) is mounted to a component such that said central axis (26) is generally perpendicular to the component. [12] Connector according to claim 1, wherein the wall structure (30) comprises a plurality of walls (42, 44, 46) which are bent into a box-like structure, wherein a first wall of the plurality of walls (42, 44, 46) comprises a first end at the wire entry end (22) of the cage structure (20) and a second end towards the wire contact end (24) of the cage structure (20), wherein said first wall has a front part at the second end, and wherein the front part is angled towards said central axis (26) to define an upper wire guide (48).

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