ELECTRICAL CONNECTORS AND ASSOCIATED PROCEDURES

Abstract

An object may comprise a blade and a shank section, wherein the blade extends from the shank section in a first direction, wherein the shank section may comprise a base providing a first width from a first lateral edge to a second lateral edge, a first rounded projection on the first lateral edge and spaced from the base in a second direction opposite to the first direction, a second rounded projection on the second lateral edge, wherein the first and second rounded projections each provide a curvature on their respective lateral edges with a radius and provide a second width greater than the first width, a first rounded recess between the first rounded projection and the base, and a second rounded recess between the second rounded projection and the base.wherein the first and the second rounded recesses each provide a curvature at their respective side edges with the radius.

Description

BACKGROUND

[0001] An electrical connector is an electromechanical device used to create an electrical connection between parts of an electrical circuit or between different electrical circuits, thereby connecting them to form a larger circuit. A pin connector is a type of electrical connector designed for connecting electrical wires to a terminal block, printed circuit board, or other connection points. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 illustrates an example connector. Fig. Figure 2 illustrates a cross-sectional view of the exemplary connector included in an exemplary pin header. Fig. 3A illustrates an exemplary leg section of the exemplary connector. Fig. Figure 3B illustrates the exemplary leg section of the exemplary connector. Fig. Figure 4A illustrates a section of the example connector. Fig. Figure 4B illustrates a section of the example connector. Fig. Figure 5 illustrates a side view of the example connector. Fig. Figure 6 illustrates another example connector. Fig. Figure 7 illustrates another example connector. Fig. Figure 8 illustrates an example pin header that accommodates the example connector. Fig. Figure 9 illustrates an example pin header that accommodates the example connector. Fig. Figure 10 illustrates a coil of exemplary connectors. DETAILED DESCRIPTION

[0002] Extensive reference will now be made to embodiments, examples of which are shown in the accompanying drawings. The following detailed description presents numerous specific details to enable a comprehensive understanding of the various described embodiments. However, it will be apparent to a person skilled in the art that the various described embodiments can be implemented without these detailed descriptions. In other cases, known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0003] “One or more” includes a function performed by one element, a function performed by more than one element, e.g. in a distributed form, multiple functions performed by one element, multiple functions performed by multiple elements, or any combination of the foregoing.

[0004] It should also be understood that, although the terms "first / first / first", "second / second / second", etc., are used herein in some instances to describe different elements, these elements should not be restricted by these terms. These terms are used only to distinguish one element from another. For example, a first contact could be referred to as a second contact, and similarly, a second contact could be referred to as a first contact, without altering the scope of the various embodiments described. The first and the second contact are both contacts, but they are not the same contact.

[0005] The terminology used in the description of the various embodiments described herein serves only to describe specific embodiments and is not to be understood as limiting. As used in the description of the various described embodiments and the accompanying claims, the singular forms "a" and "the" also include the plural forms, unless the context clearly indicates otherwise. It is also understood that the term "and / or" used herein refers to and includes any and all possible combinations of one or more of the listed elements.It is further to be understood that the terms “have”, “having”, “including”, “comprises” and / or “comprehensive”, when used in this patent specification, specify the presence of certain features, integers, steps, operations, functions, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, functions, elements, components and / or groups thereof.

[0006] As used here, the term "if" can be understood, depending on the context, as "when" or "at" or "in response to a determination" or "in response to a recognition." Likewise, the phrase "when determined" or "when [a certain condition or event] is recognized" can be interpreted, depending on the context, as meaning "at the time of a determination" or "in response to a determination" or "at the time of recognition [of the certain condition or event]" or "in response to a recognition [of the certain condition or event]."

[0007] It should be understood that terms such as "approximately", "essentially" and "general" are not intended to be limitless and should be interpreted in accordance with how a person skilled in the field would interpret these terms.

[0008] This disclosure relates to electrical connectors and associated methods for forming and connecting them. In some embodiments, the electrical connectors may be pin terminals for insertion into sockets in pin headers.

[0009] Fig. Figure 1 illustrates an exemplary object 20, namely an electrical connector, such as a pin connector. The connector 20 comprises a blade 22 that extends from a leg section 24 in a first direction D1.

[0010] Fig. Figure 2 illustrates the exemplary connector 20, which is inserted into a slot 26 of a pin header 28 that can be mounted on a printed circuit board (PCB) 30. In some embodiments, the pin header 28 can be made of plastic. In some embodiments, the pin header 28 can be made of polymer. In some embodiments, the pin header 28 can be made of liquid crystal polymer (LCP). In some embodiments, the pin header 28 can be injection molded. At least part of the leg section 24 can be inserted within the slot 26. The leg section 24 can also be connected to the printed circuit board 30. The blade 22 can extend away from the pin header 28 opposite the printed circuit board 30. The blade 22 can provide an elongated electrical contact section. In some embodiments, the blade 22 and the leg section 24 can be made of a copper-zinc alloy.In some versions, the blade 22 and the shank section 24 may be made of CUZN30 brass, also known as C2600.

[0011] The Fig. 3A and Fig. Figure 3B illustrates the exemplary leg section 24. The blade 22 extends from a base 32, which provides a first width w1 from a first side edge 34 to a second side edge 36. In some embodiments, as shown, the base 32 provides an upper section of the leg section 24. The base includes upper edges 38 extending from the blade 22. The side edges 34, 36 on the base 32, which provide the width w1, can be substantially straight and substantially parallel (±5°) to each other and substantially perpendicular (±5°) to the upper edges 38. In some embodiments, the first width w1 can be 1.74 mm (+ 0.05).

[0012] A first rounded projection 40 on the first side edge 34 is spaced from the base 32 in a second direction D2, opposite to the first direction D1. A second rounded projection 42 is provided on the second side edge 36. The first and second rounded projections 40, 42 each provide a curvature with a radius R on their respective side edges 34, 36. The first and second rounded projections 40, 42 each provide a second maximum width w2, which is greater than the first width w1. The widths w1 and w2 shown are parallel to each other. In some embodiments, the radius is 0.15 mm (+ / - 0.05). In some embodiments, the width w2 is 1.87 mm (+ 0.05). The side edges 34, 36 on the respective first and second rounded projections 40, 42 can be convex as shown.

[0013] A first rounded recess 44 is provided between the first rounded projection 40 and the base 32. A second rounded recess 46 is provided between the second rounded projection 42 and the base 32. The first and second rounded recesses 44, 46 each provide a curvature with the same radius R as the first and second rounded projections 40, 42 at their respective side edges 34, 36. The side edges 34, 36 at the respective first and second rounded recesses 44, 46 can be concave as shown. The first rounded projection 40 and the first rounded recess 44 can provide an S-shape at side edge 34. The first rounded projection 42 and the first rounded recess 46 can provide an S-shape at side edge 36.The side edges 34, 36 at the respective first and second rounded recesses 44, 46 provide a third minimum width w3, which is smaller than the widths w1 and w2. The widths w1, w2, and w3 shown are parallel to each other. The leg section 24 spans the widths w1, w2, and w3 at the marked locations.

[0014] Fig. Figure 3A illustrates a first surface 48 of the exemplary leg section 24, which provides the first and second side edges 34, 36. As shown in the Fig. 4A and Fig. As shown in Figure 4B, leg segment 24 comprises a second surface 50, which is opposite the first surface 48, with a side surface 52 extending between them. As shown, the first surface contour and the second surface contour can be identical. The surfaces 48 and 50 can have mirror symmetry. The surfaces 48 and 50 can have mirrored outer contours.

[0015] As in Fig. As shown in Figure 5, a plane of symmetry P extends through the object and is parallel to the first surface 48 and the second surface 50. The surfaces 48 and 50 are mirror-symmetric about the plane of symmetry P. The side surface 52 provides a thickness t, and the blade 22 and the leg section 24 have the same thickness t, except that in some embodiments the tip of the blade 22 may be tapered.

[0016] Fig. Figure 6 illustrates an exemplary connector 120, which is essentially similar to the connector 20, except that the exemplary connector 120 comprises two leg sections 124A, 124B. The blade 122 extends from the bases 132A, 132B of the respective leg sections 124A, 124B. As shown, the leg sections 124A, 124B can have the same features, the same geometry, and / or the same dimensions as the leg section 24.

[0017] Fig. Figure 7 illustrates an exemplary connector 220, which is essentially similar to connectors 20 and 120, except that the exemplary connector 220 comprises three leg sections 224A, 224B, 224C. The blade 222 extends from the bases 232A, 232B, 232C of the respective leg sections 224A, 224B. As shown, the leg sections 224A, 224B can have the same features, geometry, and / or dimensions as leg section 24.

[0018] As in the Fig. 8 and Fig. As shown in Figure 9, the pin header 28 can accommodate any number or combination of connectors 20, 120, 220 in its slots 26.

[0019] With returning reference to Fig. 2. Slot 26 can have a width w4 extending in the same directions as widths w1, w2, w3 when connector 20 is inserted into slot 26. The width w4 can be smaller than the width w2. In some embodiments, also with reference to the Fig. 3A and Fig. In embodiment 3B, the first width w1 can be 1.74 mm (+0.05), the width w2 1.87 mm (+0.05), the radius R 0.15 mm (+ / - 0.05), and the slot width w4 1.75 mm (+ / - 0.02). The width w3 is smaller than the widths w1 and w2. The width w4 can be constant along the slot 26, at least in the sections where the projections 40, 42, recesses 44, 46, and the base 32 interlock. The pin header 28 can be made of a plastic material, and the leg section 24 can be made of a copper-zinc alloy. The applicant has determined that this combination of geometry, dimensions, and material for the slot and the leg section results in a retention force of more than or equal to 15 N in some embodiments, which can lead to reliable connections.The projections 40, 42 press the material of the pin header 28, while the recesses 44, 46 allow the compressed material to flow into the recesses, resulting in improved retention force. The recesses 44, 46 provide a recessed area between the projections 40, 42 and the base 30 into which the compressed material of the pin header 28 can flow when the leg section 24 is inserted into the slot 26. The recesses 44, 46 and the projections 40, 42 can be provided on both sides, ensuring uniform resistance during insertion. This design can also ensure correct positioning in a stable and predictable production process.

[0020] With returning reference to Fig. 3A The leg section 24 can include a lower section 62, which is spaced apart from the projections 40, 42 in the direction D2. The lower section 62 can be connected to the circuit board 30 (see Fig. 2) come into contact, for example by soldering, a through-hole, or a surface-mount connection. In some designs, one or more cavities 64 may be provided in which solder paste can collect. One or more punched recesses 66, for example, when several connectors 20 are separated after a punching operation.

[0021] An example method may include forming an object from flat sheet metal, wherein the object comprises a blade and a leg section, the blade extending from the leg section in a first direction.The leg section may include a base providing a first width from a first side edge to a second side edge; a first rounded projection on the first side edge spaced from the base in a second direction opposite to the first; a second rounded projection on the second side edge, wherein the first and second rounded projections each provide a curvature on their respective side edges with a radius and a second width greater than the first width; a first rounded recess between the first rounded projection and the base; and a second rounded recess between the second rounded projection and the base, wherein the first and second rounded recesses each provide a curvature on their respective side edges with a radius. In some embodiments, the forming may involve a stamping process.

[0022] As in Fig. As shown in Figure 10, several items can be formed on a spool 60. The connector 20, which comprises the blade 22 and the leg section 24, can be formed from a single piece of flat sheet metal by a stamping process. The blade 22 and the leg section 24 can therefore have a uniform thickness. The blade 22 and the leg section 24 can be monolithic and formed from a single piece of metal. Several connectors 20 can be formed from the same piece of metal.

[0023] An example process could involve forming an object from a flat sheet of metal, the object being provided with a blade and a leg section. The blade extends from the leg section in one direction. The leg section includes a base extending over a first width from one side edge to the other. It also has a first rounded projection on the first side edge, positioned in the opposite direction to the base, and a second rounded projection on the second side edge. Both rounded projections have a curvature with a radius and provide a second width greater than the first width. Additionally, between each rounded projection and the base, there are a first and a second rounded depression, each depression having a curvature with the same radius as the projections.In some versions, the shaping process may include a stamping procedure.

[0024] An example procedure may involve inserting an object into a slot in a pin header. The object may comprise a blade and a leg section, the blade extending from the leg section in a first direction.The leg section can include a base providing a first width from a first side edge to a second side edge, a first rounded projection on the first side edge spaced from the base in a second direction opposite to the first direction, a second rounded projection on the second side edge, wherein the first and second rounded projections each provide a curvature on their respective side edges with a radius and provide a second width greater than the first width, a first rounded recess between the first rounded projection and the base, and a second rounded recess between the second rounded projection and the base, wherein the first and second rounded recesses each provide a curvature on their respective side edges with a radius. The slot can include a third width (e.g.,The first width is 1.75 mm (+0.02)), which is less than the second width. In some embodiments, the radius is 0.10-0.20 mm, the first width 1.74-1.79 mm, the second width 1.82-1.87 mm, and the third width 1.73-1.77 mm, the applicant having determined that such a combination results in a retention force of more than or equal to 15 N.

[0025] The pin header can be mounted on a printed circuit board. The object can be soldered to a printed circuit board while being inserted into the slot. The object can be connected to the printed circuit board using through-hole or surface mount technology. In some embodiments, the examples disclosed herein can be secured without the use of a retaining hook that engages the pin header.

[0026] In some embodiments, the techniques described herein relate to an object comprising: a blade and a shank section, wherein the blade extends from the shank section in a first direction, the shank section comprising: a base providing a first width from a first lateral edge to a second lateral edge, a first rounded projection on the first lateral edge spaced from the base in a second direction opposite to the first, a second rounded projection on the second lateral edge, wherein the first and second rounded projections each provide a curvature on their respective lateral edges with a radius and provide a second width greater than the first width, and a first rounded recess between the first rounded projection and the base.and a second rounded recess between the second rounded projection and the base, wherein the first and the second rounded recess each provide a curvature on their respective side edges with the radius.

[0027] The item may also include any of the following in any combination.

[0028] In some versions, the radius is 0.10-0.20 mm.

[0029] In some versions, the first width is 1.74-1.79 mm and the second width is 1.82-1.87 mm.

[0030] In some versions, the leg section comprises a first surface, which provides the first and second side edges, and a second surface, which adjoins the first surface via a side surface.

[0031] In some versions, a plane of symmetry extends through the object and is parallel to the first surface and the second surface.

[0032] In some designs, the side surface provides a thickness, and the blade and the shank section have the same thickness.

[0033] In some embodiments, the techniques described herein relate to an object wherein the blade extends in the first direction from a second leg section, the second leg section comprising: a second base providing the first width from a third lateral edge to a fourth lateral edge; a third rounded projection on the third lateral edge spaced from the second base in the second direction; a fourth rounded projection on the fourth lateral edge, wherein the third and fourth rounded projections each provide a curvature on their respective lateral edges with the radius providing the second width; a third rounded recess between the third rounded projection and the second base; and a fourth rounded recess between the fourth rounded projection and the second base.wherein the third and fourth rounded recesses each provide a curvature on the respective third and fourth side edges with the radius.

[0034] In some embodiments, the techniques described herein relate to an object wherein the blade extends in the first direction from a third leg section, the third leg section comprising: a third base providing the first width from a fifth lateral edge to a sixth lateral edge; a fifth rounded projection on the fifth lateral edge spaced from the third base in the second direction; a sixth rounded projection on the sixth lateral edge, wherein the fifth and sixth rounded projections each provide a curvature on their respective lateral edges with radius and provide the second width; a fifth rounded recess between the fifth rounded projection and the third base; and a sixth rounded recess between the sixth rounded projection and the third base.wherein the fifth and sixth rounded recesses each provide a curvature on the respective fifth and sixth side edges with radius .

[0035] In some embodiments, the techniques described herein relate to a process comprising: forming an object from flat sheet metal, the object comprising: a blade and a leg section, the blade extending from the leg section in a first direction, the leg section comprising: a base providing a first width from a first side edge to a second side edge, a first rounded projection on the first side edge spaced from the base in a second direction opposite to the first direction, a second rounded projection on the second side edge, the first and second rounded projections each providing a curvature on their respective side edges with a radius and providing a second width greater than the first width, a first rounded recess between the first rounded projection and the base,and a second rounded recess between the second rounded projection and the base, wherein the first and the second rounded recess each provide a curvature on their respective side edges with the radius.

[0036] The process can also include the following: In some versions, the radius is 0.10–0.20 mm. In some versions, the first width is 1.74–1.79 mm and the second width is 1.82–1.87 mm.

[0037] In some embodiments, the techniques described herein relate to a method comprising: inserting an object into a slot in a pin header, the object comprising: a blade; and a leg section, the blade extending from the leg section in a first direction, the leg section comprising: a base providing a first width from a first side edge to a second side edge, a first rounded projection on the first side edge spaced from the base in a second direction opposite to the first direction, a second rounded projection on the second side edge, the first and second rounded projections each providing a curvature on their respective side edges with a radius and providing a second width greater than the first width.a first rounded recess between the first rounded projection and the base and a second rounded recess between the second rounded projection and the base, wherein the first and second rounded recesses each provide a curvature on their respective side edges with radius , the slot having a third width which is less than the second width.

[0038] The method may also include the following: In some embodiments, the radius is 0.10–0.20 mm. In some embodiments, the first width is 1.74–1.79 mm and the second width is 1.82–1.87 mm. In some embodiments, the third width is 1.73–1.77 mm. In some embodiments, the first width is 1.74–1.79 mm, the second width is 1.82–1.87 mm, and the third width is 1.73–1.77 mm. In some embodiments, the pin header is made of LCP, and the object comprises a copper-zinc alloy. In some embodiments, the leg section comprises a first surface, which provides the first and second side edges, and a second surface, which adjoins the first surface via a side face. In some embodiments, a plane of symmetry extends through the object and is parallel to the first and second surfaces.

[0039] Although the various examples feature the specific components illustrated in the figures, the embodiments described in this disclosure are not limited to these particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another of the examples. Furthermore, the various figures accompanying this disclosure are not necessarily to scale, and some features may be exaggerated or minimized to show certain details of a particular component or arrangement.

[0040] A person skilled in the art will understand that the embodiments described above are exemplary and not limiting. This means that modifications to this disclosure would be covered by the scope of the claims. Accordingly, the following claims should be examined to determine their actual scope and content.

Claims

[1] Subject matter, encompassing: a blade; and a leg section, wherein the blade extends from the leg section in a first direction, the leg section comprising: a base that provides a first width from a first side edge to a second side edge, a first rounded projection on the first side edge, which is spaced away from the base in a second direction opposite to the first direction, a second rounded projection on the second side edge, wherein the first and the second rounded projection each provide a curvature on the respective side edges with a radius and provide a second width that is greater than the first width, a first rounded indentation between the first rounded projection and the base, and a second rounded recess between the second rounded projection and the base, wherein the first and the second rounded recess each provide a curvature on the respective side edges with the radius. [2] The object according to claim 1, wherein the radius is 0.10-0.20 mm. [3] Subject matter according to claim 2, wherein the first width is 1.74-1.79 mm and the second width is 1.82-1.87 mm. [4] Subject matter according to claim 1, wherein the leg section comprises a first surface which provides the first and second side edge, and a second surface which adjoins the first surface via a side surface. [5] Object according to claim 4, wherein a plane of symmetry extends through the object and is parallel to the first surface and the second surface. [6] The object according to claim 5, wherein the side surface provides a thickness and the blade and leg section have the thickness. [7] The object of claim 1, wherein the blade extends in the first direction from a second leg section, the second leg section comprising: a second base that provides the first width from a third side edge to a fourth side edge, a third rounded projection on the third side edge, spaced away from the second base in the second direction, a fourth rounded projection on the fourth side edge, wherein the third and fourth rounded projections each provide a curvature on their respective side edges with the radius that provides the second width, a third rounded recess between the third rounded projection and the second base, and a fourth rounded recess between the fourth rounded projection and the second base, wherein the third and fourth rounded recesses each provide a curvature on the respective third and fourth side edges with the radius. [8] The object according to claim 7, wherein the blade extends in the first direction from a third leg section, the third leg section comprising: a third base providing the first width from a fifth side edge to a sixth side edge, a fifth rounded projection on the fifth side edge, spaced from the third base in the second direction, a sixth rounded projection on the sixth side edge, wherein the fifth and sixth rounded projections each provide a curvature on the respective side edges with the radius and provide the second width, a fifth rounded recess between the fifth rounded projection and the third base, and a sixth rounded recess between the sixth rounded projection and the third base, wherein the fifth and sixth rounded recesses each provide a curvature on the respective fifth and sixth side edges with radius . [9] Procedures, comprehensive: Shapes of an object made from flat sheet metal, the object comprising: a blade; and a leg section, wherein the blade extends from the leg section in a first direction, the leg section comprising: a base that provides a first width from a first side edge to a second side edge, a first rounded projection on the first side edge, which is spaced away from the base in a second direction opposite to the first direction, a second rounded projection on the second side edge, wherein the first and the second rounded projection each provide a curvature on the respective side edges with a radius and provide a second width that is greater than the first width, a first rounded indentation between the first rounded projection and the base, and a second rounded recess between the second rounded projection and the base, wherein the first and the second rounded recess each provide a curvature on the respective side edges with the radius. [10] Method according to claim 9, wherein the radius is 0.10-0.20 mm. [11] Method according to claim 10, wherein the first width is 1.74-1.79 mm and the second width is 1.82-1.87 mm. [12] Procedures, including: Inserting an object into a slot in a pin header, the object encompassing: a blade; and a leg section, wherein the blade extends from the leg section in a first direction, the leg section comprising: a base that provides a first width from a first side edge to a second side edge, a first rounded projection on the first side edge, which is spaced away from the base in a second direction opposite to the first direction, a second rounded projection on the second side edge, wherein the first and the second rounded projection each provide a curvature on the respective side edges with a radius and provide a second width that is greater than the first width, a first rounded indentation between the first rounded projection and the base, and a second rounded recess between the second rounded projection and the base, wherein the first and the second rounded recess each provide a curvature on their respective side edges with the radius, where the slot has a third width that is smaller than the second width. [13] Method according to claim 12, wherein the radius is 0.10-0.20 mm. [14] Method according to claim 13, wherein the first width is 1.74-1.79 mm and the second width is 1.82-1.87 mm. [15] Method according to claim 14, wherein the third width is 1.73-1.77 mm. [16] Method according to claim 12, wherein the first width is 1.74-1.79 mm, the second width is 1.82-1.87 mm and the third width is 1.73-1.77 mm. [17] Method according to claim 16, wherein the pin header comprises a liquid crystal polymer and the article comprises a copper-zinc alloy. [18] Method according to claim 12, wherein the pin header comprises a liquid crystal polymer and the article comprises a copper-zinc alloy. [19] Method according to claim 12, wherein the leg section comprises a first surface which provides the first and second side edge, and a second surface which adjoins the first surface via a side surface. [20] Method according to claim 19, wherein a plane of symmetry extends through the object and is parallel to the first surface and the second surface.

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