Connector assembly

Abstract

To reliably connect components of packaged electronic devices to external systems.SOLUTION: A connector assembly includes an outer conductive body 22 having a first end 23 configured to mate with a corresponding electrical connector, and a conductive center contact 30 arranged within the outer conductive body 22. The center contact 30 comprises a first end 32 configured to mate with the corresponding electrical connector, and a second end 38 electrically connecting with a first electrical contact of a circuit board. An outer contact 40 is slidably attached to a second end 26 of the outer conductive body 22 and electrically connects with a second electrical contact of the circuit board. An elastic element 44 is provided for biasing the outer contact 40 in a direction away from the outer conductive body 22 and toward the circuit board.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 62 / 988,143, filed March 11, 2020. This disclosure relates to electrical connectors, and more particularly, to floating headers electrically connectable to circuit boards. [Background technology]

[0002] Electronic components, such as sensor assemblies, are often housed or packaged separately from the rest of the larger electrical system in which they are used to facilitate integration and to better protect sensitive components from harsh environmental conditions. Accordingly, during use, these components must be electrically interconnected with other elements of the system. Such connections are often achieved by cables that join the various components via complementary electrical connectors.

[0003] Achieving high-performance, reliable interconnections on a scale suitable for mass production can be challenging. For example, tolerance limits that adversely affect the precision with which components and / or housings can be manufactured and / or the precision with which components can be positioned on or within associated housings can have related adverse effects on the underlying electrical system. Such deviations often make it difficult to assemble components and / or to reliably form the necessary electrical connections between components of an assembly and a connector. Furthermore, the performance of some types of devices, such as radio frequency (RF) devices, can be highly sensitive to conductivity, such as impedance matching between components of a connector or interface. These performance issues place more limitations on the underlying connector. This limitation includes being limited in how such position changes can be accommodated while maintaining acceptable performance levels. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, a problem to be solved is to reliably connect the components of a packaged electronic device to an external system. [Means for solving the problem]

[0005] This problem is solved by an electrical header or connector assembly including an outer conductor having a first end configured to mate with a corresponding electrical connector, and a conductive center contact disposed within the outer conductor and electrically insulated from the outer conductor. The center contact has a first end configured to mate with the corresponding electrical connector and a second end configured to electrically connect to a first electrical contact on a circuit board. An outer contact of the assembly is slidably connected to the second end of the outer conductor and configured to electrically connect to the second electrical contact on the circuit board. A resilient element is provided to bias the outer contact toward the circuit board in a direction away from the outer conductor.

[0006] The electrical device includes a housing including a first housing portion and a second housing portion coupled to the first housing portion. A circuit board is disposed within the housing and includes a first electrical contact and a second electrical contact electrically isolated from the first electrical contact. A high frequency connector assembly is disposed within the housing and includes an outer conductor having a first end configured to mate with a corresponding electrical connector. The assembly includes: The connector further includes a conductive center contact disposed within the outer conductor and having a first end configured to mate with a corresponding electrical connector and a second end configured to contact the first electrical contact on the circuit board, and an outer contact slidably connected to the second end of the outer conductor and electrically connecting to the second electrical contact on the circuit board. A resilient element is provided to bias the outer contact away from the outer conductor into contact with the second electrical contact.

[0007] The connector assembly includes a first electrical connector including a first outer conductor, a first dielectric disposed within the first outer conductor, and a first conductive center contact disposed within the first dielectric. The second electrical connector of the assembly is matable with the first electrical connector and includes a second outer conductor, a second dielectric disposed within the second outer conductor, and a second conductive center contact disposed within the second dielectric. When the first and second connectors are mated, the first and second outer conductors and the first and second conductive center contacts of the first and second electrical connectors are electrically connected. The assembly further includes a resilient bushing that is disposed between and contacts the opposing surfaces of the first and second dielectrics when the first and second electrical connectors are mated.

[0008] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a perspective view of an exemplary electronic device useful for explaining embodiments of the present disclosure. [Figure 2] 2 is a cross-sectional view of the device of FIG. 1 including an electrical connector or header and a circuit board according to an embodiment of the present disclosure. [Figure 3] FIG. 3 is an exploded view of the connector shown in FIG. 2. [Figure 4] FIG. 4 is an assembly diagram of the connector shown in FIG. 3. [Figure 5A] 5A-5C are simplified top views of a portion of the connector of FIGS. 2-4 positioned at various lateral or radial positions relative to a circuit board, according to an embodiment of the present disclosure. [Figure 5B] 5A-5C are simplified top views of a portion of the connector of FIGS. 2-4 positioned at various lateral or radial positions relative to a circuit board, according to an embodiment of the present disclosure. [Figure 5C]5A-5C are simplified top views of a portion of the connector of FIGS. 2-4 positioned at various lateral or radial positions relative to a circuit board, according to an embodiment of the present disclosure. [Figure 6A] 6A-6C are cross-sectional views of a portion of a housing and connector according to an embodiment of the present disclosure mated to a circuit board, with the circuit board positioned at various vertical or axial positions relative to the housing and connector. [Figure 6B] 6A-6C are cross-sectional views of a portion of a housing and connector according to an embodiment of the present disclosure mated to a circuit board, with the circuit board positioned at various vertical or axial positions relative to the housing and connector. [Figure 6C] 6A-6C are cross-sectional views of a portion of a housing and connector according to an embodiment of the present disclosure mated to a circuit board, with the circuit board positioned at various vertical or axial positions relative to the housing and connector. [Figure 7] FIG. 10 is a cross-sectional view of a connector according to another embodiment of the present disclosure. [Figure 8] 1 is a cross-sectional view of a connector assembly including a first connector engaged with a mating connector according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010] Referring generally to FIG. 1 , a perspective view of an exemplary electronic device or package 10 is shown. Package 10 includes a two-part housing, including a first or upper housing 12 and a mating second or lower housing 14. Housings 12, 14 may be molded polymer housings suitable for securing electronic components or devices, such as cameras or other sensors, therein. A header or electrical connector 20 according to an embodiment of the present disclosure is disposed within housings 12, 14 and configured to mate with the device and a corresponding connector, such as the connectorized end of a coaxial RF cable. Specifically, upper housing 12 may include a connector interface 16 that receives a portion of connector 20 from within the housing. The connector interface 16 can be formed in any desired configuration, such as the standardized FAKRA interface utilized in many automotive applications.

[0011] 2 is a cross-sectional view of an exemplary package 10 according to an embodiment of the present disclosure. A printed circuit board (PCB) 50 of an electronic device (e.g., a circuit board on which a camera is mounted) is disposed within the housings 12, 14. As shown, the PCB 50 may be fixedly mounted within the housings 12, 14, such as the lower housing 14. A header or connector 20 according to an embodiment of the present disclosure is at least partially disposed within the housings 12, 14 and includes, by way of example only, a first end that extends into a connector interface 16 for connection to a coaxial cable. A second end of the connector 20 engages one or more contact surfaces or pads on the PCB 50 to establish an electrical connection between the cable and an electronic device associated with the PCB.

[0012] For example, manufacturing or positional errors associated with any of the above components can result in improper alignment of the PCB, connector, and / or connector interface during package assembly. In prior art embodiments with connectors soldered to the PCB, this type of misalignment can prevent proper assembly of the device. In other prior art assemblies, such misalignment can result in poor or unreliable electrical contact between the PCB and connector after assembly. As described in detail herein, embodiments of the present disclosure remedy such misalignment by providing a connector with contact ends that moveably make electrical contact with the PCB, accommodating any lateral or vertical misalignment between the PCB and connector during the housing assembly process.

[0013] 2 , 3 , and 4 , a connector 20 according to an embodiment of the present disclosure includes an outer conductor or shell 22 (e.g., a unitary die-cast body) having a cylindrical first end 23 that extends from within the housings 12, 14 into an opening defined in the connector interface 16. The outer conductor 22 further includes an intermediate portion defining at least one radially extending protrusion or bearing surface 24. In one embodiment, three protrusions 24 are formed and are spaced 120 degrees apart around the circumference of the outer conductor 22 relative to a central axis of the outer conductor 22. A first side of each protrusion 24 engages or abuts the inner surface of the upper housing 12 to limit the insertion depth of the first end 23 of the conductor 22 within the connector interface 16. A cylindrical second end 26 of the outer conductor 22 extends from the intermediate portion in a direction opposite the first end 23. The outer conductor 22 defines the outer electrical conductor or shield conductor (e.g., ground conductor) of the connector 20. An annular outer seal 29 may be disposed on the first end 23 to form a seal between the connector 20 and the upper housing 12 and to insulate the opening formed in the connector interface 16 from the interior of the housings 12, 14.

[0014] A hollow outer contact 40 is mounted to the second end 26 of the outer conductor 22 and defines a movable mechanical and electrical connection with the second end 26, such that the outer contact is slidable axially along the second end of the connector 20 while maintaining electrical contact therewith. The second end 26 may include a slot or cavity 27 (see FIG. 3 ) formed therein that is configured to receive a portion of the outer contact 40 and slidably secure the outer contact to the second end. More specifically, the outer contact 40 may define a slot-like opening 46 formed therethrough. A resilient arm 47 defined by or attached to the outer contact 40 may extend radially inward into the opening 46. The free end of the arm 47 is configured to engage the second end 26, and more particularly, to engage the slot 27 in the second end 26 to secure the outer contact 40 to the second end 26 with a slidable friction fit at least along the length of the slot.

[0015] The outer contact 40 further includes electrical contact legs or tabs 42 extending from an end thereof. The tabs 42 may be symmetrically arranged around the outer contact 40, e.g., three tabs spaced 120 degrees apart from one another around the circumference or diameter of the outer contact. The tabs 42 are configured to abut or otherwise contact one or more contacts or contact pads formed on the PCB 50. The tabs 42 may be integrally formed with the outer contact 40 or may comprise separate elements that are mechanically attached. In one embodiment, the tabs 42 and arms 47 may be integrally formed with one another and mechanically attached to the outer contact 40, or each may be integrally formed with the outer contact. The use of multiple tabs 42 provides multiple coaxial ground contact points, improving the shielding effectiveness of the conductor. Shielding effectiveness is also improved by the generally uniform and / or uninterrupted nature of all or a portion of outer contact 40, e.g., the continuous nature of first end 23 of outer conductor 22.

[0016] The outer contact 40 includes at least one resilient element, such as one or more springs 44, integrally formed with or attached to the outer contact 40. In the illustrated embodiment, the springs 44 define resilient arms extending from ends of the outer contact 40. Each of the springs 44 may be curved proximate a first end that is fixed relative to the outer contact 40. The remainder of each spring 44 extends generally parallel to the body of the outer contact 40 in a direction toward the outer conductor 22. The free end of each spring 44 may be shaped or curved to extend radially outward from the outer contact 40 and define a contact surface configured (i.e., sized and positioned) to abut one of the radially extending protrusions 24. More specifically, each of the radially extending projections 24 of the outer conductor 22 defines a bearing or pressure surface against which the free end of a respective spring 44 can act when the connector 20 is assembled. In this manner, the springs 44 act to urge or bias the outer contact 40 away from the outer conductor 22, thereby exerting a pressure force through the tabs 42 against the corresponding contact on the PCB 50, ensuring reliable electrical contact and low resistance or impedance while allowing for some axial positional variation of the PCB relative to the connector without adversely affecting electrical contact between the connector and the PCB. In one embodiment, the outer contact 40 includes three springs 44, which are spaced 120 degrees apart around the outer contact and radially staggered relative to the tabs 42 to distribute the force evenly. In yet another embodiment, the spring 44 may define the electrical contact of the outer contact 40 for mating with the PCB 50, thereby eliminating the need for the tab 42.

[0017] The spring 44 may be embodied as a resilient arm without departing from the scope of this disclosure. Instead, other types of resilient elements may be used. For example, FIG. 7 shows a connector having a single coil spring 80 disposed on the outer contact 40. In this embodiment, the radially extending bearing surface 24 of the intermediate portion of the conductor 22 has a reduced lateral or radial dimension to save space and improve device packaging, while still providing sufficient, evenly distributed compressive force and axial float capability. In this embodiment, the end of the coil spring 80 adjacent the PCB 50 may be supported and / or captured by the concave surface of the contact tab 42 facing the PCB.

[0018] With particular reference to the exploded view of FIG. 3 , the outer conductor 22 is hollow and receives the center contact or conductor assembly 30 of the connector 20. In one embodiment, the center contact assembly 30 comprises a conductive spring-loaded or “pogo” pin including a male pin 32 attached at a first end to a body 34. The body 34 is configured to receive a spring 36 or other resilient element and a second, movable end of the assembly, embodied as a plunger 38 or second pin. The plunger 38 is movably disposed within the body 34 and biased by the spring 36 in an opposite direction to the male pin 32. The outer conductor 22 is further configured to receive an inner seal or bushing 25 through which the male pin 32 of the assembly 30 is disposed via the second end 26. The center contact assembly 30 may be encased in a dielectric 39 to insulate the assembly from the outer conductor defined by the outer conductor 22 and the outer contact 40. Figure 4 is an isolated assembly view of the connector 20 of Figures 2 and 3 prior to installation in a housing.

[0019] 5A-5C illustrate the lateral or radial float capability of a connector 20 and PCB 50 according to an embodiment of the present disclosure, with most of the connector components removed for clarity. As shown, PCB 50 includes two electrical contacts or contact pads: a signal or center contact 52 and a ground or outer contact 54. Center contact 52 and outer contact 54 are configured to electrically connect to second movable end or plunger 38 of center contact assembly 30 and tabs 42 of outer contacts 40 of connector 20, respectively. Center contact 52 is defined as a circular, conductive contact pad formed on PCB 50 that is larger in all dimensions (e.g., diameter, in the case of a circular pad) than the opposing contact surface of plunger 38. As such, lateral or radial misalignment of connector 20 relative to PCB 50 will not prevent the center conductor from making proper electrical contact with center contact 52. In one exemplary, non-limiting embodiment, second end or plunger 38 of center contact assembly 30 and center contact 52 are sized to accommodate at least 1 mm of axial or lateral displacement in any direction from the ideal position shown in FIG. 5A. In some embodiments, the smallest dimension of center contact 52 in any direction coplanar with the contact surface of PCB 50 is approximately 2-3 times larger than the largest dimension of the contact end of center contact assembly 30 (e.g., the contact surface of plunger 38).

[0020] Similarly, the second or outer contact 54 can have an arcuate pad shape. In one embodiment, the contact 54 may be a continuous circular or ring-like profile, or may be embodied as multiple separate contacts. However, in the illustrated embodiment, the contact 54 is partially circular or semicircular, defining an arcuate profile that extends at least 240 degrees relative to the axis of curvature (e.g., an axis defined through the radial center of the center contact 52). In this manner, the outer contact 54 is sized to ensure contact with at least two contact tabs 42, or preferably three contact tabs, each evenly spaced around the end of the outer contact 40 (e.g., spaced radially about 120 degrees apart). In the illustrated embodiment, only two contact tabs 42 are formed on the outer contact 40 and contact the contacts 54, with no tabs present in the gap defined between the ends of the second contact 54. The arcuate outer contact 54 may include a thickness or width in the plane of the PCB 50 that is dimensioned similarly to or greater than the thickness or width of the center contact 52 to accommodate at least equal amounts of radial or lateral translation of the outer contact 40 relative to the PCB 50 while maintaining electrical contact therebetween. While FIGS. 5B and 5C show radial misalignment in only two directions, it is clear that embodiments of the present disclosure can accommodate any lateral or radial misalignment while maintaining electrical connectivity.

[0021] 6A-6C illustrate the axial or vertical float capability of the connector 20 and PCB 50 according to an embodiment of the present disclosure. As shown, the connector 20 can accommodate axial misalignment of the PCB, as shown in FIGS. 6B and 6C, relative to the ideal position shown in FIG. 6A. As shown in FIG. 6A, when the first housing 12 and the second housing (14, not shown) are attached to one another, the PCB 50 abuts against the contact tabs 42 of the outer contacts 40 due to the compressive force exerted by the springs 44. In the illustrated position, the second movable end or plunger 38 of the center contact assembly 30 is also positioned approximately midway relative to the rest of the assembly, yet is still free to move in either axial direction. Similarly, outer contact 40 is positioned at an intermediate position along the length of second end 26 of outer conductor 22, with second end 26 positioned a nominal distance A from PCB 50. Spring tension on outer contact 40 ensures reliable electrical contact with PCB 50 and accommodates surface irregularities (e.g., deviations from ideal planar contours and other surface variations) of the PCB.

[0022] As shown in FIG. 6B , the PCB 50 is positioned further away from the connector 20 in the illustrated axial direction. Despite this change, the outer contacts 40 remain in contact with the PCB 50 due to pressure exerted by the springs 44, which bias the outer contacts along the second end 26 of the outer conductor 22 toward the PCB. In the exemplary illustrated position, the second end 26 is positioned a maximum distance B from the PCB 50. As shown, as the outer contacts 40 move downward, the free ends of the springs 44 slide radially inward on the projections 24. However, because the springs remain in contact with the projections 24 of the outer conductor 22, they continue to exert a compressive force on the outer contacts 54 of the PCB 50, ensuring that proper electrical contact is maintained. The plunger 38 is similarly biased downward by the spring 36 to maintain compressive contact with the first contact 52 on the PCB 50 .

[0023] Similarly, Figure 6C shows the distance between PCB 50 and connector 20 being shortened, causing plunger 38 to be pushed further into connector 20. As shown, as outer contact 40 is pressed further against second end 26 of outer conductor 22, the free ends of springs 44 expand further radially outward compared to the positions shown in Figures 6A or 6B. In this manner, second end 26 of outer conductor 22 can be biased to a position corresponding to minimum distance C relative to PCB 50.

[0024] In each of the illustrated situations, electrical contact with the PCB is maintained despite such changes in axial and / or radial position, thus allowing for manufacturing or assembly imperfections that affect the relative positions of the components to be accommodated while maintaining a high performance electrical connection.

[0025] 8, a connector 20 according to the above embodiment of the present disclosure is shown engaged with a second or mating connector 90. The mating connector 90 includes an outer conductor 91. and a conductive center contact 96 supported within dielectric 92. During mating, performed in the illustrated relative mating or insertion direction I, outer conductor 22 of connector 20 can be received by and establish electrical contact with outer conductor 91 of mating connector 90. Similarly, when connectors 20, 90 are mated, male pin 32 of center contact assembly 30 of connector 20 engages a corresponding female conductive center connector or contact 96 of mating connector 90 to establish electrical contact therebetween.

[0026] As seen in FIG. 8 , prior art connectors lacking the illustrated inner seal or bushing 25 bias the front end 139 of the dielectric 39 of connector 20 and the opposing front end 94 of the dielectric 92 of the mating connector 90 toward each other until the connectors achieve the fully mated position. To ensure that these dielectrics do not contact each other before the connectors are fully mated, prior art connectors must be sized to ensure that an air gap exists between the opposing front ends 139, 94 of the dielectrics in the fully mated position. In particular, manufacturing and assembly tolerances of the parts can significantly vary the final positions of both dielectrics 39, 92 along the illustrated axial or insertion direction I. Therefore, to ensure that no unintended interference occurs between these components, an air gap must be provided to prevent the connector from ever achieving a fully mated condition. However, it should be understood that the required presence of an air gap between these insulating dielectrics degrades RF signal performance due to the change in impedance caused by the axial movement of the dielectric constant change between the connectors.

[0027] According to embodiments of the present disclosure, the exemplary inner bushing 25 of connector 20 is adapted to remedy this shortcoming by effectively joining dielectric front faces 139, 94 without preventing the connector from achieving a fully mated state or position. More particularly, in the exemplary embodiment, inner bushing 25 includes a resilient bushing mounted within outer conductor 22 (see also FIG. 3 ). An annular protruding rib 122 defined within outer conductor 22 engages a corresponding annular slot 125 defined around the periphery of bushing 25, thereby retaining bushing 25 from axial movement within outer conductor 22.

[0028] In the mated position shown in FIG. 8 , the front end 139 of the dielectric 39 abuts against the first side of the bushing 25, and the front end 94 of the dielectric 92 compressively abuts against the second side of the bushing 25. The resilience of the bushing 25 allows the bushing to accommodate the above-mentioned positional or dimensional changes that affect the final axial position of each connector 20, 90 in the mated state. Specifically, the bushing 25 is adapted to compress or expand as needed to establish the fully mated position of the connectors while maintaining contact with each dielectric 39, 92. The bushing 25 may be constructed of silicone or other suitable material, preferably having a dielectric constant equal to or similar to (e.g., within 10%, or more preferably within 5%) the dielectric constant of the dielectric 39, 92. In this way, the connector defines a continuous, uninterrupted dielectric insulating surface along the central conductive path, thereby standardizing signal impedance and improving the overall RF performance of the connector compared to the prior art arrangements described above.

Claims

1. A connector assembly (20) comprising: an outer conductor (22) having a first end (23) configured to mate with a corresponding electrical connector; a conductive center contact (30) disposed within the outer conductor (22), the conductive center contact including a first end (32) configured to mate with the corresponding electrical connector and a second end (38) configured to electrically connect to a first electrical contact (52) of a circuit board (50); an outer contact (40) including a resilient arm (47) extending radially inward and slidably connected to the second end (26) of the outer conductor (22), the outer contact (40) being configured to electrically connect to a second electrical contact (54) of the circuit board (50); a resilient element (44) configured to bias the outer contact away from the outer conductor (22); A connector assembly comprising:

2. 2. The connector assembly (20) of claim 1, wherein the second end (38) of the conductive center contact (30) is movable relative to the first end (32) in an axial direction of the conductive center contact (30) and is resiliently biased in a direction away from the first end (32).

3. The connector assembly (20) of claim 1, wherein the resilient element (44) comprises a spring disposed between the outer conductor (22) and the outer contact (40).

4. 4. The connector assembly (20) of claim 3, wherein the spring (44) includes a resilient arm fixedly connected at a first end to one of the outer conductor (22) or the outer contact (40) and a second end slidably connected to the other of the outer contact (40) or the outer conductor (22).

5. 5. The connector assembly (20) of claim 4, wherein the outer conductor (22) includes a bearing surface (24) extending radially from the outer conductor (22) and configured to slidably engage the second end of the resilient arm (44).

6. 6. The connector assembly (20) of claim 5, further comprising a plurality of resilient arms (44) having respective first ends radially disposed about the outer contact and respective second ends that engage the bearing surfaces (24) of the outer conductor (22), the bearing surfaces (24) being radially disposed about the outer conductor (22).

7. The connector assembly (20) of claim 3, wherein the spring (44) is positioned to at least partially radially overlap an outer circumferential surface of the outer conductor (22).

8. The connector assembly (20) of claim 3, wherein the spring (44) comprises a coil spring (80) disposed on the outer conductor (22).

9. Further comprising a circuit board (50); The circuit board (50) a first contact (52) formed on the circuit board (50); a second contact (54) formed on the circuit board and electrically insulated from the first contact; The connector assembly (20) of claim 1, comprising:

10. 10. The connector assembly (20) of claim 9, wherein the first contact (52) has a generally circular shape having a diameter greater than a diameter of the second end (38) of the conductive center contact (30).

11. The connector assembly (20) of claim 9, wherein the second contact (54) at least partially surrounds the first contact (52).

12. The connector assembly (20) of claim 11, wherein the second contact (54) has an arc shape that extends over an arc length of at least 240 degrees relative to an axis of curvature of the second contact.

13. Further comprising a housing (12, 14); The housing (12, 14) a first housing portion (12) for receiving the outer conductor (22); a second housing portion (14) connected to the first housing portion (12); Including, The connector assembly (20) of claim 9, wherein the circuit board (50) is fixedly attached to the second housing portion (14).

14. The connector assembly (20) of claim 1, wherein said mating electrical connector is a coaxial radio frequency connector.

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