Electrical contacts with textured contact interfaces

Abstract

An electrical contact having at least one textured contact interface. The at least one textured contact interface includes a rounded portion having a plurality of raised contact regions. A gap is located between the plurality of raised contact regions. When the rounded portion of the at least one textured contact interface is positioned in electrical contact with a mating electrical contact, the rounded portion of the at least one textured contact interface provides two or more contact points.

Description

Technical Field

[0001] The present invention relates to an electrical contact having a textured contact interface for improving the reliability of a connector under harsh environmental conditions. In particular, the textured contact interface provides two or more possible contact points over a wider range of tolerances and alignments.

Background Art

[0002] Electrical connectors are inserted into each other with a mating connector to form an electrical connection. Electrical connectors are generally used for either signal transmission or power transmission and can be defined as electromechanical systems that provide a separable interface between two electronic subsystems. For this purpose, electrical connectors typically have conductive contacts or terminals, and when these are inserted into each other with a mating connector, these conductive contacts or terminals contact (connect to, engage) the conductive contacts or terminals of the mating connector, forming an electrical connection and a mechanical connection therebetween. In many applications, when a connector and a mating connector are inserted into each other, in order to ensure a reliable conductive connection, one or both of the conductive contacts of the connector and the conductive contacts of the mating connector apply force to the other.

[0003] In many applications, connectors and contacts are exposed to harsh environmental conditions such as moisture, temperature changes, vibration, and corrosive media. When exposed to such environments, an insulating oxide layer may form in the contact area, thus risking malfunction of the connector.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Therefore, it is advantageous to provide contacts with textured contact surfaces that improve the reliability of the electrical connection between the contact and the mating contact, improve general contact reliability, and improve contact reliability even under harsh environmental conditions. In particular, it is advantageous to provide textured contact surfaces that offer two or more contact points to improve contact reliability under high vibration conditions and that can change in accordance with changes in contact tolerance / alignment. [Means for solving the problem]

[0005] The solution is provided by a connector system that includes a textured contact interface to improve connector reliability under harsh environmental conditions. The textured beam can provide two or more contact points over a wide range of connector tolerance stack-up. The textured contact surface can provide a reservoir of contact lubricant that can be drawn into the mating contact point over time / bonding cycles. Two contact points improve connector reliability under high vibration conditions. This method of achieving two contact points works over a wider range of connector tolerance stack-up than conventional designs. Furthermore, the lubricant reservoir can provide better reliability over more bonding cycles. Textures can be achieved by various manufacturing methods and may have different geometric shapes. For example, a textured pattern may be press-formed onto a contact surface using a progressive die tooling. In some embodiments, the texture may be applied by laser or other methods.

[0006] The present invention will be described below with reference to the attached drawings. [Brief explanation of the drawing]

[0007] [Figure 1] This is a perspective view of a first exemplary embodiment of an electrical contact according to the present invention, the contact having a single-beam configuration that includes a textured contact interface in the contact region. [Figure 2] This is a perspective view of a second exemplary embodiment of an electrical contact according to the present invention, the contact having a bifurcated beam configuration that includes a textured contact interface in the contact region. [Figure 3] This is a perspective view of a third exemplary embodiment of an electrical contact according to the present invention, the contact having a bifurcated inchworm beam configuration that includes a textured contact interface in the contact region. [Figure 4] This is a schematic diagram showing how the textured contact region of the contact beam is electrically in contact with the mating contact or bonding region of the wafer, with the textured contact region of the contact beam shown in a first orientation relative to the bonding region of the wafer. [Figure 5] This is a schematic diagram showing how the textured contact region of the contact beam is electrically in contact with the mating contact or bonding region of the wafer, with the textured contact region of the contact beam shown in a second orientation relative to the bonding region of the wafer. [Figure 6] This is a schematic diagram showing how the textured contact area of ​​the contact beam is electrically in contact with the mating contact or bonding area of ​​the wafer, with the textured contact area of ​​the contact beam shown in a third orientation relative to the bonding area of ​​the wafer. [Figure 7] This is an enlarged view of the textured contact area of ​​the contact beam, showing that the texture is applied at an angle to the longitudinal axis of the contact, and that the texture is applied across the surface of the contact beam's contact area, and therefore, when it contacts the flat bonding area of ​​the wafer, there are at least two contact points between the textured contact area of ​​the contact beam and the bonding area of ​​the wafer. [Figure 8]This is a magnified view of the textured contact area of ​​the contact beam, showing the contact lubricant provided in the gaps between the raised regions. [Figure 9] This is a schematic diagram showing how the textured contact area of ​​the contact beam is bonded to the bonding area of ​​the wafer. [Figure 9A] Figure 9 shows an enlarged view of the area indicated by 9A, illustrating the contact line between the textured contact region of the beam of the bonded contact and the bonded region of the wafer. The contact line between the textured contact region of the beam of the bonded contact and the bonded region of the wafer is provided across two raised regions of the textured contact region, providing two contact points that vary depending on the tolerance and alignment between the textured contact region of the beam of the bonded contact and the bonded region of the wafer. [Figure 9B] Figure 9 shows an enlarged view of the area indicated by 9B, illustrating the contact line between the textured contact region of the bonded contact beam and the bonded region of the wafer. The contact line between the textured contact region of the bonded contact beam and the bonded region of the wafer is provided across two raised regions of the textured contact region, offering two contact points that vary depending on the tolerance and alignment between the textured contact region of the bonded contact beam and the bonded region of the wafer. [Figure 10] This is a cross-sectional view of a textured contact area, showing a first, yet another exemplary configuration of the raised contact area and voids. [Figure 11] This is a cross-sectional view of a textured contact area, showing a second, different exemplary configuration of the raised contact area and voids. [Modes for carrying out the invention]

[0008] The connector system includes a textured contact interface to improve the reliability of the connector under harsh environmental conditions. The textured beam can provide two or more contact points over a wide range of connector tolerance accumulation. The textured contact surface can provide a reservoir of contact lubricant that can be drawn into the bond contact points over time / bonding cycles.

[0009] The two contact points improve the reliability of the connector under high vibration conditions. This method of achieving two contact points works over a wider range of connector tolerance accumulation than conventional designs. In addition, the lubricant reservoir can provide better reliability over more bonding cycles.

[0010] Textures can be achieved by various manufacturing methods and may have different geometric shapes. For example, the textured pattern may be pressed onto the contact surface using a progressive die tool. In embodiments, the texture may be applied by laser or other methods.

[0011] The embodiment relates to an electrical contact having at least one textured contact interface. The at least one textured contact interface has a plurality of raised contact regions, and gaps are arranged between the plurality of raised contact regions. When the at least one textured contact interface is positioned in electrical contact with a mating electrical contact, the at least one textured contact interface provides two or more contact points.

[0012] The embodiment relates to an electrical contact having at least one textured contact interface. The at least one textured contact interface includes a radiused portion (radiused portion, rounded portion, curved portion) having a plurality of raised contact areas. A gap is located between the plurality of raised contact areas. When the radiused portion of the at least one textured contact interface is positioned in electrical contact with a mating electrical contact, the radiused portion of the at least one textured contact interface provides two or more contact points.

[0013] The embodiment relates to an electrical contact having at least one textured contact interface. The at least one textured contact interface has a plurality of raised contact regions, and gaps are arranged between the plurality of raised contact regions. A lubricant is provided in the gaps. When the raised contact regions of the at least one textured contact interface are arranged in electrical contact with a mating electrical contact, the raised contact regions of the at least one textured contact interface provide two or more contact points.

[0014] The description of exemplary embodiments of the principles of the present invention is intended to be read in conjunction with the accompanying drawings, which are to be considered as part of the entire description. Any reference to direction or orientation in the description of embodiments of the present invention disclosed herein is for illustrative purposes only and is not intended to limit the scope of the invention. Relative terms such as “bottom,” “top,” “horizontal,” “vertical,” “up,” “down,” “up,” “bottom,” and “bottom,” as well as their derivatives (e.g., “horizontally,” “downward,” “upward,” etc.), should be interpreted as referring to orientations described thereafter or orientations shown in the drawings described. These relative terms are for illustrative purposes only and do not require that the apparatus be constructed or operated in a particular orientation unless expressly indicated so. Terms such as “attached,” “mounted,” “connected,” “joined,” and “interconnected,” and similar terms, unless otherwise specified, refer to relationships in which structures are fixed or attached to one another, directly or indirectly, through intervening structures, as well as both movable and fixed attachments or relationships. Furthermore, the features and advantages of the present invention are illustrated by reference to preferred embodiments. Accordingly, the present invention should not be particularly limited to such preferred embodiments that show some possible non-limiting combinations of features that may exist alone or in combination with other features, and the scope of the present invention is defined by the claims appended herein.

[0015] Hereinafter, exemplary embodiments of the present invention will be described with reference to the drawings. Reference numerals are used to refer to various elements and structures throughout the detailed description. The following detailed description includes many specific examples for illustrative purposes, but those skilled in the art will understand that many variations and alternatives to the following details are within the scope of the present invention. Therefore, the following embodiments of the present invention are described without losing generality with respect to the claimed invention and without imposing limitations on the claimed invention.

[0016] Referring to FIG. 1, an exemplary embodiment of an electrical contact 10 is shown. The contact 10 has a circuit board attachment portion 12, a housing fixing portion 14, and a joint portion 16. In the illustrated embodiment, the circuit board joint portion 12 has eyes in a needle configuration, but other configurations may be used. The circuit board joint portion 12 is configured to make mechanical and electrical contact with a circuit board (not shown). Another type of attachment portion 12 may be used.

[0017] In the illustrated embodiment, the fixing portion 14 has barbs 18 and lances 20. The barbs 18 and lances 20 are configured to cooperate with a housing (not shown) of an electrical connector (not shown) to hold the contact 10 in a predetermined position relative to the housing of the electrical connector. Another configuration of the fixing portion 14 may be used.

[0018] In the illustrated embodiment, the joint portion 16 extends from the fixing portion 14 in a direction away from the attachment portion 12. The joint portion 16 has a single contact arm 30 extending from the free end 32 of the joint portion 16. Other configurations of the contact arm 30 may be used.

[0019] Each contact arm 30 has a radiused contact portion 34 provided between the free end 32 of the joint portion 16 and the fixing portion 14. The joint portion 16 extends at an angle from the fixing portion 14, and the radiused contact portion 34 of each contact arm is offset from the plane of the fixing portion 14.

[0020] Each rounded contact portion 34 has a textured contact interface 36. As shown in Figure 7, the textured contact interface 36 has a plurality of raised contact regions 38. The raised contact regions 38 are separated by gaps or valleys 40.

[0021] The raised contact area 38 and the gap 40 are provided at an angle 41 across the surface of the textured contact interface 36 of the radius contact portion 34. In various exemplary embodiments, the raised contact area 38 extends at an angle 41 between 0 and 90 degrees with respect to a line perpendicular to the longitudinal axis of the contact arm 30 of the joint 16 of the electrical contact 10. In various other exemplary embodiments, the raised contact area 38 extends at an angle 41 between 20 and 70 degrees with respect to the longitudinal axis of the contact arm 30 of the joint 16 of the electrical contact 10. The gap 40 extends at the same angle 41 as the raised contact area 38 with respect to the longitudinal axis of the electrical contact 10.

[0022] The configurations of the textured contact interface 36 shown in Figures 1 to 8 are illustrative. The raised contact regions 38 and voids 40 of the textured contact interface 36 can take many configurations, including, but are not limited, the configurations shown in Figures 10 and 11. The raised contact regions 38 and voids 40 may be manufactured by a laser or other known method.

[0023] As shown in Figure 7, the lubricant 42 can be provided in the gap 40. While the contact 10 is being joined to the mating contact or mating substrate 44 (Figures 4 to 6), the lubricant can move from the gap 40 to the raised contact area 38. The lubricant may be any lubricant that provides lubrication properties to protect the surface to which it is applied and that allows for multiple joining cycles. The lubricant may be a solid lubricant such as graphite, or a liquid lubricant, but is not limited to these.

[0024] When the contact interface 36 of contact 10 is joined to the mating contact or mating substrate 44, the lubricant 42 moves, deposits, or is applied to the raised contact area 38 by a wiping action or the like. As joining continues, the mating contact or mating substrate 44 moves and comes into contact with the void 40 and the lubricant 42. When this occurs, the lubricant 42 from the void 40 moves, deposits, or is applied to the raised contact area 38 by a wiping action or the like.

[0025] The textured contact interface 36 improves the reliability of the contact 10 under harsh environmental conditions because the angled raised contact area 38 provides two or more contact points 46, 48 (Figure 7) over a wide range of connector tolerance accumulation. The two or more contact points improve contact reliability under high vibration conditions. The contact points 46, 48 may vary with tolerance / alignment, as shown in Figures 4-6 and Figures 9A and 9B.

[0026] Textured contact surfaces can provide a reservoir of contact lubricant that can be drawn into the bonding contact points over time / bonding cycles. Furthermore, this lubricant reservoir can provide better reliability over a longer number of bonding cycles.

[0027] The raised contact areas 38 and voids 40 of the textured contact interface 36 can be achieved by various manufacturing methods and may have different geometric shapes. For example, the textured contact interface 36 may be press-formed onto the contact surface using a progressive die tool, or the textured contact interface 36 may be applied by laser or other methods.

[0028] Referring to Figure 2, an alternative embodiment of the contact 10 is shown. The joint 16 has a bifurcated contact arm 30 extending from the free end 32 of the joint 16. In the illustrated embodiment, the bifurcated contact arm 30 has a similar configuration, but the bifurcated contact arm 30 may have a different configuration.

[0029] Each contact arm 30 has a rounded contact portion 34. Each rounded contact portion 34 has a textured contact interface 36. The textured contact interface 36 has a plurality of raised contact regions 38. The raised contact regions 38 are separated by gaps or valleys 40. The raised contact regions 38 and the gaps 40 are provided at an angle 41 across the surface of the textured contact interface 36 of the rounded contact portion 34.

[0030] Other features and operations of contact 10, as shown in Figure 2, are the same as those described above.

[0031] Referring to Figure 3, another alternative embodiment of the contact 10 is shown. The joint 16 has a bifurcated inch worm beam contact arm 30 extending from the free end 32 of the joint 16.

[0032] Each contact arm 30 has two rounded contact portions 34. Each rounded contact portion 34 has a textured contact interface 36. The textured contact interface 36 has a plurality of raised contact regions 38. The raised contact regions 38 are separated by gaps or valleys 40. The raised contact regions 38 and gaps 40 are provided at an angle 41 across the surface of the textured contact interface 36 of the rounded contact portion 34.

[0033] Other features and operations of contact 10, shown in Figure 3, are the same as those described above.

[0034] Textured contact surfaces can be applied to any type of contact tip design, including bifurcated tips, single tips, or other known designs. Textured contact surfaces provide two or more contact points over a wider tolerance and alignment range than known contacts.

Claims

1. It is an electrical contact, It comprises at least one textured contact interface, and the at least one textured contact interface is Multiple raised contact areas, A gap is placed between the plurality of raised contact regions. Includes, When the at least one textured contact interface is positioned in electrical contact with a mating electrical contact, the at least one textured contact interface provides two or more contact points to the electrical contact.

2. The electrical contact according to claim 1, wherein the at least one textured contact interface is located on at least one rounded portion of the electrical contact.

3. The electrical contact according to claim 1, wherein the electrical contact has a single contact beam, and the at least one textured contact interface is located on the single contact beam.

4. The electrical contact according to claim 1, wherein the electrical contact has a plurality of contact beams, and at least one of the at least one textured contact interface is located on each of the plurality of contact beams.

5. The electrical contact according to claim 4, wherein each of the plurality of contact beams has one of the at least one textured contact interface arranged in the curved portion of each of the plurality of contact beams.

6. The electrical contact according to claim 4, wherein each of the plurality of contact beams has a plurality of textured contact interfaces among the at least one textured contact interface arranged in the curved portion of each of the plurality of contact beams.

7. The electric contact according to claim 1, wherein the raised contact region extends at an angle between 0 and 90 degrees with respect to the longitudinal axis of the electric contact.

8. The electrical contact according to claim 7, wherein the gap extends at the same angle as the raised contact region with respect to the longitudinal axis of the electrical contact.

9. The electric contact according to claim 1, wherein the raised contact region extends at an angle between 20 and 70 degrees with respect to the longitudinal axis of the electric contact.

10. The electrical contact according to claim 9, wherein the gap extends at the same angle as the raised contact region with respect to the longitudinal axis of the electrical contact.

11. The electrical contact according to claim 1, wherein a lubricant is provided in the void, and when the at least one textured contact interface is positioned in electrical contact with the mating electrical contact, the lubricant can move from the void to the raised contact area.

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