Connector Assembly

Abstract

The connector assembly (20) includes an outer conductor (22) having a first end (23) configured to mate with a corresponding electrical connector, and a conductive center contact (30) disposed within the outer conductor (22). The center contact (30) includes a first end (32) configured to mate with a corresponding electrical connector and a second end (38) that electrically connects to a first electrical contact (52) on a circuit board (50). An outer contact (40) is slidably mounted to the second end (26) of the outer conductor (22) and electrically connects to a second electrical contact (54) on the circuit board (50). A resilient element (44) is provided to bias the outer contact (40) toward the circuit board (50) in a direction away from the outer conductor (22).

Description

Technical Field

[0001] This application claims priority to U.S. Provisional Patent Application No. 62 / 988,143, filed Mar. 11, 2020, under 35 U.S.C. § 119. The present disclosure relates to electrical connectors, and more particularly, to floating headers that can be electrically connected to a circuit board.

Background Art

[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 better protect the more delicate components from harsh environmental conditions. Thus, during use, these components must be electrically interconnected with the other elements of the system. Such connections are often achieved by cables that join the various components via complementary electrical connectors.

[0003] Achieving reliable interconnections with high performance on a scale suitable for mass production can be difficult. For example, tolerance limits that affect the accuracy with which components and / or housings can be manufactured, and / or the accuracy with which components can be placed in a related housing or within a housing, can impact the underlying electrical system. Such misalignments often make it difficult to assemble components and / or reliably form the necessary electrical connections between the components of the assembly and the connectors. Additionally, the performance of some types of devices, such as high-frequency (RF) devices, can be highly sensitive to conductivity effects, such as impedance matching between the components of the connector or interface. These performance issues place more constraints on the underlying connectors. This limitation includes having limited ways to accommodate the above-described positional variations while maintaining an acceptable level of performance.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Accordingly, the problem to be solved is to reliably connect the components of the packaged electronic device to an external system.

Means for Solving the Problem

[0005] This problem is solved by an electrical header or connector assembly comprising 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 includes a first end configured to mate with a corresponding electrical connector and a second end configured to electrically connect to a first electrical contact of a circuit board. The outer contact of the assembly is slidably connected to the second end of the outer conductor and is configured to electrically connect to a second electrical contact of the circuit board. An elastic element is provided to bias the outer contact towards the circuit board in a direction away from the outer conductor.

[0006] The electronic device comprises 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 insulated from the first electrical contact. A high-frequency connector assembly disposed within the housing includes an outer conductor having a first end configured to mate with a corresponding electrical connector. The assembly further includes a conductive center contact having a first end disposed within the outer conductor and configured to mate with a corresponding electrical connector and a second end that contacts the first electrical contact of the circuit board. The outer contact is slidably connected to the second end of the outer conductor and electrically connects to the second electrical contact of the circuit board. An elastic element is provided to bias the outer contact away from the outer conductor and 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 matingly engageable 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. In a mated state of the first connector and the second connector, the first outer conductor and the second outer conductor, the first conductive center contact and the second conductive center contact of the first electrical connector and the second electrical connector are electrically connected. The assembly further includes an elastic bushing which is disposed between and in contact with opposing surfaces of the first dielectric and the second dielectric in a mated state of the first electrical connector and the second electrical connector.

[0008] Hereinafter, the present invention will be described by way of example with reference to the accompanying drawings.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5A

Figure 5B

Figure 5C

Figure 6A

Figure 6B

Figure 6C

Figure 7

Figure 8

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-piece housing, including a first or upper housing 12 and a second or lower housing 14 that mates therewith. Housings 12, 14 may be molded polymer housings suitable for securing electronic components or devices, such as a camera or other sensor, therein. A header or electrical connector 20 according to an embodiment of the present disclosure is disposed within housings 12, 14 and is configured to mate with a device and a corresponding connector, such as a 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. Connector interface 16 can be formed in any desired configuration, such as a standardized FAKRA interface utilized in many automotive applications.

[0011] FIG. 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 to which a camera is attached) is disposed within housings 12, 14. As shown, PCB 50 can be fixedly attached within housings 12, 14, e.g., to lower housing 14. A header or connector 20 according to an embodiment of the present disclosure is at least partially disposed within housings 12, 14 and includes a first end that extends into connector interface 16, merely by way of example, for connection to a coaxial cable. To establish an electrical connection between the cable and the electronic device associated with the PCB, a second end of connector 20 engages one or more contact surfaces or contact pads of PCB 50.

[0012] For example, due to manufacturing or positional errors associated with any of the above components, during the assembly of the package, the PCB, connector, and / or connector interface cannot be ideally aligned. In prior art embodiments with a connector soldered to the PCB, this type of misalignment can prevent proper assembly of the device. In other prior art assemblies, such a defect can result in insufficient or uncertain electrical contact between the PCB and the connector after assembly. As will be described in detail herein, embodiments of the present disclosure improve such defects by providing a connector having a contact end that movably electrically contacts the PCB, enabling it to accommodate any misalignment between the PCB and the connector in the lateral or vertical directions during the housing assembly process.

[0013] Further referring to FIG. 2 and FIGS. 3 and 4, a connector 20 according to an embodiment of the present disclosure includes an outer conductor or outer shell 22 (e.g., a one-piece die-cast body), and this outer conductor or outer shell 22 has a cylindrical first end 23 that extends into an opening defined within the connector interface 16 from within the housings 12, 14. The outer conductor 22 further includes an intermediate portion that defines at least one radially extending protrusion or bearing surface 24. In one embodiment, three protrusions 24 are formed and are spaced 120 degrees apart from each other around the outer conductor 22 with respect to the central axis of the outer conductor 22. The first side of each protrusion 24 engages or abuts against 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. The cylindrical second end 26 of the outer conductor 22 extends from the intermediate portion in a direction opposite to the first end 23. The outer conductor 22 defines an outer electrical conductor or shield conductor (e.g., a ground conductor) of the connector 20. An annular outer seal 29 is 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] The hollow outer contact 40 is attached to the second end 26 of the outer conductor 22, defining a movable mechanical and electrical connection with the second end 26. The outer contact is axially slidable along the second end while maintaining electrical contact with the second end. The second end 26 can include an internally formed slot or cavity 27 (see FIG. 3), and this slot or cavity 27 is configured to receive a portion of the outer contact 40 and slidably fix the outer contact to the second end. More specifically, the outer contact 40 can define a slot-shaped opening 46 formed through the outer contact 40. An elastic arm 47 defined by or attached to the outer contact 40 can extend radially inwardly into the opening 46. The free end of the arm 47 engages the second end 26, and more specifically, engages the slot 27 of the second end 26, and is configured to frictionally fit and fix the outer contact 40 to the second end 26 slidably at least along the length of the slot.

[0015] The outer contact 40 further includes electrical contact legs or tabs 42 extending from the end. The tabs 42 can be symmetrically arranged around the outer contact 40. For example, three tabs are arranged 120 degrees apart from each other around or around the 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 can be integrally formed with the outer contact 40 or can include separate elements that are mechanically attached. In one embodiment, the tabs 42 and the arm 47 can be integrally formed with each other and mechanically attached to the outer contact 40, or each can be integrally formed with the outer contact. By using a plurality of tabs 42, a plurality of coaxial ground contact points are provided, improving the shielding effect of the conductor. The shielding effect is also improved in an overall uniform and / or continuous manner of all or part of the outer contact 40, for example, in a continuous manner of the first end 23 of the outer conductor 22.

[0016] The outer contact 40 includes at least one elastic element such as one or more springs 44 formed integrally with or attached to the outer contact 40. In the illustrated embodiment, the spring 44 defines an elastic arm extending from an end of the outer contact 40. Each of the springs 44 can curve near a first end fixed to the outer contact 40. The remaining portion 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 can be formed or curved to extend radially outward from the outer contact 40 and defines a contact surface configured (i.e., sized and positioned) to abut one or more radially extending protrusions 24. More specifically, each of the radially extending protrusions 24 of the outer conductor 22 defines a bearing surface or pressing surface against which the free end of each respective spring 44 can act in the assembled state of the connector 20. In this way, the spring 44 acts to urge or bias the outer contact 40 away from the outer conductor 22, thereby applying a pressing force to the corresponding contact of the PCB 50 via the tab 42 to ensure reliable electrical contact and low resistance or impedance, and to allow for some variation in the axial position of the PCB with respect to the connector without adversely affecting the electrical contact between the connector and the PCB. In one embodiment, the outer contact 40 includes three springs 44, which are arranged 120 degrees apart from each other around the outer contact so as to evenly distribute the force and are staggered radially with respect to the tab 42. In yet other embodiments, the spring 44 can also 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 can be embodied as an elastic arm, but other types of elastic elements may be used without departing from the scope of the present disclosure. For example, FIG. 7 shows a connector having a single coil spring 80 disposed on the outer contact 40. In the present embodiment, the lateral or radial dimensions of the radially extending bearing surface 24 of the intermediate portion of the conductor 22 are reduced to save space and improve the device packaging, yet sufficient compressive force and axial float capability that are evenly distributed can be provided. In the present embodiment, the end of the coil spring 80 proximate to the PCB 50 can be supported and / or captured by the concave surface of the contact tab 42 facing the PCB.

[0018] Referring particularly to the exploded view of FIG. 3, the outer conductor 22 is hollow and receives the central contact or conductor assembly 30 of the connector 20. In one embodiment, the central contact assembly 30 includes a conductive spring pin or “pogo” pin including a male pin 32 attached to the body 34 at a first end. The body 34 is configured to receive a spring 36 or other elastic element and a second movable end of the assembly, embodied as a plunger 38 or a second pin. The plunger 38 is movably disposed within the body 34 and is biased by the spring 36 in a direction opposite 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 a second end 26. The central contact assembly 30 can be housed in a dielectric 39 to insulate the assembly from the outer conductor defined by the outer conductor 22 and the outer contact 40. FIG. 4 is an exploded assembly view of the connector 20 of FIGS. 2 and 3 prior to installation in a housing.

[0019] Figures 5A-5C show the lateral or radial floating function of the connector 20 and the PCB 50 according to an embodiment of the present disclosure. For clarity, most of the parts of the connector have been removed. As shown, the PCB 50 includes two electrical contacts or contact pads, namely, a signal or center contact 52 and a ground or outer contact 54. The center contact 52 and the outer contact 54 are configured to be electrically connected to the second movable end or plunger 38 of the center contact assembly 30 and the tab 42 of the outer contact 40 of the connector 20, respectively. The center contact 52 is defined as a circular conductive contact pad formed on the PCB 50, and this contact pad has larger dimensions (e.g., diameter in the case of a circular pad) in all respects compared to the opposing contact surface of the plunger 38. Therefore, due to a lateral or radial misalignment of the connector 20 with respect to the PCB 50, the center conductor cannot fail to make proper electrical contact with the center contact 52. In one exemplary non-limiting embodiment, the second end or plunger 38 of the center contact assembly 30 and the center contact 52 are sized to accommodate an axial or lateral displacement of at least 1 mm in any direction from the ideal position shown in FIG. 5A. In some embodiments, the minimum dimension of the center contact 52 in any direction in the same plane as the contact surface of the PCB 50 is about two to three times larger than the maximum dimension of the contact end of the center contact assembly 30 (e.g., the contact surface of the plunger 38).

[0020] Similarly, the second or outer contact 54 can have an arcuate pad shape. In one embodiment, the contact 54 may have a continuous circular or ring-shaped outer profile, or may be embodied as a plurality of discrete contacts. However, in the illustrated embodiment, the contact 54 is partially circular or semi-circular and defines an arcuate outer profile that extends over at least 240 degrees with respect to an axis of curvature (e.g., an axis defined through the radial center of the central contact 52). In this way, the outer contact 54 is sized to ensure contact with at least two contact tabs 42, or preferably three contact tabs that are each uniformly spaced (e.g., approximately 120 degrees radially apart) around the end of the outer contact 40. In the illustrated embodiment, only two contact tabs 42 are formed on the outer contact 40 and are in contact with the contact 54, and there are no tabs in the gap defined between the ends of the second contact 54. The arcuate outer contact 54 can include a thickness or width in the plane of the PCB 50 that is as large as the thickness or width of the central contact 52, and is adapted to accommodate at least an equal amount of radial or lateral translational movement of the outer contact 40 with respect to the PCB 50 while maintaining electrical contact between the outer contact 40 and the PCB 50. FIGS. 5B and 5C show radial displacement in only two directions, but as is apparent from the figures, embodiments of the present disclosure can accommodate any lateral or radial displacement while maintaining electrical connectivity.

[0021] Figures 6A - 6C illustrate the axial or vertical floating function of the connector 20 and the PCB 50 according to an embodiment of the present disclosure. As shown, the connector 20 can accommodate for the axial misalignment of the PCB as shown in Figures 6B and 6C with respect to the ideal position shown in Figure 6A. As shown in Figure 6A, when the first housing 12 and the second housing (14, not shown) are attached to each other, the PCB 50 abuts against the contact tabs 42 of the outer contacts 40 due to the compressive force generated by the spring 44. In the illustrated position, the second movable end or plunger 38 of the center contact assembly 30 is also disposed at a substantially intermediate position with respect to the remainder of the assembly and can still move freely in either axial direction. Similarly, the outer contacts 40 are disposed at an intermediate position along the length of the second end 26 of the outer conductor 22, and the second end 26 is positioned at a nominal distance A from the PCB 50. The spring tension applied to the outer contacts 40 ensures reliable electrical contact with the PCB 50 and accommodates for unevenness on the surface of the PCB (e.g., deviations from an ideal planar profile and other surface variations).

[0022] As shown in Figure 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 the pressure applied by the spring 44 that biases the outer contacts towards the PCB along the second end 26 of the outer conductor 22. In the exemplary illustrated position, the second end 26 is disposed at a maximum distance B from the PCB 50. As shown, when the outer contact 40 moves downward, the free end of the spring 44 slides radially inward at the protrusion 24. However, since the spring remains in contact with the protrusion 24 of the outer conductor 22, it continues to apply a compressive force to the outer contact 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 of the PCB 50.

[0023] Similarly, FIG. 6C shows that the distance between the PCB 50 and the connector 20 is shortened, and the plunger 38 is further pushed into the connector 20. As shown in the figure, when the outer contact 40 is further pressed against the second end portion 26 of the outer conductor 22, the free end of the spring 44 extends further radially outward compared to the position in FIG. 6A or FIG. 6B. In this way, the second end portion 26 of the outer conductor 22 can be biased to a position corresponding to the minimum distance C with respect to the PCB 50.

[0024] In each of the illustrated situations, despite such changes in the axial and / or radial positions, electrical contact with the PCB is maintained. Thus, it is possible to accommodate manufacturing or assembly defects that affect the relative positions of the above components while maintaining a high-performance electrical connection.

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

[0026] As shown in FIG. 8, according to a prior art connector without the illustrated inner seal or bushing 25, until the connector reaches the fully mated position, the front end portion 139 of the dielectric 39 of the connector 20 and the opposing front end portion 94 of the dielectric 92 of the mating connector 90 are biased towards each other. To ensure that these dielectrics do not contact each other before the connector is fully mated, the prior art connector must be sized so that there is a gap between the opposing front end portions 139, 94 of the dielectrics at the fully mated position. Specifically, the manufacturing tolerances and assembly tolerances of the components can vary the final positions of both dielectrics 39, 92 along the illustrated axial or insertion direction I significantly. Therefore, in order to ensure that there is no unintentional interference between these components, providing a gap prevents the connector from achieving a fully mated state. However, it should be understood that the need for a gap between these insulating dielectrics degrades the RF signal performance due to the change in impedance caused by the change in dielectric constant moving axially between the connectors.

[0027] According to an embodiment of the present disclosure, the exemplary inner bushing 25 of the connector 20 is adapted to improve such drawbacks by effectively joining the front faces 139, 94 of the dielectrics without preventing the connector from achieving a fully mated state or position. More specifically, in the exemplary embodiment, the inner bushing 25 includes an elastic bushing mounted inside the outer conductor 22 (see also FIG. 3). An annular rib 122 protruding within the outer conductor 22 engages a corresponding annular slot 125 defined around the bushing 25, thereby holding the bushing 25 against axial movement within the outer conductor 22.

[0028] At the mating position shown in FIG. 8, the front end portion 139 of the dielectric 39 abuts against the first side of the bushing 25, and the front end portion 94 of the dielectric 92 abuts against the second side of the bushing 25 so as to be compressed. Due to the elasticity of the bushing 25, the bushing accommodates the above-described position changes or dimensional changes that affect the final axial positions of the respective connectors 20, 90 in the mated state. Specifically, the bushing 25 is adapted to compress or expand as necessary while maintaining contact with the respective dielectrics 39, 92 so that the connectors can establish a fully mated position. The bushing 25 can preferably be composed of silicon or other suitable material having a dielectric constant equal to or similar to (e.g., within 10%, or more preferably within 5%) the dielectric constants of the dielectrics 39, 92. In this way, since the connectors define a continuous and unbroken dielectric insulating surface along the central conductive path, the signal impedance is standardized and the overall RF performance of the connectors is improved compared to the above-described prior art arrangements.

Claims

1. A connector assembly (20), comprising: an outer conductor (22) having a first end portion (23) configured to fit into a corresponding electrical connector; a conductive center contact (30) disposed within the outer conductor (22), the conductive center contact including a first end portion (32) configured to fit into the corresponding electrical connector and a second end portion (38) configured to be electrically connected to a first electrical contact (52) of a circuit board (50); an outer contact (40) slidably connected to a second end portion (26) of the outer conductor (22) and configured to be electrically connected to a second electrical contact (54) of the circuit board (50); an elastic element (44) configured to bias the outer contact in a direction away from the outer conductor (22). The outer conductor (22) includes a bearing surface (24) extending radially from the outer conductor (22) and configured to slidably engage the elastic element (44). The elastic element (44) includes a spring disposed between the outer conductor (22) and the outer contact (40). The spring (44) includes an elastic arm fixedly connected to the outer contact (40) at a first end portion and a second end portion slidably connected to the outer conductor (22). A connector assembly.

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

3. The connector assembly (20) according to claim 1, wherein the outer conductor (22) includes the bearing surface (24) extending radially from the outer conductor (22) and configured to slidably engage the second end portion of the elastic arm (44).

4. The connector assembly (20) according to claim 3, further comprising a plurality of elastic arms (44) each having a first end portion disposed radially around the outer contact and a second end portion engaging the bearing surface (24) of the outer conductor (22), wherein the bearing surface (24) is disposed radially around the outer conductor (22).

5. Further comprising a circuit board (50), The circuit board (50) is, 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) according to claim 1, comprising.

6. The first contact (52) has an overall circular shape having a diameter larger than the diameter of the second end (38) of the conductive center contact (30). The connector assembly (20) according to claim 5.

7. The second contact (54) at least partially surrounds the first contact (52). The connector assembly (20) according to claim 5.

8. The second contact (54) has an arc shape extending over an arc length of at least 240 degrees with respect to the axis of curvature of the second contact. The connector assembly (20) according to claim 7.

9. Further comprising a housing (12, 14), The housing (12, 14) is, 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 circuit board (50) is fixedly attached to the second housing portion (14). The connector assembly (20) according to claim 5.

10. The corresponding electrical connector is a coaxial high-frequency connector. The connector assembly (20) according to claim 1.

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