WO2008016329A1

WO2008016329A1 - Electrical connector

Info

Publication number: WO2008016329A1
Application number: PCT/SG2006/000221
Authority: WO
Inventors: Lothar Berghoff
Original assignee: LOGICOM INDUSTRIAL HOLDING Pte Ltd
Current assignee: LOGICOM INDUSTRIAL HOLDING Pte Ltd
Priority date: 2006-08-03
Filing date: 2006-08-03
Publication date: 2008-02-07
Anticipated expiration: 2009-02-03
Also published as: TW200818612A

Abstract

An electrical connector having an insulative housing having two opposing side walls and two opposing end walls, wherein the side walls and end walls each have an inner surface that defines a slot capable of receiving a complementary electrical connector. The electrical connector also includes a plurality of conductive terminals arranged, in a spaced-apart relationship along the length of each side wall. Each conductive terminal includes a tail-end section that extends outwards from a base region of the slot and a contact section that creates a contact surface, wherein the tail-end section and contact section are integrally formed. The contact section has a first sub-section and a second sub-section such that the first sub-section is in between the tail-end section and second sub-section, and contacts and extends at least substantially vertically along the height of the side wall in a first direction. The second sub-section is bent into the slot such that a generally U-shaped flexural spring is defined by the first and second sub-sections, and extends at least substantially vertically along the height of the inner surface of the side wall in a second direction, said second direction being substantially opposite to the first.

Description

ELECTRICAL CONNECTOR

DESCRIPTION

[0001] The following invention relates to the field of electrical connectors for electrically connecting printed circuit boards (PCBs); in particular, to an electrical connector that is durable, provides a reliable electrical connection and prevents solder wicking.

[0002] Electrical connectors are used in a variety of applications and typically, provide an electrical connection between two printed circuit boards (PCBs). One example of electrical connectors commonly used is known as a board to board connector. A typical board to board connector includes two components, a male connector and a female connector, each connector being mounted on the respective boards to be electrically connected to together. The male and female connectors are designed such that one engages the other (and vice versa) during insertion. Although the male connector is typically inserted into the female connector, the reverse may also be applicable.

[0003] The female connector usually includes a housing having a slot in which the male connector mates with, typically via insertion. In addition to the slot, the female connector includes a plurality of conductive terminals. The conductive terminals electrically connect the PCB, on which the female connector is mounted on, to the male connector, and therefore, to the corresponding PCB on which the male connector is mounted on. The plurality of conductive terminals, in the case of the female connector, is typically arranged on either side and distributed along a substantial length of the slot. The spacing between each successive conductive terminal is known as the pitch, or terminal to terminal spacing.

[0004] Each conductive terminal typically includes a tail section and a contact section. The tail section of the terminal connects the connector, both electrically and physically, to its respective PCB mount. The contact section on the other hand, establishes the electrical and physical connection between the female connector and the inserted male connector. The tail section is typically fixed to the PCB by solder. The above-mentioned technical features of the terminals and housing described with respect to the female connector also apply to the male connector with the exception that the design of the male connector is such that it is complementary to the slot of the female connector.

[0005] In earlier types of connectors, the terminals were typically inserted into pre-formed openings in the housing, via press-fitting, for example. Press-fitting is used to fix the conductive terminals into a connector. However, a drawback of press-fitting is that it is tedious to press fit multiple conductive terminals into each connector especially as the numbers of terminals being included into a single connector is ever increasing (i.e. an ever decreasing pitch). A further drawback is that in order to insert the conductive terminals, a housing must be designed with 'adequate spacing' to allow for the accurate insertion and press-fitting of the terminal. This 'adequate spacing' is typically in the form of a through-hole into which the terminals are inserted. Subsequently, the connectors are soldered onto their respective PCBs via the tail sections of the inserted terminals. However, having a through-hole allows for solder wicking to take place. Solder wicking is the creeping up of the solder alloy along the tail section of the terminal and up to the contact section. The occurrence of solder wicking causes damage to the housing and possibly also creates short circuits within the connector.

[0006] In order to overcome the problem of solder wicking, insert molding of the terminals during production of the housing has been widely adopted. As described in U.S. patent 6,010,370, in insert molding, a group of terminals is first stamped from thin metal stock and set within a mold at a pitch as determined by the mold design. The mold is then closed and the molding material enters to form the housing with the conductive terminals embedded therein. This results in a connector where, although the terminal remains as a single piece, the tail section is considered to be separated from the contact section (i.e. no gaps or through-holes) via the molding material that forms the housing Accordingly, the solder alloy is prevented from creeping up along the conductive terminal. [0007] U.S. patent 6,010,370 discloses an electrical connector fabricated via insert-molding having a housing, said housing having a pair of side walls and end walls to define a groove. A plurality of contact terminals are mounted within each housing, each terminal having a solder section and a contact section and a housing engagement section. The solder section extends out of the bottom of the housing for connection to a PCB. The contact portion, which follows the solder portion, is aligned vertically upwards and extends from the bottom, along the height of the inner surface of the sidewall, and terminates with the housing engagement section. The housing engagement section is secured to the top of the sidewall and secures the terminal in position.

[0008] U.S. patent 6,155,886 also discloses an electrical connector manufactured by insert-molding. The electrical connector described in this U.S. patent includes an insulative housing having an elongate groove extending along a substantial length of the housing. Also along the length of an upper portion of the groove is a plurality of holes, each adapted to receive a terminal. Each terminal has a tail section, an end section and a contact section therebetween. The tail section protrudes from the bottom of the housing while the contact section is aligned along an inner wall of the groove. Each hole accommodates the end section of the terminal such that said end portion protrudes vertically upwards and away from the contact section.

[0009] European patent EP 0 693 802 B1 also discloses an insert-molded connector. This connector has a housing which has a longitudinal slot. The slot extends substantially along the length of the housing and extends to the base of the housing. As in the U.S. patent 6,155,886, the connector also includes terminals arranged in parallel along the length of the slot, each having a tail section, an end section and a contact section therebetween. The tail section extends from a lower portion of the housing for attachment to a PCB, while the contact section is arranged to be exposed along the longitudinal inner wall of the slot. As mentioned, the contact section terminates with the end section, where said end section is bent to be substantially convex and into a recess located at an upper portion of the slot. [0010] Although insert-molding overcomes the problem of solder wicking, it raises another problem of ensuring that the insert-molded terminals within a housing are suitably secured such that they remain durable and are not subject to deformation, or peel-off when a force is applied to them. Instances of deformation and peel-off may take place over time with the insertion and removal of a male connector from the slot of a female connector.

[0011] As such, there is still a need for an electrical connector that includes terminals that are securely fastened therein and is capable of withstanding deformation or peel-off during use. In addition, there is also a need for such a connector to be cost effective to produce. In this respect, an electrical connector as defined in the appended claims is capable of overcoming the above- mentioned difficulties.

[0012] One embodiment of the electrical connector of the present invention includes an insulative housing. The insulative housing has two opposing side walls and two opposing end walls wherein the side walls and end walls each have an inner surface. The arrangement of the side walls and end walls is such that they define a slot. The slot is capable of receiving a complementary electrical connector. Accordingly, electrical connectors having a slot are typically also known as female electrical connectors.

[0013] The female electrical connector also includes a plurality of conductive terminals. The conductive terminals are arranged in a spaced-apart relationship along the length of each side wall. The spaced apart relationship is also known as the pitch and is typically less than 1.0mm. While it is also possible to have a pitch greater than 1.0mm, the present trend in the industry appears to be heading towards smaller pitches. In any case, the conductive terminals of any embodiment of the present invention are not excluded from having a pitch of

1.0mm or greater. [0014] Each conductive terminal includes a tail-end section and a contact section, wherein the tail-end section and the contact section are both integrally formed as a single piece. The tail-end section extends outwards from a base region of the slot for affixation to a circuit board. The contact section creates a contact surface between the electrical connector and its complementary electrical connector and includes a first sub-section and a second sub-section.

[0015] The first sub-section is located in between the tail-end section and second sub-section. The first sub-section at least contacts the side wall and extends at least substantially vertically upwards through the base of the housing of the female connector, along the height of the side wall in a first direction. The second sub-section is bent towards or into the slot such that a generally U- shaped flexural spring is defined by the first and second sub-sections or more specifically, by the bend of the first and second sub-sections. In other words, one arm of the U-shape is formed by the first sub-section and the other arm is formed by the second sub-portion. The middle portion of the U-shape may be formed entirely by either the first sub-section, second sub-section or a combination thereof. The second sub-section (which forms one arm of the U-shaped flexural spring) further extends at least substantially vertically downwards along the height of the inner surface of the side wall, in a second direction and terminates with a free end. The second direction is one taken to be substantially opposite to the first.

[0016] In one embodiment of the female connector of the invention, the first sub-section of each of the plurality of conductive terminals is embedded within the side walls. This is typically achieved via an insert-molding process, which will be described in detail later on. In this embodiment, the first sub-section extends substantially along the height of the side wall such that it is at least substantially coplanar to the side wall. In this embodiment, the second sub-section tends to be adjacent or in contact with the inner surface of the side wall after being bent into the slot, over the top lateral surface of the side wall. [0017] In an alternative embodiment of the female connector, the first subsection of each of the plurality of conductive terminals is formed in abutment to the side walls. In this embodiment, the first sub-section extends along the height of the inner surface of the side wall and is also at least substantially parallel to the height of the side wall. The first sub-section may adhere to the inner surface of the side wall or it may just be in contact but not affixed thereto. Although the first sub-section is not embedded within the side wall, it may still be formed via insert-molding as long as at least the tail-end section of the conductive terminal is insert-molded within a region of the side wall near the base of the slot, for example. In this embodiment, the second sub-section, after being bent to form the generally U-shaped flexural spring, tends to be adjacent or even in contact with the first sub-section as the second sub-section extends downwards towards the base of the slot.

[0018] Generally, the U-shaped flexural spring formed by the first and second sub-sections of the contact section allows the second sub-section to flex between a compressed state and a released state. The compressed state is attained when the complementary electrical connector is inserted into the slot of the electrical connector. Accordingly, the default state of the second sub-section is in a released state. In the embodiment of the female connector where the first sub-section is embedded within the wall, the compressed state typically results in the second sub-section being nearer, or even in contact with the inner surface of the side wall. The released state of the second sub-section in this embodiment is therefore at least slightly adrift of the inner surface of the side wall of the slot although portions of the second sub-section may still retain contact with the inner surface of the side wall.

[0019] In the embodiment of the female connector where the first sub-section is in abutment with the inner surface of the side wall, the compressed state of the second sub-section, as above, tends to be nearer to the inner surface of the side wall, but not contacting it. Instead, the second sub-section, in one exemplary embodiment, may contact the first sub-section when in a compressed state. In another exemplary embodiment, second sub-section may flex such that it is nearer to the inner surface of the side wall but does not contact the first subsection. Accordingly, the compressed state of the second sub-section may also vary between the above-mentioned examples, if said examples are taken to be the limits between which the compressed and released states are defined.

[0020] In another embodiment of a female connector, the inner surfaces of the side walls include a plurality of recesses or grooves adapted to accommodate and/or engage the bent second sub-section of the plurality of conductive terminals. The recesses may, for example be tapered or saw-tooth in design. This is to assist and provide guiding means when the second sub-section is bent into the slot. Alternatively, and with regard to the embodiment where the first sub-section abuts the side wall, the recesses may be adapted to accommodate and/or engage either the first sub-section, second sub-section or both the first and second subsection therein.

[0021] In one embodiment of the female connector, the base of the slot may also include a pair of grooves (i.e. two). Each groove typically extends along the length of the slot and is located adjacent to the side walls. The grooves are adapted to secure the free end of the bent second sub-section therein. Alternatively, the base of the slot may have a plurality of recesses designed to accommodate therein the free end of the second sub-section of the conductive terminal. As with the grooves, the plurality of recesses may typically span the length of the slot.

[0022] As mentioned above, each conductive terminal includes a tail-end section. Generally, in all embodiments described herein, the tail-end section extends outwards from the base region of the slot, i.e. from the area under the slot or around the areas of the side wall substantially near the base of the slot. In one exemplary embodiment, the tail-end section may extend from the base of the slot either parallel to the side wall or perpendicular thereto. In an alternative exemplary embodiment, the tail-end section may extend outwards from the base of the side wall and in a direction substantially perpendicular to said side wall, i.e. substantially parallel to the plane of the base. [0023] Although the electrical connector, especially the arrangement and forming of the conductive terminals, is presently described with regard to one side wall in certain aspects, it is to be taken that each of the plurality of conductive terminals on a first side wall has a corresponding conductive terminal on a second side wall, and said corresponding conductive terminal being orientated as a mirror image thereof. Accordingly, the same description applies to all aspects of the invention for the second side wall and to the corresponding conductive terminals present there.

[0024] The female electrical connector, as described above, has a complementary electrical connector known as a male electrical connector, which is described here below. The male electrical connector includes an insulative mating portion having a top surface and at least two mating surfaces adapted to mate with the slot of the female electrical connector. The mating surfaces are typically substantially perpendicular to the top surface. The male electrical connector also includes a plurality of conductive terminals. The conductive terminals are arranged in a spaced-apart relationship along each of the mating surfaces and correspond to an arrangement of conductive terminals in the slot of the female electrical connector.

[0025] The arrangement of conductive terminals in the male connector is such that each conductive terminal along the length of the mating surfaces at least contacts its corresponding conductive terminal (of the female electrical connector) when the mating portion mates with the slot of the female electrical connector. In other words, the pitch of the male connector corresponds to the pitch of the conductive terminals in the female connector

[0026] Each of the plurality of conductive terminals of the mating portion includes a tail-end section and a contact section, both integrally formed. The tail- end section extends outwards from the top surface region for affixation to a circuit board. The contact section has a first sub-section and a second subsection such that the first sub-section is located in between the tail-end section and second sub-section. The contact section creates a contact surface between the electrical connector and the slot.

[0027] The first sub-section contacts and extends at least substantially vertically in a first direction along the height of the mating surfaces and away from the top section; and the second sub-section is bent in a manner, at least substantially transverse to the length of the mating surfaces. This results in a generally U- shaped flexural spring being defined by the first and second sub-sections. The second sub-section also extends at least substantially vertically in a second direction opposite to the first, and along the height of the mating portion to terminate with a free end.

[0028] The tail-end section typically extends outwards from the top surface region (either directly from the top surface of from areas of the mating surfaces substantially near the top surface) of the mating portion in a similar fashion as the tail-end section associated with the female connector. In one exemplary embodiment, the tail-end section of the male connector may extend from the top surface. In another exemplary embodiment, the tail-end section may extend from the mating surfaces in a direction substantially perpendicular to said mating surfaces, i.e. parallel to the plane of the top surface.

[0029] In one embodiment of the male connector, the first sub-section is embedded within the mating portion. In this embodiment, the first sub-section extends at least substantially vertically in a first direction from the top surface along the height of the mating portion or mating surfaces.

[0030] In an alternative embodiment of the male connector, the first sub-section of each of the plurality of conductive terminals is formed in abutment to the mating portion. In this alternative embodiment, the first sub-section extends at least substantially vertically from the top surface in a first direction, and along the height of the mating portion or mating surfaces. connec or o , e genera -sna c flexural spring-like portion allows the second sub-section to flex between a compressed state and a released state. The compressed state and released state for the male connector are also defined similarly as that for the female connector above.

[0032] In one embodiment of the invnetion, the mating portion of the male connector may also include a plurality of recesses or grooves. The recesses or grooves may be located along each of the mating surfaces and are adapted to accommodate and/or engage each of the bent second sub-sections of the plurality of conductive terminals.

[0033] In all the above-mentioned embodiments of either the male or female connector, the insulative housing, insulative mating portion and conductive terminals may be fabricated from any suitable material. Examples of such suitable materials for fabricating the insulative housing and insulative mating portion include, but are not limited to, plastic, hard rubber and composites thereof. Examples of suitable materials for fabricating the conductive terminals include, but are not limited to, alloys such as nickel-plated phosphor bronze, mild steel or nickel-plated beryllium copper. A layer of gold (Au) may also be deposited on the conductive terminals to improve their conductivity.

[0034] In order to aid in the better understanding of the electrical connector of the present invention, said invention is further described below with reference to the following figures, in which:

[0035] Figure 1 shows a perspective view of an exemplary embodiment of the present invention;

0036] Figures 2A - 2C show a cross-sectional view about the line X-X of the smbodiment of Figure 1 and a method of fabrication of the exemplary mbodiment of Figure 1 ; [0037] Figures 3A - 3C show method of fabrication of an exemplary embodiment of a male interconnector according to the present invention;

[0038] Figures 4A - 4B show an assembly of the exemplary embodiments of Figure 2 and Figure 3;

[0039] Figure 5A shows an embodiment of a terminal housing;

[0040] Figure 5B shows a further embodiment of a terminal housing;

[0041] Figure 6 shows a carrier strip with a plurality of conductive terminals; and

[0042] Figures 7A - 7B show a top view and a cross-sectional view about the line Y-Y of an exemplary embodiment of the invention, respectively.

[0043] Figure 1 shows a perspective view of an exemplary embodiment of the invention. This exemplary embodiment is a female connector having a pair of side walls 17 and a pair of end walls 3, which in combination with each other, define a housing 1 and a slot 7. The slot 7 is adapted to receive a complementary connector (not shown). A plurality of conductive terminals is arranged in a spaced apart relationship along the length of each side wall 7.

[0044] Each conductive terminal includes a contact section 19 and a tail-end section 11. In this exemplary embodiment, the conductive terminals are insert- molded within the side walls 17 of the housing such that the tail-end section 11 extends outwards, in a perpendicular direction, from the base of the side wall 17. The contact section of the conductive terminal extends vertically along the height of the side wall 17 and protrudes from the top lateral surface of the side wall 17. The protruding portion of the contact section is then bent into the slot 7 such that a substantially U-shaped flexural spring is formed. The substantially U-shaped flexural spring will be discussed later in greater detail. The protruding portion of the contact section bent into the slot 7 terminates with a free end which is received into a recess 9 in the base of the slot 7.

[0045] Figures 2A - 2C show a cross-section (about the line X-X of Figure 1) of the exemplary embodiment of a female interconnector according to Figure 1. From the cross-sectional view, the connector (female) has a housing which includes a pair of side walls 17 and a pair of end walls (not shown). The side walls 17 define a slot therebetween, along with a base 11 , which is adapted to accommodate a complementary electrical connector, i.e. a male connector. The electrical connector also includes a plurality of conductive terminals, each of which comprise a tail-end section 11 and a contact section 19 (for the sake of clarity only a pair of conductive terminals is illustrated here). The contact section 19 is made up of a first sub-section 13 and a second sub-section 15.

[0046] The tail-end section 11 of the conductive terminal extends perpendicularly through the lower region of the side wall 17. Alternatively, the tail-end may extend directly downwards such that it extends perpendicularly from the base (not shown). The tail section is principally used to secure the female connector to its respective PCB via soldering, for example. In this exemplary embodiment, the first sub-section 13 may be considered to begin at the point at which the conductive terminal extends vertically upwards, along the height of the side wall 17. The second sub-section 15 may be considered to begin at the point when the contact section 19 is no longer embedded within the side wall 17.

It is important to note that the tail-end section 11 and contact section 19 are a single part. Figure 2A shows the connector at a point in the manufacturing process just after the conductive terminals have been insert-molded within the housing. Details pertaining to the manufacturing process will be described below in Figure 5A and 5B.

[0047] In the fabrication of a female electrical connector according to the invention, the second sub-section 15 is bent into the slot such that a generally U- shaped flexural spring 12 is defined by both the first and second sub-sections 13, 15. The bending, and therefore definition of the generally U-shaped flexural spring 12, is achieved in two steps. The first step is when the second sub-section 15 is bent at about ninety degrees such that it is at least substantially parallel to the base of the slot, as shown in Figure 2B.

[0048] It should be noted that in this, and subsequent embodiments, the conductive terminals are typically chamfered or rounded at the portions that undergo bending, even if this is not clearly illustrated in the attached drawings.

[0049] The second step involves the bending of the second sub-section 15 in the directions indicated by the arrows, i.e. about a further ninety degrees as shown in Figure 1B, such that the U-shape is completed. However, given the nature of the flexural spring, the second sub-section does not typically contact the side wall 17. Rather, it flexes outwards at an angle theta (θ) and is held in place by recess 9. As shown in Figure 2C, one arm of the U-shape is formed by the first sub-section 13 and the other arm by the second sub-section 15. The middle portion of the U-shape may be defined by portions of the first sub subsection 13, by the second sub-section 15, or combination of thereof with the second sub-section 15 terminating with a free end, which as mentioned, is received into groove 9.

[0050] Figures 3A - 3C show a method of fabrication of an exemplary embodiment of a male interconnector according to the present invention. The male connector includes an insulative mating portion having a top surface 27 and at least two mating surfaces 28. The mating surfaces 28 of the mating portion are adapted to mate with the slot of a complementary electrical connector, such as that shown in Figure 2, for example. As in the female connector, the male connector also includes a plurality of conductive terminals.

[0051] Similarly, each of the plurality of conductive terminals of the mating portion include a tail-end section 21 that extends outwards from the top surface region for affixation to a circuit board and a contact section 29 having a first subsection 23 and a second sub-section 25. The first sub-section 23 is in between the tail-end section 21 and second sub-section 25. As in the female connector of Figure 2, the contact section 29 and tail-end section 21 of the conductive terminal are integrally formed as a single part.

[0052] The first sub-section 23 contacts and extends at least substantially vertically in a first direction (downwards, towards the lower end of the mating portion) along the height of the mating surfaces 28 and away from the top section. The formation of the complementary electrical connector for the female connector of Figure 2 is achieved via a two-step manipulation of the second sub-section 25 where the second sub-section is bent in a convex manner.

[0053] In a first step, the second sub-section 25 is bent about ninety degrees as indicated by the arrows to contact the mating surfaces 28 transversely. Figure 3B shows that the second sub-section 25 is substantially parallel to the top surface of the mating portion, i.e. substantially perpendicular to the first subsection 23. In a second step, the second sub-section 25 is further bent about ninety degrees such that is forms a generally U-shaped flexural spring. Similar to the flexural spring of the female connector of Figure 2, the second sub-section 25 also does not adhere to the mating surface 28, but rather, extends outwards by an angle phi (Φ) as shown. The U-shaped flexural spring is defined by the first and second sub-sections. As shown in Figure 3C, one arm of the U-shape is formed by the first sub-section 23 and the other arm by the second subsection 25. The middle portion of the U-shape 22 may be formed by portions of the first sub sub-section 23, portions of the second sub-section 25, or any combinations thereof, with the second sub-section 25 terminating with a free end.

[0054] Figures 4A - 4B show an assembly of a male and female interconnector of exemplary embodiments of Figure 2 and Figure 3. Typically, the tail-end sections 11 and 21 of the respective electrical connectors are soldered onto PCBs. During the soldering process, solder has a tendency to creep up along the tail and if permitted, into the housing and up to the contact section 19 and 29. In the present invention, as insert molding is utilized, the creep of the solder is prevented by the housing (side walls 17 and mating surfaces 27 and 28) of the respective electrical connectors.

[0055] Once the complementary electrical connectors are affixed to their respective PCBs, they may be mated together to electrically connect the two

PCBs together. Mating takes place by the simple insertion of the male electrical connector (mating portion) 33 into the slot of the female electrical connector 31 as shown in Figure 4A. To ensure a secure fit, the end walls 3 of the female connector may include a locking mechanism. The locking mechanism may have a simple under-cut designed to receive and hold the male connector in place.

Essentially, this results in a snap-fit mechanism between the male and female connectors.

[0056] Apart from the snap-fit means mentioned above, an additional means of securing the male and female connectors together is provided by the opposing spring forces. A spring force is exerted by the second sub-section 15 of the contact section on the second sub-section 25 of the male connector and vice versa. Thus, both the second sub-sections 15 and 25 are pressing against each other to enhance the connectivity and secure fitting of the male and female connector.

[0057] Once securely mated 35, the second sub-sections 15 and 25 of the respective electrical connectors are in physical (and therefore electrical contact) with each other. In an alternative embodiment, it may also be possible for the tail-end section 21 of the male connector to contact the middle portion 12 of the of the U-shaped flexural spring of the female connector, such that two points of contact are established further improving any electrical connectivity therebetween.

[0058] Figure 5A shows an exemplary embodiment of a housing and Figure 5B shows the housing of the exemplary embodiment of Figure 1. In the embodiment of the housing, as shown in Figure 5A, the housing may include, due to the insert-molding process, a plurality of openings 43 in which the first sub-section 13 is embedded in. Additionally, the housing may also include a plurality of recesses 41 along the length of the slot to accommodate the second sub-section 15 when it is bent into the slot. Upon being bent into the slot, the free end of the second sub-section is engaged by a groove 44 extending along the length of the slot, and adjacent to either side wall 17.

[0059] The housing shown in Figure 5B is essentially the same as that of Figure 5A with the exception that the base 49 of the slot formed by the side walls 17 and end walls 3 includes a plurality of cavities 48 instead of a groove as in Figure 5A. Each cavity 48 is adapted to engage the free end of the second sub-section of the conductive terminal when it is bent into the slot as previously described.

[0060] Figure 6 shows a carrier strip with a plurality of conductive terminals. The conductive terminals are stamped and formed from stock metal sheets. As such, the conductive terminals, prior to insert-molding, are each formed to have a tail-end section 47, and contact sections made up of a first sub-section 46 and a second sub-section 45. The various sections and sub-sections of the conductive terminal are formed as a single integral part as shown in Figure 6 and may be mounted symmetrically onto either side of a carrier strip 48. In general, the shape of the conductive terminal prior to insert molding is substantially L-shaped.

The carrier strip 48 is used to position the conductive terminals such that when a suitable mold assembly, having an upper mold assembly and a lower mold assembly, is utilized, a housing, in the case of a female electrical connector, is formed around the conductive terminals, as illustrated in the exemplary embodiment of Figure 2. As mentioned earlier, the housing includes a pair of side walls 17, each bounded by a pair of end walls 3 at opposing ends thereof to form the slot having a base 49.

[0061] Figures 7A - 7B show a top view and a cross-sectional view about the line Y-Y of an exemplary embodiment of the invention, respectively. Figure 6A is similar to Figure 5A except that it includes the conductive terminals which are insert-molded during the production of the housing, as described earlier. In Figure 6A, the housing is formed by the side walls 52 and end walls 59, which define the slot and the groove 58 along the length of the slot. The groove 58, in this exemplary embodiment, is defined between a base 54 and the respective side walls 52.

[0062] The conductive terminals each have a tail-end section 51 extending outwards, substantially perpendicular to the side wall 52 and a contact section (defined by first and second sub-sections 53 and 55) extending vertically upwards from the base of the housing, and along the height of the respective side walls 52. The second sub-section 55 is bent, as described in Figure 2B and 2C to form the generally U-shaped flexural spring.

[0063] The U-shaped flexural spring is defined by both the first and second subsections 53 and 55 respectively. One arm of the U-shape is formed by the first sub-section 53 and the other arm by the second sub-section 55. The middle portion of the U-shape 56 is formed by portions of the first sub sub-section 53 and substantially by portions of the second sub-section 55. The second sub- section 55 terminates with a free end that is engaged by the groove 58.

[0064] The above description of the invention in relation to the referenced drawings is meant to only aid in the understanding thereof. The present invention is not to be construed as being limited to the exemplary embodiments described above but rather, to the invention as defined in the appended claims that follow.

Claims

CLAIMSWhat is claimed is:

1. An electrical connector comprising: an insulative housing having two opposing side walls and two opposing end walls, wherein the side walls and end walls each have an inner surface, and together define a slot capable of receiving a complementary electrical connector; a plurality of conductive terminals arranged, in a spaced-apart relationship along the length of each side wall, each conductive terminal comprising: a tail-end section that extends outwards from a base region of the slot for affixation of the terminal to a circuit board; and a contact section, that creates a contact surface between the electrical connector and its complementary electrical connector, having, a first sub-section and a second sub-section such that the first sub-section is in between the tail-end section and the second sub-section, wherein the tail-end section and the contact section are integrally formed; wherein the first sub-section contacts and extends at least substantially vertically along the height of the side wall in a first direction; and wherein the second sub-section is bent into the slot such that a generally U-shaped flexural spring is defined by the first and second sub-sections, and wherein the second sub-section extends at least substantially vertically along the height of the inner surface of the side wall in a second direction, said second direction being substantially opposite to the first direction, and wherein the second sub-section terminates with a free end.

2. The electrical connector according to claim 1 , wherein the first subsection of each of the plurality of conductive terminals is embedded within the side walls, extends along the height of the side wall and is at least substantially coplanar to the side wall.

3. The electrical connector according to claim 1 , wherein the first subsection of each of the plurality of conductive terminals is formed in abutment to the side walls, extends along the height of the inner surface of the side wall and is at least substantially parallel to the side wall.

4. The electrical connector according to any of the preceding claims, wherein the generally U-shaped flexural spring allows the second subsection to flex between a compressed state and a released state.

5. The electrical connector according to claim 2, wherein each of the inner surfaces of the side walls comprises a plurality of recesses adapted to engage the bent second sub-section of the plurality of conductive terminals.

6. The electrical connector according to claim 3, wherein each of the inner surfaces of the side walls comprises a plurality of recesses adapted to engage the first sub-section and/or bent second sub-section of the plurality of conductive terminals.

7. The electrical connector according to any of the preceding claims, wherein the slot comprises a base with two grooves that extend along the length of the slot, and wherein each groove is adapted to secure the free end of the plurality of bent second sub-sections therein.

8. The electrical connector according to any of the preceding claims, wherein the slot comprises a plurality of recesses arranged in the spaced apart relationship along the length of the slot, and wherein each of the plurality of recesses is adapted to secure the free end of its corresponding bent second sub-section therein.

9. The electrical connector according to any of the preceding claims, wherein the tail-end section that extends outwards from the base region of the slot extends from the side walls in a direction substantially perpendicular to said side walls.

10. The electrical connector according to any of the preceding claims, wherein each of the plurality of conductive terminals on a first side wall has a corresponding conductive terminal on a second side wall, said corresponding conductive terminal being orientated as a mirror image thereof.

11.An electrical connector comprising: an insulative mating portion having a top surface and at least two mating surfaces substantially perpendicular to the top surface and adapted to mate with a slot of a complementary electrical connector; and a plurality of conductive terminals arranged in a spaced-apart relationship along the length of each of the mating surfaces to correspond to an arrangement of conductive terminals in the slot of the complementary electrical connector, such that each of the plurality of conductive terminals along the mating surfaces at least contacts its corresponding conductive terminal in the slot when the mating portion mates with the slot of the complementary electrical connector; each of the plurality of conductive terminals of the mating portion comprising: a tail-end section that extends outwards from the top surface region for affixation to a circuit board; and a contact section that creates a contact surface between the electrical connector and the slot, having a first sub-section and a second sub-section wherein the first sub-section is in between the tail-end section and second sub-section, said contact section and tail-end section being integrally formed; wherein the first sub-section contacts and extends at least substantially vertically along the height of the mating surfaces and away from the top section in a first direction; and wherein the second sub-section is bent at least substantially transverse to the length of the mating surfaces such that a generally U-shaped flexural spring is defined by the first and second sub-sections, and the second sub-section extends at least substantially vertically opposite to the first, and along the height of the mating portion in a second direction and terminates with a free end.

12. The electrical connector according to claim 11 , wherein the second sub-section is bent in a substantially concave or convex manner.

13. The electrical connector according to claim 11 , wherein the first subsection is embedded within the mating portion and extends at least substantially vertically from the top surface along the height of the mating portion in the first direction.

14. The electrical connector according to claim 11 , wherein the first subsection of each of the plurality of conductive terminals is formed in abutment to the mating surface, extends at least substantially vertically from the top surface, and along the height of the mating portion in the first direction.

15. The electrical connector according to any of claims 11 - 14, wherein the generally U-shaped flexural spring-like portion allows the second sub-section to flex between a compressed state and a released state.

16. The electrical connector according to any of claims 11 - 15, wherein each of the mating surfaces comprise a plurality of recesses adapted to engage each of the bent second sub-sections of the plurality of conductive terminals.

17. The electrical connector according to any of claims 11 - 16, wherein the tail-end section that extends outwards from the top surface region of the mating portion extends from the mating surfaces in a direction substantially perpendicular to said mating surfaces.

18. The electrical connector according to any of the preceding claims, wherein the insulative housing and insulative mating portion are fabricated from plastic, hard rubber or composites thereof.

19. The electrical connector according to any of the preceding claims, wherein the conductive terminals are fabricated from, mild steel, an alloy of nickel-plated phosphor bronze or nickel-plated beryllium copper.

20. The electrical connector according to any of the preceding claims, wherein each of the plurality of conductive terminals is separated from one another by a distance of less than 1.0mm.