CN101882718B - 电源触头及包括电源触头的连接器 - Google Patents

电源触头及包括电源触头的连接器 Download PDF

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CN101882718B
CN101882718B CN201010167655XA CN201010167655A CN101882718B CN 101882718 B CN101882718 B CN 101882718B CN 201010167655X A CN201010167655X A CN 201010167655XA CN 201010167655 A CN201010167655 A CN 201010167655A CN 101882718 B CN101882718 B CN 101882718B
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body member
power contact
plate shape
contact head
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克里斯托弗·G·戴利
威尔弗雷德·J·斯温
斯图尔特·C·斯托纳
克里斯托弗·J·克利沃斯基
道格拉斯·M·琼斯库
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/10—Sockets for co-operation with pins or blades
    • H01R13/11—Resilient sockets
    • H01R13/113—Resilient sockets co-operating with pins or blades having a rectangular transverse section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/28—Contacts for sliding cooperation with identically-shaped contact, e.g. for hermaphroditic coupling devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/70—Coupling devices
    • H01R12/71—Coupling devices for rigid printing circuits or like structures
    • H01R12/712—Coupling devices for rigid printing circuits or like structures co-operating with the surface of the printed circuit or with a coupling device exclusively provided on the surface of the printed circuit
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/70—Coupling devices
    • H01R12/71—Coupling devices for rigid printing circuits or like structures
    • H01R12/72—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures
    • H01R12/722—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures coupling devices mounted on the edge of the printed circuits
    • H01R12/724—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures coupling devices mounted on the edge of the printed circuits containing contact members forming a right angle
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/70—Coupling devices
    • H01R12/71—Coupling devices for rigid printing circuits or like structures
    • H01R12/72—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures
    • H01R12/722—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures coupling devices mounted on the edge of the printed circuits
    • H01R12/725—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures coupling devices mounted on the edge of the printed circuits containing contact members presenting a contact carrying strip, e.g. edge-like strip
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/70—Coupling devices
    • H01R12/71—Coupling devices for rigid printing circuits or like structures
    • H01R12/72—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures
    • H01R12/722—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures coupling devices mounted on the edge of the printed circuits
    • H01R12/727—Coupling devices presenting arrays of contacts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/70—Coupling devices
    • H01R12/71—Coupling devices for rigid printing circuits or like structures
    • H01R12/72—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures
    • H01R12/73—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures connecting to other rigid printed circuits or like structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/514—Bases; Cases composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them

Abstract

本发明提供了用于传输电力的电连接器和触头。一个电源触头实施例包括形成第一非偏转梁和第一可偏转梁的第一板以及形成第二非偏转梁和第二可偏转梁的第二板。第一板和第二板彼此并排设置以形成电源触头。

Description

电源触头及包括电源触头的连接器
本申请是2004年12月21日提交的申请号为“200480039373.4”(PCT/US2004/043222)的发明专利申请“电源触头及包括电源触头的连接器”的分案申请。
相关申请的交叉引用
本申请要求下列美国临时专利申请的优选权：2003年12月31日提交的No.60/533822、2003年12月31日提交的No.60/533749、2003年12月31日提交的No.60/533750、2004年1月7日提交的No.60/534809和2004年2月17日提交的No.60/545065，上述美国临时专利申请全部结合在此引作参考。
技术领域
本发明涉及设计和构造成用于输送电的电触头和连接器。至少一些优选的连接器实施例包括设置在壳体单元中的电源触头(powercontact)和信号触头这两者。
背景技术
电器件和系统设计人员在新型电连接器和电源触头的开发中会面临挑战性的因素。例如，增大的电力传输经常受到尺寸限制和不期望的热量聚积的挑战。此外，典型的电源连接器和触头梁结构可产生很大的配合力。当很大的配合力传递到连接器壳体结构中时，塑料可能蠕变，导致可能影响连接器机械和电性能的尺寸变化。本发明提供的独特的连接器和触头旨在平衡那些已经限制现有技术性能的结构因素。
发明内容
本发明提供用于电连接器中的电源触头。根据本发明的一个优选实施例，其提供了一种电源触头，所述电源触头包括第一板形本体构件，和层叠在第一板形本体构件上的第二板形本体构件，从而第一板形本体构件和第二板形本体构件沿着相对本体构件表面的至少一部分彼此接触。
根据本发明的另一个优选实施例，其提供了一种电源触头，所述电源触头包括形成组合板宽度的并置的第一板形本体构件和第二板形本体构件。第一本体构件包括第一端子并且第二本体构件包括第二端子。第一端子的与第二端子的对应的远端之间的距离大于组合板宽度。
根据另一个优选实施例，其提供了一种电源触头，所述电源触头包括相对的第一板形本体构件和第二板形本体构件。一组夹持梁从相对的板形本体构件延伸用于接合与配合电源触头相连的直梁。至少一个直梁也从相对的板形本体构件延伸用于接合与配合电源触头相连的斜角梁。
根据另一个优选实施例，其提供了一种电源触头，所述电源触头包括限定第一非偏转梁和第一可偏转梁的第一板，以及限定第二非偏转梁和第二可偏转梁的第二板。第一板和第二板彼此并排设置以形成电源触头。
本发明还提供配合式电源触头。根据本发明的一个优选实施例，其提供了配合式电源触头，所述电源触头包括第一电源触头，其包含相对的第一板形本体构件和第二板形本体构件；以及第二电源触头，其包含相对的第三板形本体构件和第四板形本体构件。第一本体构件和第二本体构件以及第三本体构件和第四本体构件中的至少一对彼此相互层叠在一起。
根据另一个优选实施例，其提供了配合式电源触头，所述电源触头包括第一电源触头，其包含一对直梁和一对斜角梁；以及第二电源触头，其包含第二对直梁和第二对斜角梁。所述一对直梁对正所述第二对斜角梁；并且所述一对斜角梁对正所述第二对直梁。
根据另一个优选实施例，其提供了配合式电源触头，所述电源触头包括第一电源触头和第二电源触头。第一电源触头包括本体构件、从本体构件延伸的偏转梁和从本体构件延伸的非偏转梁。第二电源触头包括第二本体构件、从第二本体构件延伸的第二偏转梁和从第二本体构件延伸的第二非偏转梁。当第一电源触头和第二电源触头配合时，所述偏转梁接合第二非偏转梁，并且所述非偏转梁接合第二偏转梁，以至于沿相反的方向施加配合力从而将第一电源触头和第二电源触头中每者中的应力减至最小。
根据另一个优选实施例，其提供了配合式电源触头，所述电源触头包括第一电源触头和第二电源触头。第一电源触头和第二电源触头分别都包括一对相对的非偏转梁和一对相对的可偏转梁。
本发明还提供电连接器。优选的电连接器可以包括上述电源触头。另外，根据本发明的一个优选实施例，其提供了一种电连接器，所述电连接器包括壳体和设置在壳体中的多个电源触头。每个电源触头包括板形本体构件，所述板形本体构件包含上侧部分以及分离的下侧部分中的至少一个部分，在所述上侧部分中形成有切口，所述下侧部分适于装配在所述切口中。一些电源触头设置在壳体中以至于相邻电源触头只包括上侧部分和下侧部分中的一个部分。
根据另一个优选实施例，其提供了一种电连接器，所述电连接器包括插头电连接器和插座电连接器。插头连接器包括插头壳体和设置在插头壳体中的插塞触头。插塞触头包括一对板形本体构件和从它们延伸的多个梁。插座连接器包括插座壳体和设置在插座壳体中的插座触头。插座触头包括第二对板形本体构件和从它们延伸的第二组多个梁。使插头电连接器与插座电连接器配合所需的力为每个触头大约10N或更小。
根据本发明的另一个优选实施例，其提供了一种电连接器，所述电连接器包括壳体、第一电源触头和第二电源触头。第二电源触头具有高于第一电源触头的额定电流强度。
附图说明
图1是本发明提供的示例性插头连接器的前侧透视图。
图2是可以与图1所示插头连接器配合的示例性插座连接器的前侧透视图。
图3是包括电源触头和信号触头的示例性竖直插座连接器的透视图。
图4是与图2所示插座连接器配合的图1所示插头连接器的正视图。
图5是与图3所示插座连接器配合的示例性插头连接器的正视图。
图6是根据本发明的另一个示例性插头连接器的前侧透视图。
图7是可以与图6所示插头连接器配合的插座连接器的前侧透视图。
图8是插座连接器的正视图，示出了电源触头和信号触头的一个优选的中心线间距。
图9是本发明提供的示例性电源触头的透视图。
图10是可以与图9所示电源触头配合的电源触头的透视图。
图11是与图10所示电源触头配合的图9所示电源触头的透视图。
图12至图14是三个接合级别上的示例性电源触头的正视图。
图15至图19是曲线图，举例说明了本发明提供的各个示例性电源触头中配合力与插入距离的代表性曲线关系。
图20是根据本发明的拼合式触头的透视图。
图21是可以与图20所示拼合式触头的上部和下部配合的电源触头的透视图。
图22是包括具有不同额定电流强度的电源触头的插头连接器的透视图。
图23是本发明提供的另一种配合式电源触头的透视图。
图24至图26是配合式电源触头的透视图，其中每个电源触头都包括四个层叠本体构件。
图27是使用四个层叠本体构件的另一种电源触头的透视图。
图28是具有层叠本体构件的电源触头实施例的透视图，其中本体构件具有共同形成触头接收空间的张开区域。
图29是可以插入图28所示电源触头的触头接收空间中的电源触头的透视图。
图30是用于形成本发明的电源触头的冲压带材的透视图。
图31是图30所示冲压带材的透视图，其包括在一部分冲压带上包覆模制的材料。
图32是已经与图31所示带材分离的电源触头副组件的透视图。
图33是根据本发明的信号触头副组件的透视图。
图34是示例性连接器的透视图，其包括分别如图32和图33所示的电源触头副组件和信号触头副组件。
图35是示例性电源触头的透视图，其具有在第一区域中层叠在一起并且在第二区域中隔开的相对板。
具体实施方式
参看图1，其中显示了包括连接器壳体12和设置于其中的多个电源触头14的示例性插头连接器10。壳体12可选地包括用于改进传热的开口15和16。开口15和16可以伸入电源触头14所在的壳体空腔中，由此形成从连接器内部到连接器外部的散热通道。图2中示出了示例性的配合插座连接器20。插座连接器20包括连接器壳体22和设置于其中并且可以通过开孔24接触的多个电源触头。例如，壳体22也可以采用诸如开口26的传热结构。优选的是，连接器壳体单元由下述绝缘材料模制或者成形，例如玻璃填充的高温尼龙或电连接器设计与制造领域的普通技术人员所公知的其它材料。在美国专利No.6319075中公开了一个实例，其全部内容在此被引作参考。电连接器的壳体单元也可以由非绝缘材料制成。
插头连接器10和插座连接器20都构造为与印刷电路结构直角连接，由此相应的印刷电路结构位于同一平面内。本发明还可以通过将一个电连接器构造为与印刷电路结构竖直连接而提供垂直配合结构。作为示例，图3中显示了竖直插座连接器30。插座连接器30包括壳体32，所述壳体32包括设置于其中并且可以通过开孔34接触的多个电源触头。连接器30还包括可选的散热开口33。在这两种共面配合结构和垂直配合结构中，有利的是，将连接器所连接的两个相应印刷电路结构之间的间距减至最小。图4中显示了与插座连接器20配合的插头连接器10。电连接器与共面的印刷电路结构19和29接合。印刷电路结构19和29之间的边缘至边缘的间距40优选为12.5mm或更小。图5中显示了具有插头连接器10b和插座连接器30的垂直配合结构。印刷电路结构19与竖直插座连接器30所接合的印刷电路结构39之间的边缘至边缘的间距42依然优选为12.5mm或更小。边缘至边缘的间距大约为9至14mm，优选的是，为12.5mm。还有可能使用其它间距。
至少一些优选的电连接器包括电源触头和信号触头这两者。现在参看图6，示出了示例性的插头连接器44，其包括壳体45、电源触头15阵列、信号触头46阵列以及形成于壳体45中的可选的传热开口47和48。图7中显示了适合于与插头连接器44配合的插座连接器54。插座连接器54包括壳体55、可以通过开孔24接触的电源触头阵列、可以通过开孔56接触的信号触头阵列以及延伸穿过壳体55的可选的传热开口58。
优选的连接器实施例实质上非常紧凑。现在参看图8，相邻电源触头的中心线至中心线的间距60优选为6mm或更小，并且相邻信号触头的中心线至中心线的间距62优选为2mm或更小。要注意，本发明的连接器可以包括不同于该优选范围的触头间距。
现在将说明适合用于上述连接器中的多个优选电源触头实施例。图9中显示了一种优选的电源触头70。电源触头70可以用于各种不同的连接器实施例中，例如包括图1中所示的插头连接器10。电源触头70包括层叠在第二板形本体构件74上的第一板形本体构件72(也可以称为“板”)。多个直梁或平坦梁76(也称为叶片)和多个弯曲梁或斜角梁78交替地从对应的本体构件延伸。直梁和弯曲梁的数量可以少至一个，也可以大于图中所示数量。采用层叠结构的本体构件，梁78收缩以限定“夹持”或“插座”梁。触头梁结构通过使相对的夹持梁相互交替而将产品整个寿命中接触法向力中的潜在变化减至最小。该梁结构用于消除多个附加的接触力，否则这些力将传递到壳体结构中。相对的夹持梁还有助于在配合互补的连接器的过程中保持夹在一起的板形本体构件。该触头结构提供多个配合点用于满足每个梁上较低的法向力要求，由此将多配合结构的负面效果减至最小。
当电源触头70与互补电源触头配合时，梁78必然会弯曲、偏转或以其它方式偏离它们的非接合位置，同时梁76基本上保持在它们的非接合位置中。电源触头70还包括从每个本体构件72和74的张开部分82延伸的多个端子80。非张开部分形成组合板宽度CPW。张开部分82提供端子80与印刷电路结构的连接结构的准确对正，因此在优选实施例中，相对端子的远端之间的距离大于组合板宽度CPW。端子本身可以向外斜角，从而当触头本体构件层叠或者以其它方式彼此靠近安置时，不需要张开本体部分以形成适当的间距(例如，参见图28中的端子)。张开部分82也可以提供主要通过对流方式进行散热的通道。还可以通过形成于梁78之间的间隙84和形成于自触头本体构件延伸的相邻梁之间的间隙86提供附加的散热通道。
现在参看图10，其中显示了适合于与电源触头70配合的电源触头90。电源触头90包括一对层叠的板形本体构件92和94。直梁96和斜角梁98从所述本体构件延伸，并且布置成分别与电源触头70的梁78和76准确对正。也就是说，梁78将接合梁96，并且梁76将接合梁98。每个本体构件92和94包括从张开部分93延伸用于将电源触头90电连接至印刷电路结构的多个端子95。图11中举例说明了配合结构中的电源触头70和90。
为了减小互补电源触头和容纳所述触头的电连接器的配合力，触头梁可以通过尺寸差异或偏置技术而具有交错的延伸位置。作为示例，图12至图14显示了从初始接合到基本上最终接合的过程中处于不同配合位置(或插入距离)上的示意性电源触头100和110。在表示第一级别的配合的图12中，触头100的最长直梁或叶片102接合触头110的对应夹持梁112。由于通过插入直梁或叶片而分离或偏转夹持梁所需的力的量，所以第一级别的配合中的力将最初达到峰值。之后，第一级别的配合中的配合力主要是因为直梁和斜角梁彼此相互滑动时所产生的摩擦阻力。图13中显示了第二级别的配合，其中触头110的第二长的直梁或叶片114接合触头100的对应夹持梁104。在第二级别的配合过程中的配合力由于附加的夹持梁被偏转分离以及在第一级别的配合和第二级别的配合中已接合梁的累积摩擦力而产生。图14中显示了第三级别的配合，其中触头110的其余的直梁或叶片116接合触头100的其余的对应夹持梁106。本领域的普通技术人员将容易认识到，本发明可以期望更少或更多的配合级别，而不是同一连接器内的特定电源触头中以及电源触头阵列中的三个级别。如上所述，本发明的电连接器可以同时采用电源触头和信号触头。信号触头还可以相对于彼此，并且作为选择，相对于电源触头的长度，在长度上交错。例如，信号触头可以具有至少两个不同的信号触头长度，并且这些长度可以不同于任一电源触头长度。
图15至图19是曲线图，其显示了(上面或下面说明的)各种不同的示例性电源触头的配合力与插入距离之间的代表性关系。图15中显示了使用三个级别配合的示例性电源触头的配合力，其中峰值代表在每个配合级别处与直梁接合的夹持梁的偏转。如果电源触头没有采用交错配合，那么初始力将基本上为大约8N或14.5N的第一峰值的2.5倍。采用交错的配合点，在整个插入距离中观察到的最大力小于10N。
本领域的技术人员很清楚，根据本发明的电源连接器的总体尺寸理论上只受到下面因素的限制，即母线或印刷电路结构上的有效表面积和从印刷电路结构测量的有效的连接器高度。因此，电源连接器系统可包括多个插头电源触头和插头信号触头，以及多个插座电源触头和插座信号触头。通过改变各个电源触头和信号触头的配合顺序，在两个电源连接器相隔很远时(初始接触)将插头与插座配合所需的初始力将降低，并且随着连接器插头与连接器插座之间的距离减小以及部分配合的插头与插座之间的稳定性增加而增大。根据连接器插头与连接器插座之间减小的距离而施加增大的力的与机械优势协同作用，并且有助于防止连接器插头和插座在初始配合过程中屈曲。
图20中显示了另一个示例性的电源触头120。电源触头120包括第一板形本体构件122和第二板形本体构件124。电源触头120可以称为拼合式触头，该触头包括带有切口128的上侧区段126，其中所述切口形成在所述上侧区段中用于接收下侧区段130。上侧区段126显示为具有L形形状；然而，同样可以使用其它几何形状。下侧区段130被构造为基本上适配在切口128内。如图所示，上侧区段126和下侧区段130分别包括从前侧边缘延伸的一对斜角梁132和一对直梁134，以及用于接合印刷电路结构的多个端子133。梁的数量和几何形状可以不同于图中所示。图21显示了一对平行的几乎相同的电源触头140、140a，它们适合于与拼合式触头120的上侧区段和下侧区段配合。每个电源触头140、140a具有可插在触头120的收缩斜角梁132之间的一对直梁142，和用于容纳触头120的直梁134的一对收缩斜角梁144。
要注意的是，对于单个触头位置而言，如图22中所示，本发明的电连接器也可以只使用上侧区段或下侧区段中的一者。通过在相邻触头位置中交替使用上侧触头和下侧触头，可以获得附加的触头至触头的间隔距离，从而允许触头传输大约350V的电压，基于已发布安全标准，该电压与如图9和图10以及图20和图21所示的上述触头相应的0至150V额定值相比更高。由相应拼合式触头中不存在触头的部分所形成的空出区域160可以提供散热通道。当用于总体连接器组件的情况中时，完整触头、拼合式触头和拼合式触头的上侧区段或下侧区段可以布置为使得可以在一个连接器内应用多个电流强度和电压级别。例如，图22中所示的示例性连接器150包括设置用于如上所述高压的上侧和下侧触头部分152的阵列、能够传输大约0至50A的完整触头154的阵列、以缩小间距设置的能够传输大约0至25A的拼合式触头156的阵列以及信号触头158的阵列。不同电流强度的电源触头的数量可以小于或大于三个。而且，电源触头和信号触头的结构可以不同于图22中所示。最后，不同电源触头的额定电流强度可以不同于上面所述。
现在参看图23，其中显示了附加的配合式电源触头实施例。插座电源触头170包括层叠在第二板形本体构件174上的第一板形本体构件172。第一板形本体构件和第二板形本体构件每个分别包括一组切口173和175。优选的是，切口组173与切口组175的相位不同。一个板形本体构件的切口与另一个板形本体构件的实体部分限定了多个触头接收空间176。触头接收空间176被构造为容纳配合插塞触头，例如插塞触头180的梁。第一板形本体构件和第二板形本体构件中至少一者还包括用于与印刷电路结构连接的端子171。在可选的插座触头实施例(未示出)中，使用了在外侧表面上包括一组切口的单个板形本体构件，其中所述切口具有小于单个板形本体构件的宽度。
插塞触头180包括层叠在第二板形本体构件184上的第一板形本体构件182。第一板形本体构件和第二板形本体构件每个都包括用于与触头接收空间176接合的多个延伸梁186。如图所示，一对梁186专用于配合插座触头170的每个对应单独的触头接收空间176。同样可以使用多个单独的梁。每对梁186包括可以改进传热的间隙188。梁186是顺从的并且在与触头接收空间176接合时将会弯曲。梁186可选地可包括球状端部190。触头本体构件182和184显示为可选交错结构以提供先配合-后断开的结构。
尽管上面说明的电源触头已经包括了两个板形本体构件，但是本发明提供的一些电源触头实施例(未示出)只包括单个板形本体构件。并且本发明的其它电源触头结构包括两个以上的板形本体构件。图24至图26中分别显示了示例性的插座触头200和插塞触头230。插座触头200和插塞触头230每个分别使用四个板形本体构件。
插座电源触头200包括一对外侧板形本体构件202和204，以及一对内侧板形本体构件206和208。图中以优选的层叠结构显示了外侧板形本体构件对和内侧板形本体构件对；也就是说，沿着相邻本体构件的相对表面的大部分基本上没有间隙形成于相邻本体构件之间。多个端子201从一个或多个板形本体构件延伸，并且优选的是，从全部四个本体构件延伸。成对外侧板形本体构件202、204中的每个分别包括张开部分203。张开部分203提供将端子与印刷电路结构连接的适当间隙并且可以通过所限定的间隙205而有助于散热。第一对梁210从外侧本体构件202、204延伸，并且第二对梁212从内侧本体构件206、208延伸。在优选实施例中，如图所示，第一对梁210基本上与第二对梁212相接。在可选实施例中，梁210和212延伸至不同位置以提供不同的配合顺序。梁210、212设计并且构造成接合配合插塞触头230的结构，并且还可以在相邻梁210、212之间限定一个或多个散热通道，并且由相对的梁210和212本身限定散热通道215和216。梁210和212显示为“夹持”或收缩结构，但是同样可以使用其它结构。外侧本体构件对和内侧本体构件对可以使用除上面所示之外用于接合插塞电源触头的附加的梁。
插塞触头230还包括一对外侧板形本体构件232和234，以及一对内侧板形本体构件236和238。与插座触头相似，外侧板形本体构件232、234中每个分别包括张开部分233以提供端子231从本体构件延伸的适当间隙。优选的是，外侧板形本体构件232、234包括切除部分240。切除部分240暴露了内侧板形本体构件236、238的一部分以提供通过配合插座电源触头200进行接合的可实现性，并且可以例如通过对流方式有助于散热。作为示例并且如图26中所示，插座触头200的梁210夹持插塞触头230的内侧板形本体构件236和238的暴露部分。
图27中显示了使用四个层叠本体构件的另一个示例性电源触头241。电源触头241包括一对外侧板形本体构件242和244，其中每个外侧板形本体构件包括多个从前侧边缘延伸的悬臂直梁246。电源触头240还包括位于外侧板形本体构件242与244之间的一对内侧板形本体构件248和250。内侧板形本体构件248和250包括多个斜角悬臂梁252，它们收缩以限定夹持或插座梁。直梁246隔开以允许斜角梁252安置在它们之间。优选的配合式电源触头(未示出)将包括相似的结构，其中夹持梁对正梁246并且直梁对正梁252。在配合过程中梁246所受到的力将趋向于将外侧板形本体构件242和244保持在一起，而梁252所受到的力将趋向于将内侧板形本体构件248和250推开。所述力共同作用时将彼此抵消以提供板形本体构件的稳定层叠而最少量的力传递至承载壳体。外侧板242和244也将趋向于将内侧板248和250保持在一起。
至此所显示和说明的每个电源触头实施例都采用了多个彼此层叠在一起的板形本体构件。在这种层叠结构中，本体构件至少沿着相对本体构件表面的一部分彼此相互接触。附图显示了沿它们的相对表面的大部分彼此相互接触的板形本体构件。然而，本发明所期望的可选触头实施例可以使它们相对表面的小部分相互接触。例如，图35中所示的示例性触头253包括一对板形本体构件254和255。触头253包括板形本体构件彼此层叠在一起的第一区域256和本体构件隔开的第二区域257。第一区域256和第二区域257由斜角区域258相互连接。例如，第二区域257包括可通过对流方式有助于散热的中间间隙259。要注意的是，板形本体构件的层叠的和隔开的部分可以不同于图35中所示。除了一定程度上层叠之外，多个板形本体构件还可以完全隔开从而在相邻触头本体构件之间限定中间间隙。中间间隙可有助于传热。此外，一个配合触头可包括层叠板形本体构件而另一个则不包括-在图28和29中分别以配合式触头260和290显示了这样的一个实例，下面将进行说明。
图28所示的触头260包括第一板形本体构件262，其沿着第一板形本体构件262和第二板形本体构件264的内表面的大部分层叠在第二板形本体构件264上。每个所述板形本体构件的前侧部份263、265向外张开以限定用于接合配合触头290(图29中所示)的触头接收空间266。在张开的前侧部分263、265中显示了可改进散热的可选开口268。
触头290包括并置的本体构件292和294，优选的是，所述本体构件彼此隔开以在它们之间限定中间间隙296。本体构件292、294的表面区域与中间间隙296结合从而允许主要通过对流方式进行散热。多个顺从梁300、302从相应的并置本体构件292、294延伸。在一个优选实施例中，梁300、302交替地从本体构件292和294延伸。每个梁300、302包括邻近部分304和远离部分306。相对的侧部308和310通过连接部分312连接，所有这些部分设置在邻近部分304与远离部分306之间。优选的是，连接部分312限定了远离本体构件292、294设置的封闭梁端部。前述梁的各部分共同形成球形(或箭头形)梁，其为每个单独梁300、302提供至少两个接触点。尽管所有触头梁300、302显示为在尺寸和几何形状上相同，但是本发明还期望彼此不同的多种梁，它们沿着一个本体构件变化，并且在本体构件与本体构件之间变化。图29中所示梁的数量也可以变化为包括更多或更少的梁。
如图29中所示，每个梁300、302的远离部分306与没有从其延伸的本体构件隔开，从而限定裂缝316。裂缝316有助于允许梁300、302在插入触头接收空间266时偏转。间隙318还限定在每个本体构件292、294上的相邻梁300、302之间。间隙318具有高度H1，优选的是，该高度等于或大于梁300、302的高度H2，从而一个本体构件292的梁300可以与另一个本体构件294的梁302相互咬合。
裂缝316和间隙296、318和320允许从本体构件和顺从梁散热。在图29中，触头290沿着与纸面所在的平面P重合的想象的纵向轴线L延伸。在图29的结构中，热量将大体向上并且沿着想象的纵向轴线L通过对流方式而消散。梁300、302和本体构件292、294限定了类烟囱结构，其有助于流通热量远离触头290。如果触头290在纸面所在的平面P内旋转90度，则热量仍然可以通过间隙316和318并且通过间隙296和320的开口端部消散。
本发明的优选触头可以由适当的带材冲压或以其它方式形成。触头可以单独形成或者作为选择以两个或多个为一组形成。优选的是，带材被模具冲压从而以成品前或成品形式限定多个触头结构。在模具冲压操作之后可能需要附加的操作，例如将结构连接在一起或者改变结构的初始冲压方位或构造(例如，弯曲悬臂梁或触头本体部分)。参看图30，其中显示了示例性的带条330和332，每个带条包括多个板形本体构件，所述板形本体构件包括直梁和弯曲梁(优选的是，在冲压操作之后形成)以及从所述板形本体构件延伸的多个端子。在电源触头包括第一本体构件和第二本体构件的情况下，左侧和右侧结构这两者可以冲压和设置在单个带条中。
各个触头元件可以与带条330和332的其余结构分离，然后插入连接器壳体中。在一种可选技术中，带条可以层叠在一起然后放入用于形成包覆模制的触头副组件的模具中。在触头只采用单个本体构件的情况下也可以使用单个带条。并且两个以上的带条可以层叠并且包覆模制。合适的热塑性材料在层叠本体构件的大部分周围流动并固化以形成塑料壳体334，如图31中所示。然后将触头副组件336与带条分离，如图32中所示。梁340从壳体334延伸以接合配合电源触头，并且端子342从壳体334延伸用于将包覆模制的触头连接在印刷电路结构上。信号触头副组件也可以通过以带条形式或者单独地包覆模制一组信号触头而制成。例如，图33中显示了包覆模制的信号触头副组件350，其包括壳体352和一组信号触头354。图34显示了包括壳体362、两个电源触头副组件336和多个信号触头副组件350的示例性电连接器360。
本发明的电源触头和信号触头由本领域技术人员所公知的合适的材料，例如铜合金制成。触头可以镀有各种不同的材料，例如包括金或金和镍的组合。触头的数量以及它们在连接器壳体中的结构不限于附图中所示。本发明的一些优选的电源触头包括彼此层叠在一起的板形本体构件。层叠本体构件允许连接器因为增大的横截面积(更小的电阻)而传输很大的电流并且具有增大表面积以有助于对流传热的潜力。本领域的普通技术人员将很容易认识到，板形本体构件在形状上可以为平坦的或者非平坦的。本发明还包括并置板形本体构件，以至于本体构件隔开以在它们之间限定中间间隙。中间间隙还可以主要通过对流方式改进传热。触头板形本体构件还可以包括开口或其它传热结构。本发明提供的电连接器的壳体单元还可以包括用于改进散热的结构，例如从连接器外部延伸至连接器内部的通道，和邻近所保持的电源触头的表面部分的壳体空缺或间隙。
从触头延伸的悬臂梁的数量、位置和几何形状不限于图中所示。上述梁结构中一些具有所述益处；然而，本发明的其它梁结构可能不具有同样的所述益处。
虽然已经结合各个附图的优选实施例说明了本发明，但是可以理解，在不脱离本发明的前提下，可以使用其它类似实施例或者可以对所述实施例进行改型和增添用于实现本发明的相同功能。因此，本发明不应该只限于任何单个实施例，而是限定在权利要求书中所提到的广度和范围中。

Claims (5)

1.一种配合式电源触头，包括：
a)第一电源触头，其包含多对相对的叶片和多对与所述叶片交替出现、相对的夹持梁；和
b)第二电源触头，其包含直梁和斜角梁，它们设置成分别与所述第一电源触头的所述相对的夹持梁和相对的叶片恰好对正；
其中，所述第一电源触头包括至少一对相对的板形本体构件，所述至少一对相对的板形本体构件中的每一个包括用于连接至印刷电路板的端子，在所述第一电源触头与所述第二电源触头匹配时，所述第一电源触头的交替、相对的夹持梁有助于最小化电源触头法向力振动。
2.根据权利要求1所述的配合式电源触头，其特征在于，所述至少一对相对的板形本体构件具有位于它们之间的中间间隙。
3.根据权利要求1所述的配合式电源触头，其特征在于，所述至少一对板形本体构件彼此层叠在一起。
4.根据权利要求1所述的配合式电源触头，其特征在于，所述至少一对板形本体构件包括设置在第二板形本体构件附近的第一板形本体构件，从而所述第一板形本体构件和所述第二板形本体构件沿着所述第一板形本体构件和所述第二板形本体构件的表面的至少一部分彼此相互接触。
5.根据权利要求1所述的配合式电源触头，其特征在于，还包括绝缘壳体，所述第一电源触头连接在所述绝缘壳体上。
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US7258562B2 (en) 2007-08-21
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US8187017B2 (en) 2012-05-29
TW200525827A (en) 2005-08-01

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