Electrical connector with separable contacts

• US 7,967,644 B2
• Filed: 08/25/2009
• Issued: 06/28/2011
• Est. Priority Date: 08/25/2009
• Status: Active Grant

• Current Assignee: Bison Patent Licensing, LLC
• Original Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Inventors: Pepe, Paul John, Bopp, Steven Richard
• Primary Examiner(s): Gushi; Ross N
• Application Number:
  US12/547,321
• Publication Number:
  US 20110053428A1
• Time in Patent Office: 672 Days
• Field of Search: 439/676, 439/941, 439/620.17, 439/620.19, 439/620.11, 439/620.23
• US Class Current: 439/676
• CPC Class Codes: H01R 13/02 Contact members
• CPC Class Codes: H01R 13/46 Bases; Cases
• CPC Class Codes: H01R 13/6461 Means for preventing cross-talk
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 24/00 Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure contact members H01R13/02; securing contact members in or to a base or case or insulating of contact members H01R13/40; bases or cases H01R13/46; means for supporting coupling part when not engaged H01R13/60; means for facilitating engagement or disengagement of coupling parts or for holding them in engagement H01R13/62; means for preventing, inhibiting or avoiding incorrect coupling H01R13/64
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45

Abstract

A contact sub-assembly is provided for an electrical connector. The contact sub-assembly includes a printed circuit and an array of mating contacts. Each mating contact includes a terminating end portion and a mating interface. The contact sub-assembly also includes an array of circuit contacts that is discrete from the array of mating contacts. Each circuit contact is engaged with and electrically connected to the printed circuit. Each circuit contact is separably engaged with and electrically connected to the terminating end portion of a corresponding one of the mating contacts such that the array of circuit contacts electrically connects the array of mating contacts to the printed circuit.

Claims

1. A contact sub-assembly for an electrical connector, said contact sub-assembly comprising:

a printed circuit;

an array of mating contacts, each mating contact comprising a terminating end portion and a mating interface; and

an array of circuit contacts that is discrete from the array of mating contacts, each circuit contact being engaged with and electrically connected to the printed circuit, wherein each circuit contact is separably engaged with and electrically connected to the terminating end portion of a corresponding one of the mating contacts such that the array of circuit contacts electrically connects the array of mating contacts to the printed circuit, and wherein at least one of the circuit contacts has a greater surface area than at least one of the mating contacts.

2. The contact sub-assembly according to claim 1, wherein each circuit contact comprises a base, a printed circuit terminating portion extending from the base, and a mating contact engagement portion extending from the base, the printed circuit terminating portion being engaged with and electrically connected to the printed circuit, the mating contact engagement portion being engaged with and electrically connected to the terminating end portion of the corresponding mating contact.

3. The contact sub-assembly according to claim 1, wherein each circuit contact comprises a mating contact engagement portion, the mating contact engagement portion comprising a pair of arms, the terminating end portion of the corresponding mating contact being engaged with and held between the arms.

4. The contact sub-assembly according to claim 1, wherein each circuit contact comprises a base, a printed circuit terminating portion extending from the base in a first direction toward the printed circuit, and a mating contact engagement portion extending from the base in a second direction toward the corresponding mating contact.

5. The contact sub-assembly according to claim 1, wherein the contact sub-assembly further comprises a base, the mating contacts extending along the base, each circuit contact comprising a connection member engaged with the base such that the circuit contact is mechanically connected to the base.

6. The contact sub-assembly according to claim 1, wherein the printed circuit is a first printed circuit, the contact sub-assembly further comprising a second printed circuit, each circuit contact being engaged with and electrically connected to the second printed circuit.

7. The contact sub-assembly according to claim 1, wherein the at least one circuit contact comprises a circuit contact side that faces an adjacent circuit contact within the array of circuit contacts, the at least one mating contact comprising a mating contact side that faces an adjacent mating contact within the array of mating contacts, the circuit contact side of the at least one circuit contact having a greater surface area than the mating contact side of the at least one mating contacts contact.

8. The contact sub-assembly according to claim 1, wherein the terminating end portions of the mating contacts are aligned within a common plane.

9. The contact sub-assembly according to claim 1, wherein each of the circuit contacts comprises a printed circuit terminating portion that is engaged with and electrically connected to the printed circuit, the printed circuit terminating portions of at least three of the circuit contacts being aligned within different planes.

10. The contact sub-assembly according to claim 1, wherein each circuit contact is separately formed from the corresponding mating contact.

11. An electrical connector comprising:

a housing; and

a contact sub-assembly held by the housing, the contact sub-assembly comprising;

a printed circuit;

an array of mating contacts, each mating contact comprising a terminating end portion and a mating interface; and

an array of circuit contacts that is discrete from the array of mating contacts, each circuit contact being engaged with and electrically connected to the printed circuit, wherein each circuit contact is separably engaged with and electrically connected to the terminating end portion of a corresponding one of the mating contacts such that the array of circuit contacts electrically connects the array of mating contacts to the printed circuit, each circuit contact comprising a mating contact engagement portion, the mating contact engagement portion comprising a pair of arms, the terminating end portion of the corresponding mating contact being engaged with and held between the arms.

12. The electrical connector according to claim 11, wherein each circuit contact comprises a base, a printed circuit terminating portion extending from the base, and the mating contact engagement portion extending from the base, the printed circuit terminating portion being engaged with and electrically connected to the printed circuit, the mating contact engagement portion being engaged with and electrically connected to the terminating end portion of the corresponding mating contact.

13. The electrical connector according to claim 11, wherein each circuit contact comprises a printed circuit terminating portion, the printed circuit terminating portion comprising a press fit contact.

14. The electrical connector according to claim 11, wherein each circuit contact comprises a base, a printed circuit terminating portion extending from the base in a first direction toward the printed circuit, and the mating contact engagement portion extending from the base in a second direction toward the corresponding mating contact.

15. The electrical connector according to claim 11, wherein the contact sub-assembly further comprises a base, the mating contacts extending along the base, each circuit contact comprising a connection member engaged with the base such that the circuit contact is mechanically connected to the base.

16. The electrical connector according to claim 11, wherein the printed circuit is a first printed circuit, the contact sub-assembly further comprising a second printed circuit, each circuit contact being engaged with and electrically connected to the second printed circuit.

17. The electrical connector according to claim 11, wherein at least one of the circuit contacts has a greater surface area than at least one of the mating contacts.

18. The electrical connector according to claim 11, wherein the terminating end portions of the mating contacts are aligned within a common plane.

19. The electrical connector according to claim 11, wherein each of the circuit contacts comprises a printed circuit terminating portion that is engaged with and electrically connected to the printed circuit, the printed circuit terminating portions of at least three of the circuit contacts being aligned within different planes.

20. The electrical connector according to claim 11, wherein each circuit contact is separately formed from the corresponding mating contact.

21. A contact sub-assembly for an electrical connector that is configured to mate with a mating plug, said contact sub-assembly comprising:

a printed circuit;

an array of mating contacts, each mating contact comprising a terminating end portion and a mating interface, the mating interface of each mating contact being configured to engage the mating plug; and

an array of circuit contacts that is discrete from the array of mating contacts, each circuit contact being engaged with and electrically connected to the printed circuit, wherein each circuit contact is separably engaged with and electrically connected to the terminating end portion of a corresponding one of the mating contacts such that the array of circuit contacts electrically connects the array of mating contacts to the printed circuit, the circuit contacts being engaged with the corresponding mating contacts when the mating interfaces are disengaged from the mating plug.