Integrated connector apparatus and methods

• US 8,147,278 B2
• Filed: 02/28/2008
• Issued: 04/03/2012
• Est. Priority Date: 03/01/2007
• Status: Active Grant

• Current Assignee: Pulse Electronics Incorporated (Yageo Corporation)
• Original Assignee: Pulse Electronics Incorporated (Yageo Corporation)
• Inventors: Renteria, Victor H., Gutierrez, Aurelio J., Mahlerbe, William, Hurd, Gary L., Machado, Russell L.
• Primary Examiner(s): Gilman, Alexander
• Application Number:
  US12/074,112
• Publication Number:
  US 20080233803A1
• Time in Patent Office: 1,496 Days
• Field of Search: 439/676, 439/76.1, 439/620, 439/736
• US Class Current: 439/676
• CPC Class Codes: H01R 12/70 Coupling devices
• CPC Class Codes: H01R 13/66 Structural association with built-in electrical component coupling devices having concentrically or coaxially-arranged contacts H01R24/38
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 13/719 specially adapted for high frequency, e.g. with filters
• CPC Class Codes: H01R 13/7193 with ferrite filters
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45
• CPC Class Codes: H05K 1/0233 Filters, inductors or a magnetic substance
• CPC Class Codes: H05K 1/18 Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 2201/1003 Non-printed inductor
• CPC Class Codes: H05K 2201/1006 Non-printed filter
• CPC Class Codes: H05K 2201/10189 Non-printed connector
• CPC Class Codes: H05K 2201/10515 Stacked components
• CPC Class Codes: H05K 2201/10537 Attached components
• CPC Class Codes: H05K 2201/10568 Integral adaptations of a component or an auxiliary PCB for mounting, e.g. integral spacer element
• CPC Class Codes: H05K 2201/2036 Permanent spacer or stand-off in a printed circuit or printed circuit assembly

Abstract

An electrical connector mountable on a printed circuit board. In one embodiment, the electrical connector comprises an insulative housing comprising one or more electronic components, a plurality of electrical conductors in signal communication with the electronic components and adapted to interface with a plug and a plurality of terminals in signal communication with the one or more electronic components. In one aspect, the plurality of terminals are adapted to interface with one or more externally mounted electronic components on the printed circuit board thereby filtering signals passing between the electrical conductors and the printed circuit board, with the externally mounted electronic components mounted within the footprint of the electrical connector. Methods of manufacture for the aforementioned electrical connector and business methods are also disclosed.

Claims

1. A connector assembly, comprising:

a connector housing comprising, a vertically mounted connector housing, a plug receiving recess and an electronic component receiving recess;

a conductor insert, said conductor insert comprising a plurality of conductors residing at least partly within said plug receiving recess and said electronic component recess and further comprising an insulating header portion having a bottom surface; and

an electronic component residing within said electronic component receiving recess and above said bottom surface, said electronic component comprising a plurality of leads, at least one of said plurality of leads connected directly to one of said plurality of conductors;

wherein said electronic component receiving recess comprises a depth, said depth permitting said electronic component to be mass terminated to said one of said plurality of conductors without damaging said electronic component; and

wherein said electronic component comprises a wound toroid and at least one of said plurality of conductors comprises a notched end adapted to receive said at least one of said plurality of leads.

2. An electrical connector mounted on a printed circuit board in a telecommunications apparatus and having a footprint associated therewith, comprising:

an insulative housing comprising a bottom surface that is disposed adjacent to said printed circuit board;

one or more electronic components disposed at least partly in said housing;

a plurality of electrical conductors in signal communication with said one or more electronic components and adapted to interface with a plug; and

a plurality of terminals in signal communication with said one or more electronic components;

wherein said plurality of terminals are adapted to interface with one or more externally mounted electronic components disposed on said printed circuit board, thereby filtering signals passing between said plurality of electrical conductors and said printed circuit board, said externally mounted electronic components mounted within the footprint of said electrical connector and within an open cavity of the housing, the open cavity being resident on the bottom surface of the insulative housing; and

wherein said printed circuit board is larger than said footprint.

3. The electrical connector of claim 2, further comprising an organizer, said organizer comprising an insulative insert, said plurality of electrical conductors residing at least partly within said insulative insert and in signal communication with said one or more electronic components.

4. The electrical connector of claim 3, wherein:

said insulative housing comprises at least one port cavity and at least one electronic component cavity; and

individual ones of said at least one port cavity are adapted to receive said organizer such that individual ones of said at least one port cavity are inaccessible from said at least one electronic component cavity when said organizer is received within its respective port cavity.

5. The electrical connector of claim 2, wherein said electrical connector comprises a vertically mounted electrical connector comprising a connector port and an interface surface to said printed circuit board;

wherein said one or more electronic components are positioned within said insulative housing so as to not reside between said connector port and said interface surface.

6. The electrical connector of claim 2, wherein said plurality of terminals in signal communication with said one or more electronic components are distributed throughout said insulative housing so that said one or more electronic components are substantially equidistant from their respective terminal or terminals.

7. The electrical connector of claim 2, wherein said insulative housing is adapted to accommodate said one or more externally mounted electronic components substantially between said insulative housing and said printed circuit board.

8. The electrical connector of claim 7, wherein said one or more externally mounted electronic components comprise chip-like electronic components, and said one or more electronic components comprise toroidal inductive devices.

9. A method of supplying a functional filtered connector assembly mounted on a circuit board, the connector comprising a connector housing comprised of one or more coil assemblies that are mounted within said connector housing, the method comprising:

placing one or more electronic components on said circuit board; and

placing said connector housing over said placed one or more electronic components such that said connector housing is disposed on said circuit board, and said one or more electronic components are housed within said connector housing.

10. The method of claim 9, wherein said one or more electronic components comprise one or more chip-like electronic components.

11. A connector assembly, comprising:

a connector housing comprising a vertically oriented connector port and an interface surface to an external printed circuit board, said connector housing further comprising a plurality of terminals extending below said interface surface and an open cavity on the underside of said connector housing, said open cavity configured to accommodate externally mounted electronic components when said connector housing is disposed over said externally mounted electronic components; and

a plurality of internally mounted electronic components in signal communication with at least a portion of said plurality of terminals, said plurality of internally mounted electronic components being disposed within said connector housing;

wherein a plug receiving face of said vertically oriented connector port and said external printed circuit board are substantially parallel to one another.

12. The connector assembly of claim 11, wherein said plurality of terminals in signal communication with said plurality of internally mounted electronic components are distributed throughout said connector housing so that each of said plurality of internally mounted electronic components are substantially equidistant from their respective terminal or terminals.

13. The connector assembly of claim 11, further comprising an organizer, said organizer comprising:

an insulative insert; and

a plurality of electrical conductors in signal communication with said one or more internally mounted electronic components.

14. The connector assembly of claim 13, wherein said connector port is adapted to receive said organizer such that said connector port is inaccessible from said open cavity when said organizer is received within said connector port.

15. The connector assembly of claim 13, wherein said one or more externally mounted electronic components comprise chip-like electronic components, and said plurality of internally mounted electronic components comprise toroidal inductive devices.

16. The connector assembly of claim 13, wherein said connector housing comprises a substantially L-shape.

17. The connector assembly of claim 16, wherein said insulative insert comprises one or more locking features, said one or more locking features adapted to interface with one or more receiving elements on said connector housing.

18. The connector assembly of claim 17, wherein said insulative insert is shaped so as to separate said connector port from said open cavity when said one or more locking features is engaged with said one or more receiving elements.

19. The connector assembly of claim 13, wherein said plurality of electrical conductors in signal communication with said one or more internally mounted electronic components each comprise a termination end;

wherein said open cavity has a depth sufficient to permit the mass termination of said termination end of said electrical conductors without damaging said plurality of internally mounted electronic components housed within said open cavity.

20. A connector assembly, comprising:

a connector housing comprising a plug receiving recess defined by a top plug receiving surface and an electronic component receiving recess, said electronic component receiving recess having an opening that is substantially parallel with a mounting surface of said connector housing;

a conductor insert, said conductor insert comprising a plurality of conductors residing at least partly within said plug receiving recess and said electronic component recess; and

a plurality of electronic components, at least some of said electronic components comprise wound toroids, residing within said electronic component receiving recess, said plurality of electronic components each comprising a plurality of leads, at least one of said plurality of leads connected directly to one of said plurality of conductors, at least some of said plurality of conductors comprise a notched end adapted to receive said at least one of said plurality of leads;

wherein said plurality of electronic components reside in a substantially coplanar fashion and further reside substantially between the level of said plug receiving top surface and the level of said mounting surface, at least some of said electronic comprise wound toroids; and

wherein said electronic component receiving recess comprises a depth, said depth permitting one or more of said electronic components to be mass terminated to said plurality of conductors without damaging said one or more electronic components.

21. A connector assembly, comprising:

a connector housing comprising a vertically oriented connector port and an interface surface to an external printed circuit board, said connector housing further comprising a plurality of terminals extending below said interface surface and a cavity on the underside of said connector housing, said cavity capable of accommodating externally mounted electronic components when said connector housing is disposed over said externally mounted electronic components; and

a plurality of internally mounted electronic components in signal communication with at least a portion of said plurality of terminals, said plurality of internally mounted electronic components being disposed within said connector housing;

wherein a plug receiving face of said vertically oriented connector port and said external printed circuit board are substantially parallel to one another.

22. The connector assembly of claim 21, further comprising an organizer, said organizer comprising:

an insulative insert; and

a plurality of electrical conductors in signal communication with said one or more internally mounted electronic components.

23. The connector assembly of claim 22, wherein said connector port is adapted to receive said organizer such that said connector port is inaccessible from said open cavity when said organizer is received within said connector port.

24. The connector assembly of claim 21, wherein said connector housing comprises a substantially L-shape.

25. The connector assembly of claim 21, wherein said plurality of electrical conductors in signal communication with said internally mounted electronic components each comprise a termination end;

and

wherein said cavity has a depth sufficient to permit the mass termination of said termination end of said electrical conductors without damaging said plurality of internally mounted electronic components housed within said cavity.