Electrical connector with separable contacts

• US 8,287,316 B2
• Filed: 06/20/2011
• Issued: 10/16/2012
• 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, Popp, Steven Richard
• Primary Examiner(s): GUSHI, ROSS N
• Application Number:
  US13/164,443
• Publication Number:
  US 20110250802A1
• Time in Patent Office: 484 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;

a base;

an array of mating contacts held by the base, 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, at least one of the circuit contacts comprising a connection member having at least one barb engaged with the base for mechanically connecting the at least one circuit contact to the base.

2. The contact sub-assembly according to claim 1, wherein the base is a sub-assembly base, each circuit contact comprising a contact base, a printed circuit terminating portion extending from the contact base in a first direction toward the printed circuit, and a mating contact engagement portion extending from the contact base in a second direction toward the corresponding mating contact, the connection member comprising an extension extending outwardly from the contact base of the at least one circuit contact in the second direction, the extension comprising the at least one barb.

3. The contact sub-assembly according to claim 1, wherein the base comprises at least one opening, the connection member of the at least one circuit contact being received within the at least one opening of the base, the at least one barb being engaged with a portion of the base that defines the at least one opening.

4. The contact sub-assembly according to claim 1, wherein the connection member of the at least one circuit contact comprises an extension, the at least one barb comprising a pair of barbs that extend outwardly from the extension in generally opposite directions.

5. 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, at least one of the circuit contacts comprising an extension engaged with at least one of an electrical contact or an electrical trace of the second printed circuit such that the at least one circuit contact is electrically connected to the second printed circuit.

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 held by the base, at least one of the circuit contacts being electrically connected to the second printed circuit such that the at least one circuit contact and the second printed circuit define portions of a secondary path for electrical energy to propagate through the contact sub-assembly.

7. 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 held by the base, each mating contact comprising a tip end portion, the mating interface extending between the terminating and tip end portions, the tip end portion of at least one of the mating contacts being engaged with and electrically connected to the second printed circuit.

8. 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 held by the base, the mating contacts comprising tip end portions, at least a first of the circuit contacts being electrically connected to the second printed circuit, a primary path for electrical energy to propagate through the contact sub-assembly being defined along a first mating contact from the mating interface, through the terminating end portion, and through the first circuit contact to the first printed circuit, a secondary path for electrical energy to propagate through the contact sub-assembly being defined from the mating interface of the first mating contact, through the tip end portion, at least one of along or through the second printed circuit, and through the first circuit contact to the printed circuit.

9. The contact sub-assembly according to claim 1, wherein the base is a sub-assembly base, each circuit contact comprising a contact base having a pair of opposite sides and a pair of opposite edges, the connection member of the at least one circuit contact extending outwardly from one of the edges of the contact base.

10. The contact sub-assembly according to claim 1, wherein the electrical connector is an RJ-45 jack.