Electrical connector with separable contacts

• US 9,787,015 B2
• Filed: 02/12/2016
• Issued: 10/10/2017
• Est. Priority Date: 08/25/2009
• Status: Active Grant

• Current Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: CommScope Technologies, LLC (CommScope Holding Company, Inc.)
• Inventors: Pepe, Paul John, Bopp, Steven Richard
• Primary Examiner(s): GUSHI, ROSS N
• Application Number:
  US15/042,554
• Publication Number:
  US 20170025781A1
• Time in Patent Office: 606 Days
• 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 base;

a first printed circuit extending from the base;

a second printed circuit held by the 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, each circuit contact being engaged with and electrically connected to the first 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 first printed circuit.

2. The contact sub-assembly according to claim 1, wherein at least one of the circuit contacts comprises 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, and wherein the extension defines a portion of a secondary path for electrical energy to propagate through the contact sub-assembly.

3. The contact sub-assembly according to claim 2, wherein the extension comprises at least one barb that is engaged with the at least one of an electrical trace or an electrical contact of the second printed circuit.

4. The contact sub-assembly according to claim 2, 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 first printed circuit, and a mating contact engagement portion extending from the contact base in a second direction toward the corresponding mating contact, the extension extending outwardly from the contact base of the at least one circuit contact in the second direction.

5. The contact sub-assembly according to claim 2, 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 extension of the at least one circuit contact extending outwardly from one of the edges of the contact base.

6. The contact sub-assembly according to claim 1, wherein each mating contact comprises 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.

7. The contact sub-assembly according to claim 1, wherein the mating contacts comprise tip end portions, 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 at least one 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 at least one circuit contact to the first printed circuit.

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

9. The contact sub-assembly according to claim 1, wherein the array of circuit contacts at least one of reduces crosstalk or improves return loss.

10. The contact sub-assembly according to claim 1, wherein the array of circuit contacts is discrete from the array of mating contacts.

11. 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.

12. The contact sub-assembly according to claim 1, wherein at least one of the circuit contacts has a greater surface area than at least one of the mating contacts.

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

14. 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 two of the circuit contacts being aligned within different planes.

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