WO2015116407A1 - Electrical terminals - Google Patents

Electrical terminals Download PDF

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Publication number
WO2015116407A1
WO2015116407A1 PCT/US2015/011767 US2015011767W WO2015116407A1 WO 2015116407 A1 WO2015116407 A1 WO 2015116407A1 US 2015011767 W US2015011767 W US 2015011767W WO 2015116407 A1 WO2015116407 A1 WO 2015116407A1
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WO
WIPO (PCT)
Prior art keywords
electrical terminal
electrical
terminal
recited
along
Prior art date
Application number
PCT/US2015/011767
Other languages
French (fr)
Inventor
James M. Sabo
Original Assignee
Fci Asia Pte. Ltd
Fci Americas Technology Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fci Asia Pte. Ltd, Fci Americas Technology Llc filed Critical Fci Asia Pte. Ltd
Publication of WO2015116407A1 publication Critical patent/WO2015116407A1/en

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Classifications

    • 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
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • 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
    • H01R13/22—Contacts for co-operating by abutting
    • H01R13/24—Contacts for co-operating by abutting resilient; resiliently-mounted
    • H01R13/2442—Contacts for co-operating by abutting resilient; resiliently-mounted with a single cantilevered beam
    • 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
    • H01R12/75—Coupling devices for rigid printing circuits or like structures connecting to cables except for flat or ribbon cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/60—Contacts spaced along planar side wall transverse to longitudinal axis of engagement
    • H01R24/62—Sliding engagements with one side only, e.g. modular jack coupling devices

Definitions

  • an electrical connector is used to transmit data signals and/or electrical power, such as alternating current (AC) power and/or direct current (DC) power, between electrical components.
  • an electrical connector can include a plurality of electrical terminals, including power and/or signal terminals, which mate with complementary electrical terminals of a complementary electrical connector.
  • the electrical terminals typically define a mounting end that is configured to mount to an electrical component, such as a circuit board, cable, flex cable, or the like, and an opposed mating end that is configured to mate with the mating end of the complementary electrical terminal.
  • Electrical connectors are typically configured such that, as the electrical terminals mate along a wiping distance, the mating ends apply a normal force against each other that maintains the mated contacts in electrical connection with each other.
  • the mated electrical connectors are subject to thermal expansion particularly associated with electrical power contacts, and vibration, which can result in relative micromotion at the interface of the mating ends of the mated electrical terminals, which can cause localized fretting at the mating ends.
  • some electrical connectors undergo a high number of mating cycles, whereby the electrical connectors are mated and unmated with other electrical connectors.
  • the high number of mating cycles can cause the mating ends to become fretted due to abrasions at the mating ends caused by the high volume of mating and unmating with other electrical terminals.
  • Applying anti-corrosion materials, such as metal coatings for example, onto an electrically conductive base of the electrical terminals can reduce corrosion.
  • anti-corrosion materials such as gold plating for example, can wear off an electrically conductive base of electrical terminals due to the high number of mating cycles.
  • applying metal coatings, for instance noble or precious metal coatings, to electrical terminals can increase manufacturing costs due to the high costs of many metals.
  • an electrical terminal includes a body that defines a first end and a second end spaced from the first end along a length of the electrical terminal.
  • One of the first and second ends can define a projection along a first direction perpendicular to the length, and the other of the first and second ends can define a recess that extends into the body along a second direction perpendicular to the length and the first direction.
  • a metal coating can be selectively positioned on the electrical terminal. The metal coating can be positioned on the body adjacent at least one side of at least one of the pro jection and the recess with respect to the first direction,
  • FIG. 1 is an exploded perspective view of an electrical connector system constructed in accordance with one embodiment, including a first electrical connector and a second or complementary electrical connector;
  • FIG. 2 is a perspective view of portions of the first electrical connector and the complementary electrical connector aligned to be mated along a mating direciion;
  • FIG. 3 is a perspective view of the first electrical connector shown in Figs. 1 and
  • FIG. 4 is a perspective view of a portion of the first electrical connector, showing electrical terminals
  • FIG. 5A is an isolated view of an example electrical terminal, in particular a mating portion of a ground terminal of the first and complementar electrical connectors, in accordance with the example embodiment illustrated in Figs. 1-4;
  • Fig. 5B is a perspective view of an inner surface of a free distal end of the mating portion shown in Fig. 5 A;
  • Fig. 5C is a perspective view of an outer mating surface of the free distal end of the mating portion shown in Fig. 5A;
  • FIG. 6A is an isolated view of an example eiectricai terminal in particular a mating portion of a signai terminal of the first and complementary eiectricai connectors, in accordance with the example embodiment illustrated in Figs. 1-4;
  • Fig. 6B is a perspective view of an inner surface of a free distal end of the mating portion shown in Fig. 6A;
  • Fig. 6C is a perspective view of an outer mating surface of the free distal end of the mating portion shown in Fig. 6A;
  • Fig. 7 is a perspective view of a cross-section of the electrical connector system shown in Fig. 1, wherein the first electrical connector and the complementary electrical connector are in a mated position with each other.
  • an electrical connector system 20 constructed in accordance with one embodiment can include a first electrical connector assembly 22 and a seeond or complementary electrical connector assembly 24.
  • the first electrical connector assembly 22 is configured to be mated with the second or complementary eiectricai connector assembly 24 in a mating direction M.
  • the first electrical connector assembly 22 can include a first electrical connector 100 and a second electrical component such as a substrate 400 that can be configured as a printed circuit board.
  • the complementary electrical assembly 24 can include a complementary or second electrical connector 300 and at least one first electrical component such as at least one electrical cable 200, including a plurality of electrical cables 200.
  • the first and second electrical connectors 100 and 300 can be configured to be mated with each other so as to establish an electrical connection between the first and second electrical connectors 100 and 300, and thus between the first and complementary electrical connector assemblies 22 and 24, respectively.
  • the second electrical connector 300 can be configured to be mounted to the plurality of electrical cables 200 so as to place the second electrical connector 300 in electrical communication with the plurality of electrical cables 200.
  • the first, electrical connector 100 can be configured to be mounted to the substrate 400 so as to establish an electrical connection between the first electrical connector 100 and the substrate 400.
  • the electrical cables 200 can be placed in electrical communication with the substrate 400 when the first and second electrical connectors 100 and 300 are mounted to the substrate 400 and the electrical cable 200, respectively, and mated to each other.
  • the substrate 400 can be provided as a backplane, midplane, daughtercard, or the like.
  • the electrical cables 200 can be configured as signal cables, power cables, optica! cables, or any suitable alternatively constructed cables.
  • the second electrical connector assembly 24 can be referred to as an electrical cable assembly, including the second electrical connector 300 that can be referred to as a cable connector configured to be mounted to the plurality of electrical cables 200 so as to place the second electrical connector 300 in electrical communication with each of the plurality of electrical cables 200.
  • the first electrical connector 100 can include a first dielectric or electrically insulative connector housing 106 and a plurality of electrical terminals 150 that are supported by the connector housing 106.
  • the complementary electrical connector 300 can include a second or complementary dielectric or electrically insulative connector housing 302 and electrical terminals 150 that are supported by the connector housing 302.
  • the plurality of electrical terminals 150 can include a plurality of signal terminals 352 and a plurality of ground terminals 154.
  • the electrical terminals 150 are illustrated in Fig. 1 as being included in the first and complementary electrical connectors 100 and 300, respectively, but it will be understood that the electrical terminals 150 can be arranged in any electrical connector as desired.
  • the first electrical connector 100 and the complementary electrical connector 300 are constructed as vertical electrical connectors.
  • the connector housing 302 defines a mating interface 306 that is configured to engage a mating interface 102 of the first electrical connector 100 when the first and second electrical connectors 100 and 300 mate with each other.
  • the connector housing 106 further defines a mounting interface 104 that is configured to engage the substrate 400 when electrical connector 100 is mounted to the substrate 400.
  • the connector housing 302 further defines a mounting interface 308 that is configured to engage the electrical cables 200 when the complementary electrical connector 300 is mounted to the electrical cables 200.
  • the mating interface 306 can be oriented parallel to the mounting interface 308.
  • the electrical terminals 150 of the first electrical connector 100 can include electrical signal terminals 152 and ground terminals 154.
  • the electrical terminals 150 of the first electrical connector 100 can define respective mating portions 156 that are configured to mate with complementary mating portions of electrical terminals of the complementary electrical connector 300, and respective mounting portions that are configured to be mounted to the substrate 400.
  • the mating interface 102 can be oriented parallel to the mounting interface 104.
  • the first electrical connector 100 can be configured as a right-angle electrical connector whereby the mating interface 102 and the mounting interface 104 are oriented perpendicular with respect to each other, and the mating portions and the mounting portions are oriented perpendicular to each other.
  • the electrical terminals 150 can include the plurality of signal terminals 152 and ground terminals 154 arranged in any manner as desired.
  • adjacent signal terminals can define differential signal pairs or single ended signal terminals as desired.
  • each of the ground terminals 154 of the electrical connector 100 can define respective ground mating portions 156 and ground mounting portions in electrical communication with the ground mating portions 156.
  • each of the signal terminals 152 of the electrical connector 102 can define respective mating portions 156 and mounting portions in electrical communication with the mating portions 56.
  • the mating portions 156 of the electrical terminals 56 can define mating portions that can include the mating portions of the electrical signal terminals 152 and the ground mating portions, and the electrical terminals 150 can further define mounting portions that can include the mounting portions of the electrical signal terminals and the ground mounting portions. Because the mating ends of the signal terminals and the ground mating ends of the second electrical connector 300 are provided as receptacle mating ends and receptacle ground mating ends, respectively, the second electrical connector 300 can be referred to as a receptacle connector.
  • ground terminals 154 which can also be referred to collectively as ground terminals 154, can be disposed between adjacent pairs of differential signal pairs.
  • adjacent signal terminals 152 for instance along a first or transverse direction T, can define differential signal pairs.
  • the leadframe assemblies can include ground terminals 154 disposed between adjacent pairs of differential signal pairs along the transverse direction T.
  • the electrical connector 100 can include at least one electrical terminal
  • the at least one electrical terminal can be a first electrical terminal, and the electrical connector 100 can further include a second electrical terminal 150 disposed adjacent the first electrical terminal 150 along the transverse direction T.
  • the first and second electrical terminals 150 can be signal terminals 152.
  • the first terminal can be a signal terminal, and the second terminal can be a ground terminal.
  • the ground terminals 154 can define a width along the transverse direction T that is greater than that of the signal terminals 152.
  • the electrical connector 00 can include at least one electrical terminal that is a first eiectrical terminal 150, and the electrical connector can further include a second electrical terminal 150 disposed between the first electrical terminal and a third electrical terminal 150 along the transverse direction T.
  • the first and second electrical terminals can be signal terminals and the third electrical terminal can be a ground terminal.
  • the third terminal can define a width along the first direction that is greater than that of each of the first and second electrical terminals.
  • the first and second electrical terminals can define a differential signal pair.
  • the longitudinal direction "L” extends along a forward/rearward direction of the first electrical connector 100, and defines a mating direction M along which one or both of the electrical connectors 100 and 300 are moved relative to the other so as to mate the first electrical connector assembly 22 with the complementary electrical connector assembly 24, and thus to mate the first eiectrical connector 100 with the complementary electrical connector 300.
  • the mating direction M of the first electrical connector 100 is in a forward direction along longitudinal direction L, and the electrical connector can be unmated from the complementary' connector 44 by moving the first electrical connector 100 in an opposed longitudinally rearward direction relative to the complementar connector 300.
  • the lateral direction "A" extends along a width of the first electrical connector 100.
  • inboard and outboard and outer when used with respect to a specified directional component are intended to refer to directions along the directional component toward and away from the center of the apparatus being described.
  • the term “in” when used with a specified direction component is intended to refer to the single specified direction
  • the term “along” when used with a specified direction component is intended to refer to both directions (i.e., toward and away) of the specified direction component.
  • the longitudinal and lateral directions L and A are illustrated as extending along a horizontal plane
  • the transverse direction T is illustrated as extending along a vertical plane
  • the planes that encompass the various directions may differ during use, depending, for instance, on the orientation of the various components.
  • the directional terms “vertical” and “horizontal” are used to describe the electrical connector system 20 and its components as illustrated merely for the purposes of clarity and convenience, it being appreciated that these orientations may change during use.
  • each of the electrical terminals 150 can define a body 158 and the mating portion 156 that can be elongate along the mating direction M, which can thus be along a length of the electrical terminal 150.
  • the mating portions 156 of the electrical terminals 150 of the first electrical connector 100 are disposed proximate to the mating interface 102, and are configured to contact respective complementary electrical terminals 150, for instance complementary electrical terminals 150a of the complementary electrical connector 300, when the electrical connector 100 is electrically mated with the complementary electrical connector 300.
  • the electrical terminals 150 of the electrical connector 100, and the complementary electrical terminal, for instance the complementary electrical terminal 150a of the complementary electrical connector 300, are hermaphroditic.
  • the mating portion 156, and thus the body 158, can define a first or proximal end 156a and a second or free distal end 156b that is spaced from the proximal end 156a along the mating direction M, which can be along the length the electrical terminal 150.
  • One of the proximal or distal ends 156a and 156b can define a projection 162 along the transverse direction T perpendicular to the length of the mating portion 156.
  • the other of the proximal and distal ends 156a and 156b can define a recess 168 that extends into the body 158 along the lateral direction A perpendicular to the length, and thus the mating direction M, and the transverse direction T.
  • the recess 168 can be sized so as to receive the projection 162.
  • a rnetal coating for instance a noble or precious metal coating, can be selectively positioned on the electrical terminal 150.
  • Example metals that can be positioned on the electrical terminal 150 include gold, other noble or precious metals, tin, tin-lead, or the like.
  • the rnetal coating can be positioned on the body 158 adjacent at least one side of at least one of the projection 162 and the recess 168 with respect to the transverse direction T.
  • the projection 162 can include opposed sides, for instance a first side 160a and a second side 160b, spaced along the transverse direction T,
  • the recess can include opposed sides, for instance a third side 160c and a fourth side 160d, spaced along the transverse direction T.
  • the metal coating can be positioned on the body 158 adjacent at least one side of the projection 162.
  • the metal coating is positioned on the body 1 58 adjacent the first and second sides 160a and 160b of the projection 162 with respect to the transverse direction T.
  • the projection 162 can define a first length Li along the mating direction M, and thus along the length of the electrical terminal 150.
  • the first length Lj can be at least equal to, for instance greater than, a second length L 2 defined by the metal coating positioned on the body 158 adjacent at least one side of the projection 162,
  • the second length L 2 can be measured along the length of electrical terminal 150.
  • the metal coating can be positioned on the body 158 adjacent at least one side of the recess 168.
  • the metal coating is positioned on the body 158 adjacent the third and fourth sides 160c and 160d of the recess 168 with respect to the transverse direction T.
  • the recess 168 can define a third length L 3 along the mating direction M, and thus along the length of the electrical terminal 150 that is substantially perpendicular to both the transverse and lateral directions T and A.
  • the third length L3 can be at least equal to, for instance greater than, a fourth length L 4 defined by the metal coating positioned on the body 158 adjacent at least one side of the recess 168.
  • the fourth length L 4 can be measured along the length of the electrical terminal 150 that is substantially perpendicular to both the transverse and lateral directions T and A.
  • the metal coating can be positioned on the body 158 adjacent opposed sides of at least one of the projection 162 and the recess 168 with respect to the transverse direction T.
  • the projection 362 can define a peak surface 162a that is offset relative to the first and second sides 160a and 360b along the lateral direction A that is substantially perpendicular to the mating and transverse directions M and T, respectively.
  • distal end 156b contacts the complementary electrical terminal 150a before the proximal end 156a contacts the
  • the direction terms “distal” and “forward” and derivatives thereof can refer to a direction along the longitudinal direction L from the proximal end 156a of the mating portion 156 toward the distal end 156b of the mating portion 156.
  • the direction terms “proximal” and “rearward” and derivatives thereof can refer to a direction along the longitudinal direction L from the distal end 156b of the mating portion 156 toward the proximal end 156a of the mating portion 156.
  • the projection 162 including the first and second sides 160a and 160b are disposed at the free distal end 156b.
  • the mating portion 156 of the electrical terminal 150, and in particular the distal end 156b, can define a curved tip 157.
  • the mating portion 156 can further define a connecting portion 159 that extends along the length of the mating portio 156 from the curved tip 157 to, and including, the proximal end 156a.
  • the connecting portion 159 can be constructed as a planar portion such that the connecting portion 159 includes a outer surface that is substantially flat.
  • the connecting portion 159 can be constructed as a planar portion that lies in a plane defined by the longitudinal and transverse directions L and T, respectively.
  • the mating portion 156 and thus the electrical terminal 150, can define the planar portion that extends along the length of the mating portion 156 from the curved tip 157 to at least the recess 168, for instance including the proximal end 156a.
  • the planar portion can extend along a plane defined by the length of the mating portion 156, and thus the electrical terminal 150, and the transverse direction T.
  • the mating portion 156 can be alternatively shaped as desired.
  • the connecting portion 159 can be alternatively shaped as desired. For instance, at least a portion, for instance all, of the connecting portion 159 can be constructed as a non-planar portion.
  • the connecting portion 159 can include the outer surface, and at least a portion of the outer surface can be curved such that at least a portion of the connecting portion 159 is a radiused portion.
  • the mating portion 156, and thus the electrical terminal 150 can define the non-planar or radiused portion that extends along the length of the mating portion 156 from the curved tip 157 to at least the recess 168, for instance including the proximal end 156a,
  • the mating portion 156 and thus the body 158, can define an outer mating surface 158a and an inner surface 158b opposite the outer mating surface 158a.
  • the outer mating surface of 158a of the electrical terminal can define an outer mating surface 158a and an inner surface 158b opposite the outer mating surface 158a.
  • the projection 162 can define a ridge 164 that projects out from the body 158, and in particular the outer mating surface 158a of the body 158.
  • the projection 162, and thus the ridge 164 can be monolithic with the body 158.
  • the ridge 164 can be separate and attached to the body 158.
  • the distal end 156b can define a dimple 166 that that extends into the body 158 such thai a thickness of the projection 162 is substantially uniform along the transverse direction T. While the illustrated electrical terminals 150 that include the ridge 64 and the dimple 166 are the ground terminals 154, it will be understood that the signal terminals 152 can include the ridge 164 and/or the dimple 166 as desired. Further, it will be understood that the projection 162 can be alternatively shaped as desired.
  • the projection 162 and the opposed sides of the projection 162 can define a continuous or non-continuous convex surface such that the projection 162, and in particular the peak surface 162a, is configured to ride along the complementary mating portion of the complementary electrical terminal 150a as the electrical connector 100 is electrically mated with the complementary electrical connector 300 along the mating directio M, which can be along the length of the mating portion 156.
  • the outer mating surface 158a can include the convex surface such that the convex surface can face the outer mating surface of a complementary electrical terminal, for instance the electrical terminal 150a of the complementary electrical connector 300, when the electrical connector 100 is mated with the complementary electrical connector 300.
  • a complementary electrical terminal for instance the electrical terminal 150a of the complementary electrical connector 300
  • the illustrated electrical terminals 150 that include the convex surface are the signal terminals 152, it will be understood that the ground terminals 154 can alternatively, or additionally, include the convex surface as desired.
  • the projection can be alternatively constructed such that the projection rides along the
  • the projection 162 can define the first length L s along the mating direction M and the metal coating positioned adjacent the first and second sides 160a and 160b can define a second length L 2 along the mating direction M.
  • the length L 2 can be defined by a metallic layer of anti-corrosion material, for instance gold, other noble or precious metals, tin, tin-lead, or the like, or a combination thereof, that is disposed on a base of the electrical terminals 150 at the outer mating surface 158a.
  • the first length L; of the projection 162 can be least equal to, for instance greater than, the second length L 2 .
  • the lengths of the metal coating positioned adjacent the first and second sides 160a and 160b are substantially equal to each other, although it will be understood that the lengths defined by the metal adjacent to the first and second sides can be alternatively sized as desired.
  • the first length L; of the projection 162 and the second lengths L 2 of the metals positioned adjacent to the opposed sides 160 and 160b can be centered with respect to each other such that the metal coatings are aligned with the projection 162 when viewed along the transverse direction T.
  • the recess 168 can be configured to at least partially receive a complementary projection 162 of the complementary electrical terminal 150a such that the metal positioned adjacent to the third and fourth sides 160c and 160d contacts the complementary electrical terminal when the electrical connector 100 is mated with the complementary electrical connector 300.
  • the recess 168 and the opposed sides 160c and 1 0d of the recess 168 can define a continuous concave surface that faces the complementary electrical terminal 150a when the electrical terminal 150 is electrically mated with the
  • the complementary electrical terminal 150a along the length of the electrical terminal 150, and in particular along the length of the mating portion 156.
  • the illustrated electrical ierminals 50 that include the outer mating surface 158a that includes the continuous concave surface are the signal terminals 152
  • the ground terminals 154 can include the outer mating surface 158a that includes the continuous concave surface as desired.
  • the recess 168 and the opposed sides 160c and 160d of the recess 168 can define a non-continuous concave surface that faces a complementary electrical terminal when the electrical terminal 150 is electrically mated with the complementary electrical terminal along the length of electrical terminal 150, and in particular along the length of the mating portion 156.
  • the illustrated electrical terminals 150 that include the outer mating surface 158a that includes the non-continuous concave surface are the signal terminals 152
  • the ground terminals 154 can include the outer mating surface 158a that includes the non-continuous concave surface as desired.
  • the recess 168 can be an opening 170 that is partially defined by the third and fourth sides 160c and 160d.
  • the opening 170, and thus the recess 168, can extend through the body 358 along the lateral direction A.
  • the recess 168 can extend into, but not through, the body 158 along the lateral direction A (see Fig. 6A).
  • the recess 168 is defined by the proximal end 156a of the mating portion 156, although it will be understood that the recess 168 can be alternatively disposed as desired.
  • the illustrated electrical terminals 150 that include the opening 170 are the ground terminals 154, although it will be understood that the signal terminals 152 can include the opening 170 as desired.
  • the recess 168 can define the third length L3 along the mating direction M, and the metal coating positioned adjacent to the third and fourth sides 160c and 160d can define a fourth length L4 along the mating direction M.
  • the length L 4 of the metal coating positioned adjacent to the third and fourth sides 160c and 160d can be defined by a metallic layer of anti-corrosion material, for instance gold, tin, or the like, that is disposed on a base of the electricai terminals 150 at the outer mating surface 158a, as further described below.
  • the length L 3 of the recess 168 can be least equal to, for instance greater than, the length L 4 defined by the metal coating positioned adjacent to the third and fourth sides 160c and 160d. Further, as shown, the lengths of the metal coatings positioned adjacent to the third and fourth sides 160c and 160d are substantially equal to each other, although it will be understood that the lengths of the metal coating positioned adjacent to the third and fourth sides 160c and 160d can be alternatively constructed as desired. The lengths L 3 and L 4 can be centered with respect to each other such that the metal coating positioned adjacent to the third and fourth sides 160c and 160d are aligned with the recess 368 when viewed along the transverse direction T.
  • the metal coating does not extend continuously from a first location that is aligned with the projection 162 along the transverse direction T to a second location that is aligned with the recess 168 along the length of the mating portion 156.
  • the electrical terminals 150 can include an electrically conductive base and a metallic layer of a metal or alloy thereof disposed on an outer mating surface of the base.
  • the metallic layer is only disposed on the outer mating surface 158a adjacent to the sides 160a-d along the transverse direction T.
  • the body 156 can be gold-plated to reduce corrosion at locations of the electrical terminal 150 that are electrically mated when the electricai terminal 50 is mated with a complementary electrical terminal, such as when the electrical connector 100 is mated with the complementary electrical connector 300.
  • the metallic layer need not be applied to the entire mating portion 156 of the electrical terminal 1 50.
  • the metallic layer can include a noble metal, for instance gold, or any other anti-corrosive material as desired.
  • the electrically conductive base can include any electrically conductive material, for instance copper or a copper alloy. Further, because the metal coating of the electrical terminal 150 does not contact a complementary electrical terminal as the electrical terminal 150 is mated with the complementary electrical terminal, the metal coating is subject to less friction and wear as compared to conventional electrical terminals, enabling the metal coating to last longer before being worn off the body 158.
  • the first electrical connector 100 can be mated to the
  • the complementary electrical connector 300 along the mating direction M (see Figs. 1 and 7) so that the distal end 156b of the mating portion 158 moves toward the proximal end 156a of the complementary electrical terminal 150a of the complementary electrical connector 300.
  • a pair of the electrical terminals 150 that are included in different electrical connectors for instance the electrical terminal 150 of the electrical connector 100 and the electrical terminal 150a of the complementary electrical connector 300, can be mated with each other (see Fig. 7 in particular).
  • the mating portions 156 of the electrical terminals 150 can be brought into contact with each other.
  • the projections 162, in particular the peak surfaces 162a come into contact with other.
  • the projection 162 of the select electrical terminal 150 rides along the outer surface of the connecting portion 159, and thus the mating portion 156, of the complementary electrical terminal 150.
  • the projection 162 of the complementary electrical terminal 350 rides along the outer surface of the connecting portion 359, and thus the outer surface of the mating portion 356, of the select electrical terminal 150.
  • a method of mating the electrical connector 100 that includes at least one electrical terminal 350 with a complementary electrical connector that includes at least one complementary electrical terminal can include causing the projection 162 of the electrical terminal 150 to ride along the length of the body 158 of the complementary electrical terminal 150 until the projection 162 is at least partially received by the recess 168 of the complementary electrical terminal (see Fig. 7).
  • the method can further include causing the metal coating positioned on the body 158 of the electrical terminal 150 adjacent at least one side of at least one of the projection 162 and the recess 168 to contact the metal coating positioned on at least one side of the other of the projection 162 and the recess 168 of the body 158 of the complementary electrical terminal.
  • a method can be provided for reducing the amount of a metal positioned on an electrical terminal.
  • the method can include the step of providing or teaching the use of an electrical terminal having the body 158 that defines a first end and a second end spaced from the first end along the length of the electrical terminal 150, wherein one of the first and second ends defines the projection 162 along a first direction perpendicular to the length, and the other of the first, and second ends defines the recess 68 that extends into the body 158 along a second direction perpendicular to the length and the first direction.
  • the method cars further include selectively positioning the metal coating on the body 158 adjacent at least one side of at least one of the projection 162 and the recess 168 with respect to the first direction.
  • the method can further include selling to the third party the electrical terminal or purchasing the electrical terminal from the third party.
  • a method can be provided for creating an electrical terminal, such as one of the electrical terminals described herein.
  • the method can include depressing the inner surface 158b of the body 158 to define the projection 162 that projects out from the outer mating surface 158a of the body 158 that is opposite the inner surface 158b of the body 158.

Abstract

When electrical connectors are mated with each other, friction can cause anti-corrosion material, such as gold for example, to wipe away from electrical terminals of the electrical connectors. Embodiments of electrical connectors and electrical terminals including selectively plated electrical terminals are disclosed.

Description

ELECTRICAL TERMINALS
BACKGROUND
[0001] Electrical connectors are used to transmit data signals and/or electrical power, such as alternating current (AC) power and/or direct current (DC) power, between electrical components. For instance, an electrical connector can include a plurality of electrical terminals, including power and/or signal terminals, which mate with complementary electrical terminals of a complementary electrical connector. The electrical terminals typically define a mounting end that is configured to mount to an electrical component, such as a circuit board, cable, flex cable, or the like, and an opposed mating end that is configured to mate with the mating end of the complementary electrical terminal.
[0002] Electrical connectors are typically configured such that, as the electrical terminals mate along a wiping distance, the mating ends apply a normal force against each other that maintains the mated contacts in electrical connection with each other. During use, the mated electrical connectors are subject to thermal expansion particularly associated with electrical power contacts, and vibration, which can result in relative micromotion at the interface of the mating ends of the mated electrical terminals, which can cause localized fretting at the mating ends. Furthermore, some electrical connectors undergo a high number of mating cycles, whereby the electrical connectors are mated and unmated with other electrical connectors. The high number of mating cycles can cause the mating ends to become fretted due to abrasions at the mating ends caused by the high volume of mating and unmating with other electrical terminals. Applying anti-corrosion materials, such as metal coatings for example, onto an electrically conductive base of the electrical terminals can reduce corrosion. However, anti- corrosion materials, such as gold plating for example, can wear off an electrically conductive base of electrical terminals due to the high number of mating cycles. Further, applying metal coatings, for instance noble or precious metal coatings, to electrical terminals can increase manufacturing costs due to the high costs of many metals. SUMMARY
[0003] In accordance with one embodiment, an electrical terminal includes a body that defines a first end and a second end spaced from the first end along a length of the electrical terminal. One of the first and second ends can define a projection along a first direction perpendicular to the length, and the other of the first and second ends can define a recess that extends into the body along a second direction perpendicular to the length and the first direction. A metal coating can be selectively positioned on the electrical terminal. The metal coating can be positioned on the body adjacent at least one side of at least one of the pro jection and the recess with respect to the first direction,
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The foregoing summary, as well as the following detailed description of a preferred embodiment of the application, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the selectively-positioned coating and related instruments of the present application, there is shown in the drawings example embodiments. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. In the drawings:
[0005] Fig. 1 is an exploded perspective view of an electrical connector system constructed in accordance with one embodiment, including a first electrical connector and a second or complementary electrical connector;
[0006] Fig. 2 is a perspective view of portions of the first electrical connector and the complementary electrical connector aligned to be mated along a mating direciion;
[0007] Fig. 3 is a perspective view of the first electrical connector shown in Figs. 1 and
■i-
[0008] Fig. 4 is a perspective view of a portion of the first electrical connector, showing electrical terminals;
[0009] Fig. 5A is an isolated view of an example electrical terminal, in particular a mating portion of a ground terminal of the first and complementar electrical connectors, in accordance with the example embodiment illustrated in Figs. 1-4;
[ 0010] Fig. 5B is a perspective view of an inner surface of a free distal end of the mating portion shown in Fig. 5 A; [00111 Fig. 5C is a perspective view of an outer mating surface of the free distal end of the mating portion shown in Fig. 5A;
[0012] Fig. 6A is an isolated view of an example eiectricai terminal in particular a mating portion of a signai terminal of the first and complementary eiectricai connectors, in accordance with the example embodiment illustrated in Figs. 1-4;
[0013] Fig. 6B is a perspective view of an inner surface of a free distal end of the mating portion shown in Fig. 6A;
[0014] Fig. 6C is a perspective view of an outer mating surface of the free distal end of the mating portion shown in Fig. 6A; and
[0015] Fig. 7 is a perspective view of a cross-section of the electrical connector system shown in Fig. 1, wherein the first electrical connector and the complementary electrical connector are in a mated position with each other.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0016| For convenience, the same or equivalent elements in the various embodiments illustrated in the drawings have been identified with the same reference numerals. Referring initially to Fig. 1 , an electrical connector system 20 constructed in accordance with one embodiment can include a first electrical connector assembly 22 and a seeond or complementary electrical connector assembly 24. The first electrical connector assembly 22 is configured to be mated with the second or complementary eiectricai connector assembly 24 in a mating direction M. The first electrical connector assembly 22 can include a first electrical connector 100 and a second electrical component such as a substrate 400 that can be configured as a printed circuit board. The complementary electrical assembly 24 can include a complementary or second electrical connector 300 and at least one first electrical component such as at least one electrical cable 200, including a plurality of electrical cables 200.
[0017] The first and second electrical connectors 100 and 300 can be configured to be mated with each other so as to establish an electrical connection between the first and second electrical connectors 100 and 300, and thus between the first and complementary electrical connector assemblies 22 and 24, respectively. The second electrical connector 300 can be configured to be mounted to the plurality of electrical cables 200 so as to place the second electrical connector 300 in electrical communication with the plurality of electrical cables 200. Similarly, the first, electrical connector 100 can be configured to be mounted to the substrate 400 so as to establish an electrical connection between the first electrical connector 100 and the substrate 400. Thus, the electrical cables 200 can be placed in electrical communication with the substrate 400 when the first and second electrical connectors 100 and 300 are mounted to the substrate 400 and the electrical cable 200, respectively, and mated to each other.
[0018] The substrate 400 can be provided as a backplane, midplane, daughtercard, or the like. The electrical cables 200 can be configured as signal cables, power cables, optica! cables, or any suitable alternatively constructed cables.
[§019] With continuing reference to Fig. 1, the second electrical connector assembly 24 can be referred to as an electrical cable assembly, including the second electrical connector 300 that can be referred to as a cable connector configured to be mounted to the plurality of electrical cables 200 so as to place the second electrical connector 300 in electrical communication with each of the plurality of electrical cables 200. Referring additionally to Fig. 2, the first electrical connector 100 can include a first dielectric or electrically insulative connector housing 106 and a plurality of electrical terminals 150 that are supported by the connector housing 106. Further, the complementary electrical connector 300 can include a second or complementary dielectric or electrically insulative connector housing 302 and electrical terminals 150 that are supported by the connector housing 302. The plurality of electrical terminals 150 can include a plurality of signal terminals 352 and a plurality of ground terminals 154. The electrical terminals 150 are illustrated in Fig. 1 as being included in the first and complementary electrical connectors 100 and 300, respectively, but it will be understood that the electrical terminals 150 can be arranged in any electrical connector as desired.
[0020] In accordance with the illustrated embodiment, the first electrical connector 100 and the complementary electrical connector 300 are constructed as vertical electrical connectors. n particular, the connector housing 302 defines a mating interface 306 that is configured to engage a mating interface 102 of the first electrical connector 100 when the first and second electrical connectors 100 and 300 mate with each other. The connector housing 106 further defines a mounting interface 104 that is configured to engage the substrate 400 when electrical connector 100 is mounted to the substrate 400. The connector housing 302 further defines a mounting interface 308 that is configured to engage the electrical cables 200 when the complementary electrical connector 300 is mounted to the electrical cables 200. The mating interface 306 can be oriented parallel to the mounting interface 308. Further, the electrical terminals 150 of the first electrical connector 100 can include electrical signal terminals 152 and ground terminals 154. The electrical terminals 150 of the first electrical connector 100 can define respective mating portions 156 that are configured to mate with complementary mating portions of electrical terminals of the complementary electrical connector 300, and respective mounting portions that are configured to be mounted to the substrate 400. As shown, the mating interface 102 can be oriented parallel to the mounting interface 104. Alternatively, the first electrical connector 100 can be configured as a right-angle electrical connector whereby the mating interface 102 and the mounting interface 104 are oriented perpendicular with respect to each other, and the mating portions and the mounting portions are oriented perpendicular to each other.
[0021] Referring to Figs, 1-4, the electrical terminals 150 can include the plurality of signal terminals 152 and ground terminals 154 arranged in any manner as desired. For instance, adjacent signal terminals can define differential signal pairs or single ended signal terminals as desired. For instance, each of the ground terminals 154 of the electrical connector 100 can define respective ground mating portions 156 and ground mounting portions in electrical communication with the ground mating portions 156. Furthermore, each of the signal terminals 152 of the electrical connector 102 can define respective mating portions 156 and mounting portions in electrical communication with the mating portions 56. Thus, it can be said that the mating portions 156 of the electrical terminals 56 can define mating portions that can include the mating portions of the electrical signal terminals 152 and the ground mating portions, and the electrical terminals 150 can further define mounting portions that can include the mounting portions of the electrical signal terminals and the ground mounting portions. Because the mating ends of the signal terminals and the ground mating ends of the second electrical connector 300 are provided as receptacle mating ends and receptacle ground mating ends, respectively, the second electrical connector 300 can be referred to as a receptacle connector.
[0022] One or more ground terminals 154, which can also be referred to collectively as ground terminals 154, can be disposed between adjacent pairs of differential signal pairs. For instance, when the electrical terminals 150 are supported by respective !eadframe housings, adjacent signal terminals 152, for instance along a first or transverse direction T, can define differential signal pairs. The leadframe assemblies can include ground terminals 154 disposed between adjacent pairs of differential signal pairs along the transverse direction T. When the electrical connector 100 is mounted to the substrate 400 along a mounting direction, the electrical terminals 150 are placed in electrical communication with electrical traces of the substrate 400.
[§023] Thus, the electrical connector 100 can include at least one electrical terminal
150. The at least one electrical terminal can be a first electrical terminal, and the electrical connector 100 can further include a second electrical terminal 150 disposed adjacent the first electrical terminal 150 along the transverse direction T. The first and second electrical terminals 150 can be signal terminals 152. Alternatively, the first terminal can be a signal terminal, and the second terminal can be a ground terminal. As illustrated, the ground terminals 154 can define a width along the transverse direction T that is greater than that of the signal terminals 152. By way of another example, the electrical connector 00 can include at least one electrical terminal that is a first eiectrical terminal 150, and the electrical connector can further include a second electrical terminal 150 disposed between the first electrical terminal and a third electrical terminal 150 along the transverse direction T. The first and second electrical terminals can be signal terminals and the third electrical terminal can be a ground terminal. For instance, the third terminal can define a width along the first direction that is greater than that of each of the first and second electrical terminals. Further, the first and second electrical terminals can define a differential signal pair.
[0024] Various structures are described herein as extending horizontally along a longitudinal direction "L" and a second or lateral direction "A" that is substantially
perpendicular to the longitudinal direction L, and vertically along a first or transverse direction "T" that is substantially perpendicular to the longitudinal and lateral directions L and A, respectively. As illustrated, the longitudinal direction "L" extends along a forward/rearward direction of the first electrical connector 100, and defines a mating direction M along which one or both of the electrical connectors 100 and 300 are moved relative to the other so as to mate the first electrical connector assembly 22 with the complementary electrical connector assembly 24, and thus to mate the first eiectrical connector 100 with the complementary electrical connector 300. For instance, the mating direction M of the first electrical connector 100 is in a forward direction along longitudinal direction L, and the electrical connector can be unmated from the complementary' connector 44 by moving the first electrical connector 100 in an opposed longitudinally rearward direction relative to the complementar connector 300. As illustrated, the lateral direction "A" extends along a width of the first electrical connector 100.
[0025] Thus, unless otherwise specified herein, the terms "lateral," "longitudinal," and
"transverse" are used to describe the orthogonal directional components of various components.
The terms "inboard" and "inner," and "outboard" and "outer" and like terms when used with respect to a specified directional component are intended to refer to directions along the directional component toward and away from the center of the apparatus being described.
Further, the term "in" when used with a specified direction component is intended to refer to the single specified direction, and the term "along" when used with a specified direction component is intended to refer to both directions (i.e., toward and away) of the specified direction component. It should be appreciated that while the longitudinal and lateral directions L and A are illustrated as extending along a horizontal plane, and that while the transverse direction T is illustrated as extending along a vertical plane, the planes that encompass the various directions may differ during use, depending, for instance, on the orientation of the various components. Accordingly, the directional terms "vertical" and "horizontal" are used to describe the electrical connector system 20 and its components as illustrated merely for the purposes of clarity and convenience, it being appreciated that these orientations may change during use.
[0026] With particular reference to Figs. 4, 5A, and 6A, each of the electrical terminals 150 can define a body 158 and the mating portion 156 that can be elongate along the mating direction M, which can thus be along a length of the electrical terminal 150. In accordance with the illustrated embodiment the mating portions 156 of the electrical terminals 150 of the first electrical connector 100 are disposed proximate to the mating interface 102, and are configured to contact respective complementary electrical terminals 150, for instance complementary electrical terminals 150a of the complementary electrical connector 300, when the electrical connector 100 is electrically mated with the complementary electrical connector 300. In accordance with the illustrated embodiments, the electrical terminals 150 of the electrical connector 100, and the complementary electrical terminal, for instance the complementary electrical terminal 150a of the complementary electrical connector 300, are hermaphroditic. The mating portion 156, and thus the body 158, can define a first or proximal end 156a and a second or free distal end 156b that is spaced from the proximal end 156a along the mating direction M, which can be along the length the electrical terminal 150. One of the proximal or distal ends 156a and 156b can define a projection 162 along the transverse direction T perpendicular to the length of the mating portion 156. The other of the proximal and distal ends 156a and 156b can define a recess 168 that extends into the body 158 along the lateral direction A perpendicular to the length, and thus the mating direction M, and the transverse direction T. The recess 168 can be sized so as to receive the projection 162. A rnetal coating, for instance a noble or precious metal coating, can be selectively positioned on the electrical terminal 150. Example metals that can be positioned on the electrical terminal 150 include gold, other noble or precious metals, tin, tin-lead, or the like. For instance, the rnetal coating can be positioned on the body 158 adjacent at least one side of at least one of the projection 162 and the recess 168 with respect to the transverse direction T.
[0027] For instance, the projection 162 can include opposed sides, for instance a first side 160a and a second side 160b, spaced along the transverse direction T, The recess can include opposed sides, for instance a third side 160c and a fourth side 160d, spaced along the transverse direction T. The metal coating can be positioned on the body 158 adjacent at least one side of the projection 162. For instance, in accordance with the illustrated embodiments, the metal coating is positioned on the body 1 58 adjacent the first and second sides 160a and 160b of the projection 162 with respect to the transverse direction T. The projection 162 can define a first length Li along the mating direction M, and thus along the length of the electrical terminal 150. The first length Lj can be at least equal to, for instance greater than, a second length L2 defined by the metal coating positioned on the body 158 adjacent at least one side of the projection 162, The second length L2 can be measured along the length of electrical terminal 150. The metal coating can be positioned on the body 158 adjacent at least one side of the recess 168. For instance, in accordance with the illustrated embodiments, the metal coating is positioned on the body 158 adjacent the third and fourth sides 160c and 160d of the recess 168 with respect to the transverse direction T. The recess 168 can define a third length L3 along the mating direction M, and thus along the length of the electrical terminal 150 that is substantially perpendicular to both the transverse and lateral directions T and A. The third length L3 can be at least equal to, for instance greater than, a fourth length L4 defined by the metal coating positioned on the body 158 adjacent at least one side of the recess 168. The fourth length L4 can be measured along the length of the electrical terminal 150 that is substantially perpendicular to both the transverse and lateral directions T and A.
[0028] Thus, the metal coating can be positioned on the body 158 adjacent opposed sides of at least one of the projection 162 and the recess 168 with respect to the transverse direction T. The projection 362 can define a peak surface 162a that is offset relative to the first and second sides 160a and 360b along the lateral direction A that is substantially perpendicular to the mating and transverse directions M and T, respectively.
[0©29] in accordance with the illustrated embodiment the distal end 156b contacts the complementary electrical terminal 150a before the proximal end 156a contacts the
complementary electrical terminal 150a when the electrical connector 100 is mated with the complementary electrical connector 300 along the mating direction M. it should be appreciated that the direction terms "distal" and "forward" and derivatives thereof can refer to a direction along the longitudinal direction L from the proximal end 156a of the mating portion 156 toward the distal end 156b of the mating portion 156. t should further be appreciated that the direction terms "proximal" and "rearward" and derivatives thereof can refer to a direction along the longitudinal direction L from the distal end 156b of the mating portion 156 toward the proximal end 156a of the mating portion 156. n accordance with the illustrated embodiments, the projection 162 including the first and second sides 160a and 160b are disposed at the free distal end 156b. Further, the mating portion 156 of the electrical terminal 150, and in particular the distal end 156b, can define a curved tip 157.
[0030] With reference to Figs. 5A-7, in accordance with the illustrated embodiment, the mating portion 156, and thus the electrical terminal 150, can further define a connecting portion 159 that extends along the length of the mating portio 156 from the curved tip 157 to, and including, the proximal end 156a. For instance, at least a portion, for instance all, of the connecting portion 159 can be constructed as a planar portion such that the connecting portion 159 includes a outer surface that is substantially flat. Thus, the connecting portion 159 can be constructed as a planar portion that lies in a plane defined by the longitudinal and transverse directions L and T, respectively. Further, in accordance with the illustrated embodiment, the mating portion 156, and thus the electrical terminal 150, can define the planar portion that extends along the length of the mating portion 156 from the curved tip 157 to at least the recess 168, for instance including the proximal end 156a. The planar portion can extend along a plane defined by the length of the mating portion 156, and thus the electrical terminal 150, and the transverse direction T. It will be understood that the mating portion 156 can be alternatively shaped as desired. It. will further be understood that the connecting portion 159 can be alternatively shaped as desired. For instance, at least a portion, for instance all, of the connecting portion 159 can be constructed as a non-planar portion. For instance, the connecting portion 159 can include the outer surface, and at least a portion of the outer surface can be curved such that at least a portion of the connecting portion 159 is a radiused portion. Thus, the mating portion 156, and thus the electrical terminal 150, can define the non-planar or radiused portion that extends along the length of the mating portion 156 from the curved tip 157 to at least the recess 168, for instance including the proximal end 156a,
[§031] With reference to Figs. 5A-6C, the mating portion 156, and thus the body 158, can define an outer mating surface 158a and an inner surface 158b opposite the outer mating surface 158a. Referring also to Fig, 7, the outer mating surface of 158a of the electrical terminal
150 can be configured to contact the complementary electrical terminal, for instance the electrical terminals 150a of the complementary electrical connector 300, when the electrical connector 100 is electrically mated with the complementary electrical connector 300. As shown in Figs. 5A-B, the projection 162 can define a ridge 164 that projects out from the body 158, and in particular the outer mating surface 158a of the body 158. The projection 162, and thus the ridge 164, can be monolithic with the body 158. Alternatively, the ridge 164 can be separate and attached to the body 158. In accordance with the illustrated embodiment, the mating portion
156, in particular the distal end 156b, can define a dimple 166 that that extends into the body 158 such thai a thickness of the projection 162 is substantially uniform along the transverse direction T. While the illustrated electrical terminals 150 that include the ridge 64 and the dimple 166 are the ground terminals 154, it will be understood that the signal terminals 152 can include the ridge 164 and/or the dimple 166 as desired. Further, it will be understood that the projection 162 can be alternatively shaped as desired.
[0032] With particular reference to Figs. 6A-C, the projection 162 and the opposed sides of the projection 162, for instance the first side 160a and the second side 160b, can define a continuous or non-continuous convex surface such that the projection 162, and in particular the peak surface 162a, is configured to ride along the complementary mating portion of the complementary electrical terminal 150a as the electrical connector 100 is electrically mated with the complementary electrical connector 300 along the mating directio M, which can be along the length of the mating portion 156. The outer mating surface 158a can include the convex surface such that the convex surface can face the outer mating surface of a complementary electrical terminal, for instance the electrical terminal 150a of the complementary electrical connector 300, when the electrical connector 100 is mated with the complementary electrical connector 300. While the illustrated electrical terminals 150 that include the convex surface are the signal terminals 152, it will be understood that the ground terminals 154 can alternatively, or additionally, include the convex surface as desired. It will further be understood that the projection can be alternatively constructed such that the projection rides along the
complementary electrical terminal 150a as the electrical connector 100 is mated with
complementary electrical connectors.
|0033| n accordance with the illustrated embodiments, the projection 162 can define the first length Ls along the mating direction M and the metal coating positioned adjacent the first and second sides 160a and 160b can define a second length L2 along the mating direction M. Thus, the length L2 can be defined by a metallic layer of anti-corrosion material, for instance gold, other noble or precious metals, tin, tin-lead, or the like, or a combination thereof, that is disposed on a base of the electrical terminals 150 at the outer mating surface 158a. As shown, the first length L; of the projection 162 can be least equal to, for instance greater than, the second length L2. Further, as shown, the lengths of the metal coating positioned adjacent the first and second sides 160a and 160b are substantially equal to each other, although it will be understood that the lengths defined by the metal adjacent to the first and second sides can be alternatively sized as desired. The first length L; of the projection 162 and the second lengths L2 of the metals positioned adjacent to the opposed sides 160 and 160b can be centered with respect to each other such that the metal coatings are aligned with the projection 162 when viewed along the transverse direction T.
[0034] The recess 168 can be configured to at least partially receive a complementary projection 162 of the complementary electrical terminal 150a such that the metal positioned adjacent to the third and fourth sides 160c and 160d contacts the complementary electrical terminal when the electrical connector 100 is mated with the complementary electrical connector 300. With particular reference to Fig. 6A, the recess 168 and the opposed sides 160c and 1 0d of the recess 168 can define a continuous concave surface that faces the complementary electrical terminal 150a when the electrical terminal 150 is electrically mated with the
complementary electrical terminal 150a along the length of the electrical terminal 150, and in particular along the length of the mating portion 156. While the illustrated electrical ierminals 50 that include the outer mating surface 158a that includes the continuous concave surface are the signal terminals 152, it will be understood that the ground terminals 154 can include the outer mating surface 158a that includes the continuous concave surface as desired. Alternatively, the recess 168 and the opposed sides 160c and 160d of the recess 168 can define a non-continuous concave surface that faces a complementary electrical terminal when the electrical terminal 150 is electrically mated with the complementary electrical terminal along the length of electrical terminal 150, and in particular along the length of the mating portion 156. It will further be understood that while the illustrated electrical terminals 150 that include the outer mating surface 158a that includes the non-continuous concave surface are the signal terminals 152, the ground terminals 154 can include the outer mating surface 158a that includes the non-continuous concave surface as desired.
[§035] With particular reference to Fig. 5 A, the recess 168 can be an opening 170 that is partially defined by the third and fourth sides 160c and 160d. The opening 170, and thus the recess 168, can extend through the body 358 along the lateral direction A. Alternatively, the recess 168 can extend into, but not through, the body 158 along the lateral direction A (see Fig. 6A). As illustrated, the recess 168 is defined by the proximal end 156a of the mating portion 156, although it will be understood that the recess 168 can be alternatively disposed as desired. Further, the illustrated electrical terminals 150 that include the opening 170 are the ground terminals 154, although it will be understood that the signal terminals 152 can include the opening 170 as desired.
[0036] In accordance with the illustrated embodiments, the recess 168 can define the third length L3 along the mating direction M, and the metal coating positioned adjacent to the third and fourth sides 160c and 160d can define a fourth length L4 along the mating direction M. The length L4 of the metal coating positioned adjacent to the third and fourth sides 160c and 160d can be defined by a metallic layer of anti-corrosion material, for instance gold, tin, or the like, that is disposed on a base of the electricai terminals 150 at the outer mating surface 158a, as further described below. As shown, the length L3 of the recess 168 can be least equal to, for instance greater than, the length L4 defined by the metal coating positioned adjacent to the third and fourth sides 160c and 160d. Further, as shown, the lengths of the metal coatings positioned adjacent to the third and fourth sides 160c and 160d are substantially equal to each other, although it will be understood that the lengths of the metal coating positioned adjacent to the third and fourth sides 160c and 160d can be alternatively constructed as desired. The lengths L3 and L4 can be centered with respect to each other such that the metal coating positioned adjacent to the third and fourth sides 160c and 160d are aligned with the recess 368 when viewed along the transverse direction T. Thus, in accordance with the illustrated embodiments, the metal coating does not extend continuously from a first location that is aligned with the projection 162 along the transverse direction T to a second location that is aligned with the recess 168 along the length of the mating portion 156.
[0037] The electrical terminals 150 can include an electrically conductive base and a metallic layer of a metal or alloy thereof disposed on an outer mating surface of the base. In accordance with the illustrated embodiments, the metallic layer is only disposed on the outer mating surface 158a adjacent to the sides 160a-d along the transverse direction T. For instance, the body 156 can be gold-plated to reduce corrosion at locations of the electrical terminal 150 that are electrically mated when the electricai terminal 50 is mated with a complementary electrical terminal, such as when the electrical connector 100 is mated with the complementary electrical connector 300. Thus, significant cost savings can be realized because the metallic layer need not be applied to the entire mating portion 156 of the electrical terminal 1 50. The metallic layer can include a noble metal, for instance gold, or any other anti-corrosive material as desired. The electrically conductive base can include any electrically conductive material, for instance copper or a copper alloy. Further, because the metal coating of the electrical terminal 150 does not contact a complementary electrical terminal as the electrical terminal 150 is mated with the complementary electrical terminal, the metal coating is subject to less friction and wear as compared to conventional electrical terminals, enabling the metal coating to last longer before being worn off the body 158.
[0038] n operation, the first electrical connector 100 can be mated to the
complementary electrical connector 300 along the mating direction M (see Figs. 1 and 7) so that the distal end 156b of the mating portion 158 moves toward the proximal end 156a of the complementary electrical terminal 150a of the complementary electrical connector 300. For instance, a pair of the electrical terminals 150 that are included in different electrical connectors, for instance the electrical terminal 150 of the electrical connector 100 and the electrical terminal 150a of the complementary electrical connector 300, can be mated with each other (see Fig. 7 in particular). Thus, as the electrical terminals 150 are mated with each other along the mating direction M, the mating portions 156 of the electrical terminals 150 can be brought into contact with each other. More specifically, as the mating portions 156 come into contact with each other, the projections 162, in particular the peak surfaces 162a, come into contact with other. As a select electrical terminal 150 is mated with another (complementary) electrical terminal 150, the projection 162 of the select electrical terminal 150, in particular the peak surface 162a of the select electrical terminal 150, rides along the outer surface of the connecting portion 159, and thus the mating portion 156, of the complementary electrical terminal 150. Similarly, as the complementary electrical terminal 150 is mated with the select electrical terminal 350, the projection 162 of the complementary electrical terminal 350, in particular the peak surface 162a of the complementary electrical terminal 350, rides along the outer surface of the connecting portion 359, and thus the outer surface of the mating portion 356, of the select electrical terminal 150.
[0039f Thus, a method of mating the electrical connector 100 that includes at least one electrical terminal 350 with a complementary electrical connector that includes at least one complementary electrical terminal, for instance a complementary electrical terminal that is constructed substantially the same as the electrical terminal 150, can include causing the projection 162 of the electrical terminal 150 to ride along the length of the body 158 of the complementary electrical terminal 150 until the projection 162 is at least partially received by the recess 168 of the complementary electrical terminal (see Fig. 7). The method can further include causing the metal coating positioned on the body 158 of the electrical terminal 150 adjacent at least one side of at least one of the projection 162 and the recess 168 to contact the metal coating positioned on at least one side of the other of the projection 162 and the recess 168 of the body 158 of the complementary electrical terminal.
[0040] In accordance with one embodiment, a method can be provided for reducing the amount of a metal positioned on an electrical terminal. The method can include the step of providing or teaching the use of an electrical terminal having the body 158 that defines a first end and a second end spaced from the first end along the length of the electrical terminal 150, wherein one of the first and second ends defines the projection 162 along a first direction perpendicular to the length, and the other of the first, and second ends defines the recess 68 that extends into the body 158 along a second direction perpendicular to the length and the first direction. The method cars further include selectively positioning the metal coating on the body 158 adjacent at least one side of at least one of the projection 162 and the recess 168 with respect to the first direction. The method can further include selling to the third party the electrical terminal or purchasing the electrical terminal from the third party.
[0041] In accordance with another embodiment, a method can be provided for creating an electrical terminal, such as one of the electrical terminals described herein. The method can include depressing the inner surface 158b of the body 158 to define the projection 162 that projects out from the outer mating surface 158a of the body 158 that is opposite the inner surface 158b of the body 158.
[0042] The foregoing description is provided for the purpose of explanation and is not to be construed as limiting the invention. While various embodiments have been described with reference to preferred embodiments or preferred methods, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Furthermore, although the embodiments have been described herein with reference to particular structure, methods, and embodiments, the invention is not intended to be limited to the particulars disclosed herein. Those skilled in the relevant art, having the benefit of the teachings of this specification, may effect numerous modifications to the invention as described herein, and changes may be made without departing from the spirit and scope of the invention, for instance as set forth by the appended claims.

Claims

What is Claimed:
1. An electrical terminal comprising:
a body that defines a first end and a second end spaced from the first end along a length of the electrical terminal, wherein one of the first and second ends defines a projection along a first direction perpendicular to the length, and the other of the first and second ends defines a recess that extends into the body along a second direction perpendicular to the length and the first direction; and
a metal coating selectively positioned on the electrical terminal, the metal coating positioned on the body adjacent at least one side of at least one of the projection and the recess with respect to the first direction,
2. The electrical terminal as recited in claim 1 , wherein the metal coating is positioned on the body adjacent at least one side of the projection.
3. The electrical terminal as recited in claim 2, wherein the projection defines a first length along the length of the electrical terminal, the first length at least equal to a second length defined by the metal coating positioned on the body adjacent at least one side of the projection, the second length measured along the length of the electrical terminal.
4. The electrical terminal as recited in any of the preceding claims, wherein the metal coating is positioned on the body adjacent at least one side of the recess.
5. The electrical terminal as recited in claim 4, wherein the recess defines a third length along the length of the electrical terminal that is at least equal to a fourth length defined by the metal coating positioned on the body adjacent at least one side of the recess, the fourth length measured along the length of the electric terminal.
6. The electrical terminal as recited in any of the preceding claims, wherein the metal coating is positioned on the body adjacent opposed sides of the at least one of the projection and the recess with respect to the first direction.
7. The electrical terminal as recited in claim 5, wherein the projection and the opposed sides of the projection define a continuous or non-continuous convex surface such that the projection is configured to ride along a complementary electrical terminal as the eiectrical terminal is electrically mated with the complementary electrical terminal along the iength.
8. The electrical terminal as recited in any one of claims 5 and 6, wherein the recess and the opposed sides of the recess define a continuous concave surface or a non-continuous concave surface thai face a complementary electrical terminal when the electrical terminal is electrically mated with the complementary electrical terminal along the iength of the electric terminal.
9. The electrical terminal as recited in any of the preceding claims, wherein the metal coating is positioned on the body adjacent opposed sides of the projection.
10. The electrical terminal as recited in any of the preceding claims, wherein the metal coating is positioned on the body adjacent opposed sides of the recess.
1 1 . The electrical terminal as recited in any of the preceding claims, wherein the metal coating does not extend continuously from a first location that is aligned with the projection along the first direction to a second location that is aligned with the recess along the length.
12. The electrical terminal as recited in any of the preceding claims, wherein the recess extends through the body along the second direction.
13. The eiectrical terminal as recited in any of claims 1 to 1 1 , wherein the recess extends into, hut not through, the body along the second direction.
14. The electrical terminal as recited in any of the preceding claims, wherein the electrical terminal is a ground terminal.
15. The electrical terminal as recited in any of the preceding claims, wherein the electrical terminal is a signal terminal.
16. The electrical terminal as recited in any of the preceding claims, wherein the recess is sized to receive the projection.
17. The electrical terminal as recited in any of the preceding claims, wherein the metal coating is gold.
18. The electrical terminal as recited in any of the preceding claims, wherein the second end defmes a curved tip, and the electrical terminal defines a planar portion thai extends along the length from the curved tip to, and including, the first end.
19. The electrical terminal as recited in any of the preceding claims, wherein the second end defines a curved tip, and the electrical terminal defines a non-planar or radiused portion thai extends along the length from the curved tip, and including, the first end,
20. The electrical terrninal as recited in any one of the preceding claims, wherein the second end defmes the projection and the first end defines the recess.
21. The electrical terminal as recited in claim 20, wherein the second end further defines a dimple that extends into the body such that a thickness of the projection is substantially uniform along the first direction.
22. The electrical terminal as recited in claim 18, wherein the planar portion extends along a plane defined by the length and the first direction.
23. The electrical terrninal as recited in any of the preceding claims, wherein the projection is monolithic with the body.
24. The electrical terminal as recited in any one of the preceding claims, wherein the metal coating is only positioned on the body adjacent opposed sides of the projection with respect to the first direction and opposed sides of the recess with respect to the first direction.
25. The electrical terminal as recited in any one of the preceding claims, wherein the contact body is copper or a copper alloy.
26. The electrical terminal as recited in any of the preceding claims, wherein the electrical terminal is hermaphroditic,
27. An electrical connector configured to mate with a complementary electrical connector along a mating direction, the electrical connector comprising:
an electrically insulative connector housing; and
at least one electrical terminal as recited in any one of the preceding claims.
28. The electrical connector as recited in claim 27, wherein the at least one electrical terminal is a first electrical terminal, the electrical connector further comprising a second electrical terminal disposed adjacent the first electrical terminal along the first direction.
29. The electrical connector as recited in claim 28, wherein the first and second terminals are signal terminals.
30. The electrical connector as recited in claim 28, wherein the first terminal is a signal terminal, and the second terminal is a ground terminal.
31. The electrical connector as recited in claim 30, wherein the ground terminal defines a width along the first direction that is greater than that of the signal terminal.
32. The electrical connector as recited in claim 28, wherein the at least one electrical terminal is a first electrical terminal, the electrical connector further comprising a second electrical terminal disposed between the first electrical terminal and a third electrical terminal along the first direction.
33. The electrical connector as recited in claim 32, wherein the first and second electrical terminals are signal terminals and the third electrical terminal is a ground terminal.
34. The electrical connector as recited in any of claims 32 and 33, wherein the third terminal defines a width along the first direction that is greater than that of each of the first and second electrical terminals.
35. The eiecirical connector as recited in any of claims 32 to 34, wherein the first and second electrical terminals define differentia! signal pair.
36. A method of reducing a metal positioned on an electrical terminal the method comprising:
applying a metal coating on a body that defines a first end and a second end spaced from the first end along a length of the electrical terminal, wherein one of the first and second ends defines a projection along a first direction perpendicular to the length, and the other of the first and second ends defines a recess that extends into the body along a second direction
perpendicular to the length and the first direction; and
positioning the metal coating on the body adjacent at least one side of at least one of the projection and the recess with respect to the first direction.
37. The method of claim 36, further comprising the step of depressing an inner surface of the body to define the projection that projects out from an outer mating surface of the body that is opposite the inner surface of the body.
38. A method of mating an electrical connector that includes at least one electrical terminal as recited in claim 1 with a complementary electrical connector that includes at least one complementary electrical terminal constructed in accordance with the electrical terminal of claim 1 , the method comprising:
causing the projection of the electrical terminal to ride along the length of the body of the compiementarv' electrical terminal until the projection is at least partially received by the recess of the complementary electrical terminal.
39. The method of claim 38, the method further comprising:
causing the metal coating positioned on the body of the electrical terminal adjacent at least one side of at least one of the projection and recess to contact the metal coating positioned on at least one side of the other of the projection and recess of the body of the complementary electrical terminal.
40. A method of reducing a metal positioned on an electrical terminal, the method comprising the steps of:
providing or teaching to a third party the use of an electrical terminal having a body that defines a first end and a second end spaced from the first end along a length of the electrical terminal, wherein one of the first and second ends defines a projection along a first direction perpendicular to the length, and the other of the first and second ends defines a recess that extends into the body along a second direction perpendicular to the length and the first direction; teaching the step of selectively positioning the metal coating on the body adjacent at least one side of at least one of the projection and the recess with respect to the first direction; and
selling to the third party the electrical terminal.
PCT/US2015/011767 2014-01-31 2015-01-16 Electrical terminals WO2015116407A1 (en)

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