INSERT MOLDED LEADFRAME ASSEMBLY

FIELD OF THE INVENTION

[0001] The invention relates generally to electrical connectors. More specifically, the invention relates to an insert molded lead frame assembly.

BACKGROUND OF THE INVENTION

[0002] Electrical connectors, such as ball-grid array (BGA) connectors, are usually mounted on the surface of a substrate using multiple solder connections. The solder connections act as electrical and mechanical connections between the substrate and contact pads on the connector.

[0003] The weight of some BGA connectors is not distributed evenly across the solder balls (or other fusible elements). For example, the center of gravity of some BGA connectors, such as right angle BGA connectors, may be offset from the geometric center thereof to an extent that causes the connector to tilt (or tip) on the substrate. Such tilting can vary the pressures on the solder balls of the ball-grid array. In other words, the weight of the connector may be distributed unevenly among the solder balls. Such uneven distribution can result in differences in the collapsing properties and the height of the solder balls as the solder balls are melted to form electrical connections. These factors degrade the strength and integrity of the resulting solder connections. In extreme cases, tilting can result in separation of the solder ball from the associated contact pad, thereby inhibiting the formation of an electrical connection.

SUMMARY OF THE INVENTION

[0004] The invention provides an insert molded leadframe assembly (IMLA) or an electrical connector that comprises a plurality of IMLAs. The EVILAs/connector may contain a mass. The mass may be formed from traditional scrap material left over from a contact or carrier frame stamping operation.

[0005] Such an IMLA may include an array of electrically conductive contacts, a dielectric leadframe housing overmolded onto the array of contacts, and a mass

disposed within the leadframe housing. Initially, the IMLA may have a first center of gravity in the absence of the mass. When the mass is added, the IMLA may have a second center of gravity about which the IMLA is balanced. In such a balanced IMLA, there may be an even distribution of weight and the solder balls may be compressed uniformly.

[0006] More specifically, the present invention may include a leadframe assembly that include an array of electrically-conductive contacts formed from a conductive sheet of metal, a dielectric leadframe housing overmolded onto the array of contacts, an a mass disposed on the dielectric leadframe housing such that the leadframe assembly has a first center of gravity in the absence of the mass and a second center of gravity with the mass, wherein the leadframe assembly is unbalanced about the first center of gravity and balanced about the second center of gravity. The electrically- conductive contacts and the mass may both be stamped from the same conductive sheet of metal or the mass be a retained scrap portion of the conductive sheet of metal that reduces waste of the conductive sheet of metal. Solder balls may be connected to the array of electrically-conductive contacts, wherein the solder balls define a fusible area and the second center of gravity is over a center of the fusible area. The mass may weigh three to seven times more than a similarly sized plastic mass, with 5.5 times more preferred. The array of electrically-conductive contacts may be right-angle electrically- conductive contacts. The leadframe assembly may further include a carrier frame, wherein the leadframe assembly is disposed on the carrier frame. A housing capable of receiving the leadframe assembly may also be provided.

[0007] A method of manufacturing a right-angle electrical connector may include the steps of providing a connector housing, stamping electrically-conductive right angle contacts and a counterbalance mass from at least one conductive sheet of metal, forming a plurality of leadframe assemblies that each comprise a dielectric leadframe housing that carries the electrically-conductive right angle contacts and the mass, and positioning the plurality of leadframe assemblies in the connector housing so that the solder balls define a fusible area and a center of gravity of the right-angle electrical connector is positioned over the fusible area. The step of stamping the electrically-conductive right angle contacts and the counterbalance mass from at least one conductive sheet of metal may further include the step of stamping the electrically-conductive right angle contacts and

the counterbalance mass from the same conductive sheet of metal. The step of stamping the electrically-conductive right angle contacts and the counterbalance mass from the same conductive sheet of metal may further comprise the step of stamping the counterbalance mass from a scrap portion of the same conductive sheet of metal.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a side view of an insert molded leadframe assembly (IMLA).

[0009] FIG. 2 is a side view of a conductive leadframe after stamping.

[0010] FIG. 3 is a side view of the conductive leadframe of FIG. 2 after overmolding.

[0011] FIG. 4 is a side view of the conductive leadframe of FIG. 2 with the carrier frame removed, depicting the center of gravity of the entire connector assembly.

[0012] FIG. 5 is a perspective view of an IMLA being positioned into a connector housing.

[0013] FIG. 6 is a perspective view of the EVILA of FIG. 5 almost completely inserted into the connector housing.

[0014] FIG. 7 is a perspective view of the IMLA of FIG. 5 completely inserted into the connector housing

[0015] FIGs. 8A and 8B are perspective views of a right angle connector.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0016] The figures depict an embodiment of an insert molded leadframe assembly (EVILA) for use in a right-angle ball-grid array (BGA) connector. The EVILA 10 is described in conjunction with this particular type of connector for exemplary purposes only; alternative embodiments of the EVILA 10 can be configured for use with virtually any type of surface-mounted connector. In general, the invention may include an array of electrically-conductive contacts 15 formed or stamped from a conductive sheet of metal 46, a dielectric leadframe housing 18 overmolded onto the array of electrically-conductive contacts 15, and a mass 20 formed or stamped from the conductive sheet of metal 46 and disposed on the dielectric leadframe housing 18 such that the leadframe assembly 10 has a first center of gravity in the absence of the mass 20 and a second center of gravity with the mass 20, wherein the leadframe assembly 10 is

unbalanced about the first center of gravity and balanced about the second center of gravity.

[0017] FIG. 1 depicts an example embodiment of an IMLA 10. As shown, the IMLA 10 may include a plurality of electrically conductive contacts 15 that extend through a leadframe housing 18. The IMLA 10 may also include a mass 20 (Fig. 2) embedded within the leadframe housing 18, and an alignment member 22 for positioning the EVILA 10 in a connector housing 24 (shown in FIGs. 5-6). A void in the plastic, shown as an exemplary right angle triangle in Figs. 1 and 5-8B, may also be used to shift the center of gravity of the electrical connector. The void may take any shape or size.

[0018] Each contact 15 may include a terminal end 32, a lead portion 36, and a mating end 38. Each lead portion 36 may extend between its respective terminal end 32 and its respective mating end 38. The lead portions 36 may bend such that the terminal ends 32 extend in a direction orthogonal to the direction in which the mating ends 38 extend. The direction in which the terminal ends 32 extend relative to the mating ends 38 may vary, depending on the use of the connector.

[0019] The contacts 15 may be arranged side-by-side within the leadframe housing 18 so that the mating ends 38 form a linear contact array 42 adjacent to a front edge 43 of the housing 18, and the terminal ends 32 form a horizontally-oriented row 44 along the bottom of the housing 18. As shown, the linear contact array 42 may be arranged as a contact column, though it should be understood that the linear contact array 42 could be arranged as a contact row. Also, though the IMLA 10 is depicted with a certain number of contacts 15, it should be understood that the IMLA 10 may include any desired number of contacts 15.

[0020] The terminal ends 32 of the contacts 15 may include fusible elements, such as solder balls for example. The solder balls may form a ball grid array 45 (Shown in FIG. 8B). The solder balls may each contact an associated contact pad on the printed circuit board (PCB) which may define the fusible area when the connector is mounted thereon.

[0021] The IMLA 10 may be manufactured using well know techniques in the art. For example, the mass 20, the alignment member 22, and the contacts 15 may be stamped or formed out of the same conductive sheet 46 of metal, preferably in the same stamping or forming operation. The mass 20 may be a retained portion of the conductive

sheet of metal 46 that would, prior to the invention, been removed from the conductive sheet of metal or carrier frame during the contact or carrier frame stamping operation and discarded as scrap metal. This reduces waste of the conductive sheet and simultaneously provides a mass distribution and balancing mechanism or system for the assembled electrical connector 90 (Fig. 8A). As shown in FIG. 2, the mass 20, the alignment member 22 and the contacts 15 can remain attached to a carrier frame 47 after stamping. The mass may be electrically isolated from the electrical contacts defined by the post- stamped carrier frame 47 after the electrical contacts are overmolded and the BVlLA is separated from the carrier frame 47.

[0022] Next, the leadframe housing 18 may be overmolded onto the contacts 15, the mass 20, and the alignment member 22. The leadframe housing 18 may be made of a dielectric material, such as a plastic, for example. The leadframe housing 18 may include an IMLA retention member 60 extending from a top portion 64 of the leadframe housing 18. The retention member 60 may be capable of engaging a retention slot 68 formed in the connector housing 24 (described below). The retention member 60 is depicted in the FIGs. as a dovetail, however, the member 60 is not limited to such a structure. For example, the member 60 and slot 68 combination may also be a tongue and groove fit.

[0023] The mass 20 is depicted as being positioned in an upper corner of the IMLA 10, and as having a certain shape. The mass 20, however, is not limited to the depicted position, nor is it limited to the depicted shape. Accordingly, mass 20 may have any position and any shape that may be capable of shifting the initial center of gravity of the πvlLA 10.

[0024] Typically, IMLA' s do not contain the mass 20 and have an initial center of gravity that causes the connector, and particularly a right angle connector perched on the edge of a PCB to tilt away from a mounting surface of the PCB. With the addition of mass 20, the connector's initial center of gravity may be shifted to a second center of gravity 72. As shown in FIG. 4, the second center of gravity 72 may be substantially above a center 74 of the ball grid array 45. The mass 20 may weigh approximately 3 to 7 times as much as the similarly sized plastic mass it replaces or displaces, with a 5.5 increase in weight preferred. The weight of the mass, however, may depend on several factors, such as the number of contacts 15 and the size of the IMLA 10, for example.

Preferably the mass 20 may have a weight that balances the IMLA 10 and shifts the IMLA's center of gravity to a position over the center of the ball grid array 45.

[0025] Once the IMLA 10 has been manufactured, it may be positioned into the connector housing 24. FIGs. 5-7 depict the IMLA 10 being positioned into the housing 24. As shown in FIG. 5, the retention member 60 may engage the retention slot 68 that is formed in a top portion 78 of the housing 24. When the IMLA 10 is almost fully inserted, as shown in FIG. 6, the alignment member 22 may engage an alignment slot 84 formed in a base 88 of the housing 24. The fit between the alignment member 22 and the slot 84 may have an interference fit or latch for retention to the housing 24. FIG. 7 shows the IMLA 10 fully inserted in the housing 24.

[0026] FIGs. 8A and 8B depict a completed right angle connector 90. As shown, the connector 90 may include a plurality of IMLAs 10. In that regard, the connector 90 may include any number of DVILAs 10. For example, as depicted, connector 90 may include thirteen IMLAs 10.

[0027] The connector 90 may be placed on a PCB so that the solder balls each substantially align with a corresponding contact pad on the PCB as noted above. The solder balls may subsequently be heated by a suitable process such as a reflow operation. The heating melts the solder balls, and upon cooling, forms electrical connections between the terminal ends 32 of the contacts 15 and the associated contact pads.

[0028] Typical right angle connectors have a center of gravity that is offset from the center of the ball grid array of the connector. The weight of the connectors (acting through the center of gravity), in combination with the reactive force exerted by the PCB on the connector by way of the solder balls, generate a moment on the connector. The moment, if not counteracted, can cause the connector to tilt, thereby causing at least some of the solder balls to lose contact with their corresponding contact pads or to not have a common geometry.

[0029] By using DVILAs 10, the connector 90 may have a center of gravity that may be substantially over the center of the connector's ball grid array 45. The combined additional mass 20 embedded within the leadframe housing 24 of each BVILA 10 may act as a counterweight that counteracts the moment acting on typical connectors. Accordingly, the above described tilting in the connectors may be prevented. Li other words, the combined center of gravity of the connector housing 24 and the IMLAs 10 or

the second center of gravity may be located over the ball grid array 45, more specifically over the center of the fusible area, so that the reactive force exerted by the solder balls in response to the weight of the connector 90 does not cause the connector 90 to tip. The addition of mass 20 in each IMLA 10 thereby can help to align and maintain contact between each solder ball and its associated contact pad when the connector 90 is placed on the PCB during installation.