ASSEMBLY METHOD

The present invention relates to an electrical connector for being connected to a mating connector, said electrical connector comprising a casing and at least one connector module. The present invention further relates to an electronic module comprising such an electrical connector and to an assembly method for fabricating the electronic module.

Today electrical connectors— in particular plug connectors— represent a component decisive for the performance of the majority of electronic devices and components in all fields of application. Specifically for aerospace, defense, and marine applications the electrical connectors often are not merely cheap mass products, but high-quality precision components which are too costly to be discarded in case that only a part of the connector is defective or outdated. Especially modular electrical connectors comprising a casing and a connector module inserted therein could allow maintenance or repair by exchanging the defective or no longer desired connector module for another one that is functioning properly or of another type. However, the disassembly of conventional modular electrical connectors is either cumbersome or not possible at all.

The concept of a conventional electronic module that can for instance be used in connection with in-flight entertainment systems in the aeronautical application field will be explained in the following with reference to Figures 7 to 10. As can be seen from Fig. 7, the electronic module comprises a circuit carrier 201 with a substrate 202, for instance a printed circuit board (PCB), that carries a plurality of connector modules 204 which are connected to different electrically conductive leads (not shown in the Figure). Usually, one or more integrated circuit(s) and/or other passive and/or active electronic components are mounted on the substrate 202, but are not shown in the Figure for the sake of simplicity. The connector modules 204 are angular connector modules essentially of a similar type as the connector modules shown in the international application WO 201 1/160971 A1.

It is a known mounting technique to assemble the circuit carrier in a two-part casing having a retainer shell 206 and a separate cover shell 208 (shown in Figures 9 and 10). As shown in Fig. 7, the circuit carrier 201 is mounted in the retainer shell 206 by sliding it into guiding grooves 210 in an inserting direction 212 which is essentially parallel to a mating direction of the connector module 204. The retainer shell 206 has a receiving passage 214 for each connector module. In a fully assembled state, the receiving passage 214 encompasses the connector module 204 and is formed to guide a mating connector (not shown in the Figures) when being connected with the electronic module. Each of the connector modules 204 comprises latching means 216 for fixing the connector module 204 inside the receiving passage 214. Thereby, the connector module 204 is secured inside the casing against any movements in a direction opposite to the insertion direction 212. Fig. 8 shows the circuit carrier 201 in its final position firmly mounted in the retainer shell 206. The connector modules 204 are each locked within a corresponding receiving passage 214 and the substrate 202 is stabilized in the guiding grooves 210 on each side wall 218 of the retainer shell 206. In this locked position, the connector modules 204 can no longer be removed from the retainer shell 206 with destroying the electronic module 200. Fig. 9 shows in a schematic cut through the arrangement of Fig. 8 how the latching means 216 interact with belonging recesses of the receiving passages 214 for locking the connector module 204 irreversibly. Moreover, it can be seen that by mounting the circuit carrier carrying the connector module 204 within the receiving passages 214, undesired mechanical forces are exerted on the electrical contacts in a region where they are held within the substrate 202. These forces may cause a deformation of the contacts.

In the next assembly step (refer to Fig. 10) the casing of the electronic module 200 is closed by mounting a cover shell 208. The cover shell 208 is moved in the direction 212 until it has reached its final position. In the finally mounted position, the cover shell is secured at the retainer shell 206 by locking protrusions 220 which engage with respective openings at the cover shell 208, and by a resilient snap hook 222. The snap hook 222 engages with corresponding reasons 224 provided at the cover shell 208.

In Fig. 1 1 the completely mounted electronic module 200 is shown. For maintenance or repair purposes, the cover shell 208 can be removed by actuating the snap hook 222 and subsequently removing the cover shell backwards in a direction opposite to the direction 212. However, only repairs that can be performed at the inserted printed circuit board are possible. The connector modules 204 can no longer be removed from the receiving passages 214.

From the international application WO 201 1/160971 A1 it is known to provide at the receiving passage latching recesses that are accessible from the outside of each receiving passage in order to allow for the latching means to be actuated. However, as each connector module 204 has its own latching means, actuating the latching means of all connector modules 204 at the same time and simultaneously pulling back the circuit carrier 201 is difficult and necessitates dedicated tools.

The object underlying the present invention is to provide a modular electrical connector that is robust and reliable during operation, but at the same time can easily be fully disassembled for maintenance and repair purposes. This object is solved by the subject matter of the independent claims. Advantageous embodiments of the present invention are the subject matter of the dependent claims.

The present invention is based on the idea that by providing a modular electrical connector where a connector module is mounted in a casing where it is secured against movement parallel to a mating direction by the retaining member, but still can be removed from the retaining member in a direction across the mating direction, a particularly simple disassembly of the electrical connector is feasible. Nevertheless, the connector module is safely fixed at the casing against all movements along the mating direction.

According to an advantageous embodiment of the present invention, the casing comprises a retainer shell wherein said retaining member is arranged, and a separate cover shell for at least partly covering the at least one connector module. This particular construction allows securing the connector modules also in a direction transverse to the mating direction. Nevertheless, the modular electrical connector can still be disassembled because the cover shell may be fixed releasably at the retainer shell. In particular, the retainer shell may comprise releasable locking means for unlocking the cover shell at the retainer shell. This may for instance be realized by providing a snap hook at the retainer shell which engages with an opening at the cover shell. It is clear for a person skilled in the art that the arrangement can also be vice versa, that is, the snap hook may be arranged at the cover shell, and the opening may be provided at the retainer shell.

According to an advantageous embodiment, the cover shell comprises at least one receiving passage being formed to receive the at least one connector module and being further adapted to guide the mating connector. In contrast to the conventional arrangement explained above, the receiving passages do not interlock with the connector modules, but can be removed together with the cover shell if necessary. The mechanical function of retaining the connector modules within the casing is fulfilled by the retaining member which is part of the retainer shell, but not an integral part of the receiving passages.

A particularly secure retaining function can be achieved by providing a retaining projection which interacts with a corresponding retaining recess arranged at the connector module. Specifically, the retaining projection may extend in a direction across the mating direction, so that the connector module can be pushed in its final position in a direction transversal to the mating direction. According to an advantageous embodiment, this retaining recess may be shaped as a guiding groove that receives the retaining projection. In order to meet respective requirements regarding electric insulation and current creepage paths, the retaining projection may be formed as a partition wall for electrically insulating the electrical contact elements of one connector module against adjacent electrical contact elements, for instance of another connector module. By introducing electrically conductive particles into the partition wall material, also an electromagnetic shielding of the contact elements and the signals transmitted thereto can be achieved.

Advantageously, the connector module is an angled connector module, wherein the at least one electrically conductive contact element has a contact region which is contacted by the mating connector and extends along the mating direction, and a connection region which is connected to a lead inside the connector and extends across the mating connection. Angled connectors are well known in the art and the International application WO 201 1/160971 A1 shows some examples of such an angled connector module.

In addition or alternatively to the retaining projection, the retaining member may also comprise a retaining groove that interacts with a stop collar at the connector module for inhibiting movements along the mating direction. In particular, the retainer member for each connector module may have a U-shaped cross section with a base and two legs forming the retaining projections. The stop collar is formed around at least a part of the circumference of the connector module so that it surrounds the mating face of the connector module. The stop collar can be inserted into the retaining groove so that additional mechanical stability is given to the fully mounted connector module. Because of the U-shaped cross section the connector module can easily be disassembled from the retainer member by removing it in a direction across to the mating direction.

When using the electrical connector according to the present invention for aerospace applications, high temperature performance is demanded as well as a good resistance against solvents and a low weight. Moreover, the materials have to meet flammability and toxicity standards. According to an advantageous embodiment, polyether imide (PEI) or a PEI composite material is used for fabricating the electrically insulating parts, i.e. the contact carrier and/or the casing. Composite materials for instance include carbon fiber/PEI composites. These materials are inherently flame resistant with low smoke emission, only soluble to solvents partially halogenated, but resistant to alcohol, acids, and solvents made of hydrocarbon. Moreover, PEI is stable against gamma rays and ultra violet radiation, demonstrates good electrical properties, and remains mechanically stable over a wide range of temperatures.

According to an advantageous embodiment of the present invention, sealing means are provided in order to avoid the intrusion of moisture or dust at the interface between the contact carrier and the casing. For instance, an elastic grommet can be provided at an outer surface of the connector module around the mating face.

The present invention also relates to an electronic module having a circuit carrier and an electrical connector according to the present invention. Advantageously, the electrical connector module is arranged on the substrate of the circuit carrier and is electrically connected to an electrically conductive lead arranged on the substrate. The casing at least partially encompasses the circuit carrier and the retaining member retains the connector module together with the circuit carrier in a way that the connecting module and the circuit carrier can be removed in a direction across the mating direction of the connecting module. The circuit carrier may carry a plurality of connector modules which are connected to different electrically conductive leads. Usually, one or more integrated circuit(s) and/or other passive and/or active electronic components are mounted on the substrate. The substrate may be formed by a printed circuit board (PCB) according to the general knowledge of the person skilled in the art. The advantage of this solution can be seen in the fact that in case one of the electronic components or of the connector modules arranged on the substrate need repair and/or replacement, the same can be achieved without having to discard the complete electronic module.

According to an advantageous embodiment, the casing comprises a retainer shell having the retaining member and a separate cover shell. The retainer shell and the cover shell advantageously form a sealed housing that encompasses the circuit carrier. Thereby the electronic module is formed and a completely sealed box which can be mounted where its functions are needed. In this context, the term "sealed" is intended to mean either merely "closed" or "sealed against dust" or even "watertight", depending on the requirements of the particular application. A possible field of application is to provide access to in-flight entertainment in an aircraft. In order to achieve the sealed connection between the retainer shell and the cover shell on the one hand and between the cover shell and the individual connector module on the other hand, the retainer shell is provided with guiding means for mounting and fixing the cover shell. The guiding means extend in a direction along the mating direction, so that for being mounted at the retainer shell, the cover shell is slid— guided by the guiding means— along the mating direction. The present invention further relates to a method for assembly of the electronic module according to the present invention. In particular, the assembly method comprises the following steps: providing a retainer shell and a circuit carrier comprising a substrate with at least one electrically conductive lead and at least one electrical connector module being arranged on the substrate and being connected to said at least one electrically conductive lead, inserting said circuit carrier into the retainer shell in a direction across to the mating direction of said connector module, so that said connector module removably engages with said retaining member for exerting retaining forces in a direction along a mating direction of the electrical connector.

This particular technique of mounting the circuit carrier within the retainer shell allows a facilitated disassembly of the electronic module in case that a repair or maintenance of any of the components, including the connector module, is necessary. No irreversible locking mechanisms are needed for avoiding any movement of the circuit carrier with the connector modules along the mating direction.

According to the present invention, a cover shell is mounted in a directing along said mating direction, so that said retainer shell and said cover shell are forming a sealed housing that encompasses the circuit carrier. Thereby the electronic module can be effectively protected against environmental influences, but at the same time a complete disassembly is still possible.

The accompanying drawings are incorporated into and form a part of the specification to illustrate several embodiments of the present invention. These drawings together with the description serve to explain the principles of the invention. The drawings are merely for the purpose of illustrating the preferred and alternative examples of how the invention can be made and used, and are not to be construed as limiting the invention to only the illustrated and described embodiments. Furthermore, several aspects of the embodiments may form— individually or in different combinations— solutions according to the present invention. Further features and advantages will become apparent from the following more particular description of the various embodiments of the invention, as illustrated in the accompanying drawings, in which like references refer to like elements, and wherein:

FIG. 1 shows schematically a perspective view of a circuit carrier during assembly in the retainer shell according to the present invention;

FIG. 2 shows a detail of Fig. 1 ; FIG. 3 shows a schematic representation of the circuit carrier in its finally mounted position in the retainer shell; FIG. 4 shows a perspective view of the cover shell and the retainer shell with the circuit carrier during assembly of the cover shell;

FIG. 5 shows the electronic module according to the present invention in its final assembled state;

FIG. 6 shows a schematic sectional view of the electronic module shown in Fig. 5; FIG. 7 shows the assembly of the circuit carrier into a conventional retainer shell; FIG. 8 shows the arrangement of Fig. 7 in the final assembled state;

FIG. 9 shows a schematic sectional view of the conventional retainer shell with the mounted circuit carrier as shown in Fig. 8;

FIG. 10 shows the mounting of a conventional cover shell;

FIG. 11 shows a conventional electronic module in the fully assembled state.

The present invention will now be explained in more detail with reference to the Figures. Referring now to FIG. 1 , a schematic representation of a circuit carrier 101 during assembly in a retainer shell 106 is shown. The retainer shell 106 forms part of a casing 105 (see Fig. 5) that surrounds and protects the circuit carrier 101 and allows its mounting in a larger unit. The circuit carrier 101 comprises a substrate 102, preferably a printed circuit board (PCB), which has a pattern of electrically conductive leads (not shown in the Figures). Furthermore, a plurality of connector module 104 is mounted on the substrate 102 and connected to the electric currently conductive lead pattern. The substrate 102 furthermore may carry one or more integrated circuit(s) and/or other passive and/or active electronic components (not shown in the Figures).

A mating direction of the connector module 104 is indicated by the arrow 107. According to the present invention, the circuit carrier 101 is mounted within the retainer shell 106 in a direction 1 12 which extends across to the mating direction 107. According to the present invention, the retainer shell 106 comprises retaining members 126 for interacting with the connector modules 104 in order to exert retaining forces in a direction along the mating direction 107 of the electrical connector. In particular, each retaining member is formed by two retaining projections 128, so that an essentially U-shaped cross-section is generated, the retaining projections 128 forming the legs of the U. The retaining projections 128 engage with corresponding retaining recesses 130 which are provided at both sidewalls of each connector module 104. In the embodiment shown in Fig. 1 , the connecting units 104 have an electrically insulating contact carrier 132 that is formed by a first housing 134 and a second housing 136. The retaining recess 130 is formed between a stop collar 138 formed at the first housing 134, and an outer edge 140 of the second housing 136. It should be mentioned that in the present Figures the connector modules 104 are identical to the conventional ones shown in Figures 7 to 10. However, of course also any other design of the connector module that is formed to interact with the retainer shell 106 can be used. In particular, it is clear for a person skilled in the art, that the retaining recess 130 can also be formed as a molded indentation in a single-part housing.

Each of the retaining projections 128 is formed as part of the partition wall 142. These partition walls 142, which fit into slots 144 provided at the substrate 102, separate the contact elements 146 of one connector module 104 from the contact elements 146 of an adjacent connector module. Moreover, the partition walls 142 also provide additional mechanical stability to the retaining projections 128.

In addition to the retaining projections 128, each retaining member 126 further comprises a retaining groove 148. These retaining grooves 148 receive the stop collars 138 of the connector modules 104. Thereby, an additional safeguard against a movement in the direction 107 can be provided in the fully assembled state.

Moreover, each of the partition walls 142 comprises support steps 154 supporting the substrate 102 in the assembled state. According to the present invention, inserting the circuit carrier 101 into the retainer shell 106 does not involve any latching, locking, or irreversible connecting steps, so that the circuit carrier can easily be removed in a direction opposite to the direction 1 12 when this is needed.

Fig. 2 shows a detail of Fig. 1 for better illustrating the mechanical details explained above with reference to Fig. 1. Moreover, it can be seen, that each of the connector modules 104 has latching means 1 16 corresponding to those shown in Fig. 7. However, these latching means are not used according to the present invention. As will be explained with respect to Fig. 6, the receiving passages 1 14 do not have corresponding openings for engaging with the latching means 1 16.

Fig. 3 shows the circuit carrier 101 in its final position within the retainer shell 106. For better illustrating this position, some of the components are at least partly represented as being transparent. In order to close the casing 105, a separate cover shell 108 is mounted on the retainer shell 106. Fig. 4 illustrates this mounting step. In particular, the cover shell 108 is slid onto the retainer shell 106 in a direction along the mating direction 107. It should be noted, that compared to the conventional arrangement the cover shell 108 is mounted from the mating faces of the connectors towards the rear side, whereas the mounting direction 212 for the conventional cover shell 208 extends opposite to the mating direction.

For locking the cover shell 108 at the retainer shell 106, the retainer shell has a snap projection 122 which engages with recess 124 arranged at the cover shell 108. This snap projection 122 courses the much weaker locking force than the snap hook 122, so that the cover shell 108 can be removed from the retainer shell 106 much more easily.

Fig. 5 shows the completely mounted electronic module 100 in a perspective view.

Fig. 6 illustrates in a schematic sectional view the position of the connector modules 104 in the finally mounted state, as can be seen from this Figure, each of the connector modules 104 comprises a plurality of contact elements 146. The contact element 146 are angled so that a contact region 152, which extends along the mating direction and is connected to the mating connector, is angled by preferably 90° with respect to a connection region 154, that is inserted into the substrate 102. Moreover, by inserting the circuit carrier 101 in the direction 1 12 across to the mating direction 107 it can be ensured that no undesired mechanical forces are exerted on the connection regions 152 of the contact elements 146. According to the present invention, the receiving passages 1 14 are part of the cover shell 108. According to the present invention, the connector module 104 and in particular the latching means 1 16 do not interlock with the receiving passageway 1 14. The only interaction that occurs is an enhanced friction and the exact definition of the position between the mating face 156 of the connector module 104 and the receiving passage 1 14. In order to achieve a secure fitting, the receiving passage is supported against the retainer shell 106 in support region 158. the connector module, on the other hand, is supported at the retainer shell 106 by its stop collar 138. Thus, no irreversible mechanical connection exists between the cover shell 108 and the connector module 104.

Consequently, a nondestructive easy disassembly of the electronic module 100 is achieved according to the present invention.

The use of the terms "a" and "an" and "the" and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprising", "having", "including", and "containing" are to be construed as open-ended terms (i. e., meaning "including, but not limited to") unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. "such as") provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Exemplary embodiments are described herein. Variations of those embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor(s) expect skilled artisans to employ such variations as appropriate, and the inventor(s) intend for the invention to be practiced otherwise than as specifically described herein, in particular, the Figures only show complete electronic module according to the present invention. However, the ideas according to the present invention are of course applicable to electrical connectors only comprising the connector module and the casing, but not necessarily comprising a printed circuit board. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

REFERENCE NUMERALS

Reference Numeral Description

100 Electronic module

101 Circuit carrier

102 Substrate

104 Connector module

105 Casing

106 Retainer shell

107 Mating direction

108 Cover shell

1 12 Inserting direction

1 14 Receiving passage

1 16 Latching means

1 18 Side wall of retainer shell

122 Snap projection

124 Recess

126 Retaining member

128 Retaining projection

130 Retaining recess

132 Contact carrier

134 First housing

136 Second housing

138 Stop collar

140 Outer edge of second housing

142 Partition wall

144 Slot

146 Contact element

148 Retaining group

150 Support step

152 Contact region

154 Connection region

156 Mating face

158 Support region

200 Conventional electronic module

201 Circuit carrier 202 Substrate

204 Connector module

206 Retainer shell

208 Cover shell

210 Guiding groove

212 Inserting direction

214 Receiving passage

216 Latching means

218 Side wall of retainer shell

220 Locking protrusion

222 Snap hook

224 Recess for snap hook