Mobile phone connector and the art of assembly of contacts and a housing

[0002] 1. Field of the Invention

[0003] The present invention relates to an electrical connector, and particularly to a composite connector having small dimensions used in a mobile phone for alternative connection with mating connectors in order to transmit signals or DC power from a charge.

[0004] 2. Description of Prior Art

[0005] With developments in the communications industry, the functions and use of portable phones are improving day by day. Accordingly, connectors used in portable phones are developing rapidly. The trend today is to integrate many functions and produce units having smaller dimensions for facilitating consumer carrying. U.S. Pat. No. 5,812,660 discloses a prior art connector shown in FIG. 7. The prior art connector comprises an insulative housing 6 having a rectangular connection recess 611 extending rearward from a front surface 61. A flat connector 612 and a pair of RF terminals 613 are arranged within the connection recess 611. The flat connector 612 includes an insulation plate 612 and signal terminals 7 on upper and lower surfaces of the insulation plate. The RF terminals 613 are disposed on opposite sides of the flat connector. A pair of metallic reinforcing members 614 is provided on opposite sides of the connection recess 611 not only to reinforce the thin upper wall of the connection recess but also to serve as power terminals for recharging by means of a charger. The connector is also provided with a DC jack 615, which is accessible from the front surface 61. Battery terminals 8 project diagonally upward through the upper left sidewall of the housing 6 for contact with a battery within the portable phone. An integrated mating connector is required to mate the plate connector 612 and the RF terminals 613 and it is impossible to use two small size and optional use connectors in the prior art. In addition, when the battery is charged with a charge the flat connector and the RF terminals do not work at the same time, so do not facilitate use by the consumer. Hence, an improved electrical connector is required to overcome the disadvantages of the prior art.

[0006] A first object of the present invention is to provide a mobile phone connector, which has many functions assembled therein.

[0007] A second object of the present invention is to provide a mobile phone connector, which can alternatively connect with mating connectors in order to transmit signal or DC power.

[0008] A third object of the present invention is to provide a mobile phone connector which has small dimensions for facilitating consumer carrying.

[0009] An electrical connector of the present invention comprises a plurality of contacts, an insulative housing and a shell. The insulative housing comprises a first receptacle portion defining first receiving passageways therethrough, a second receptacle portion defining second receiving passageways therethrough, a barrier separating the first receptacle portion from the second receptacle portion and a pair of arms respectively laterally extending. A plurality of positioning apertures are defined from a top wall to a bottom wall of the housing in communication with corresponding receiving passageway. Positioning slots are defined between each receptacle portion and the barrier and between each receptacle portion and each side plate of the shell. The contacts are molded into the housing and include signal contacts and power contacts respectively received in the first and the second receiving passageways of the first and the second receptacle portions. All contacts are identical, each having a vertical section received in a distal end of a corresponding receiving passageway and extending upwardly into the corresponding positioning aperture, and a horizontal section received in the receiving passageway and having a solder tail exposed out of the housing. The shell encloses the housing and has a locking aperture on a bottom plate thereof under each positioning slot of the housing.

[0010] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description of the present embodiment when taken in conjunction with the accompanying drawings.

[0011] FIG. 1 is a perspective view of a mobile phone connector in accordance with the present invention;

[0012] FIG. 2 is an exploded view of the mobile phone connector of FIG. 1;

[0013] FIG. 3 is a front view of the connector of FIG. 1;

[0014] FIG. 4 is a rear view of the connector of FIG. 1;

[0015] FIG. 5 is an assembled view of housing and contact strips;

[0016] FIG. 6 is a sectional view take along line of 6—6 of FIG. 5; and

[0017] FIG. 7 is a perspective view of a connector of the prior art.

[0018] Referring to FIGS. 1-2, a mobile phone connector in accordance with the present invention comprises a shell 1, an insulative housing 2 and a plurality of contacts 3 which include signal contacts 3aand power contacts 3b.The signal contacts 3aand the DC contacts 3bare identical for facilitating manufacture. Each contact 3aor 3bcomprises a vertical section 31 and a horizontal section 32 having barbs 321 on a central portion for interferentially engaging with the housing 2. The horizontal section 32 forms a solder tail 322 on a distal end thereof slightly downwardly inclining and then extending horizontally for soldering to a printed circuit board (not shown).

[0019] The elongate housing 2 comprises a first receptacle portion 21, a second receptacle portion 22, a rectangular barrier 23 separating the first receptacle portion 21 from the second receptacle portion 22, and two opposite arms 24. The first receptacle portion 21 and the second receptacle portion 22 respectively define first receiving passageways 210 therethrough for receiving the contacts 3aand second receiving passageways 220 for receiving contacts 3b.In the present invention, the first receptacle portion 21 receives seven signal contacts 3aand the second receptacle portion 22 receives three DC power contacts 3b.Each receiving passageway defined a mating portion 200 (in FIG. 6) at a front end thereof. The housing 2 defines a plurality of positioning apertures 202 form a top wall 25 to a bottom wall 27 thereof in communication with corresponding receiving passageways 210, 220. Positioning slots 206, 207 are defined between the barrier 23 and each receptacle portion 21, 22. A protrusion 203 is formed on a right side of the first receptacle portion 21 extending into the positioning slot 206 for correct insertion of a signal plug (not shown). The second receptacle portion 22 forms a protrusion 204 on a left side thereof extending into the positioning slot 207 and defines a recess 205 in a right side thereof for correct insertion of a DC power plug (not shown). Each arm 24 laterally extends from the adjacent receptacle portion 21, 22 and defines a recess 242 on a front face 241 thereof.

[0020] The shell 1 has a shape and size suitable for enclosing the housing 2 and has a top plate 11, a bottom plate 12 and two opposite side plates 13. The shell 1 forms an array of flanges 100 for aiding insertion of mating plugs (not shown). In assembly, positioning slots 208 are defined between each receptacle portion 21, 22 and each side plate 13 of the shell 1 for receiving the plugs (not shown). A locking aperture 120 is defined in the bottom plate 12 under each position slot 206-208 for fixing the plugs (not shown). A locking tab 131 is formed on each side plate 13 extending inwardly into the recess 242 of the housing 2 for preventing outward movement of the housing 2. Retaining tabs 111 are formed on opposite rear sides of the top plate 11 and retaining tabs 132 are formed on a rear distal end of each side plate. During assembly the retaining tabs 111, 132 are bent and abut against a rear face 26 of the housing 2 for fixing the housing 2 in the shell 1.

[0021] Overall dimensions of a mobile phone are largely dependent on the dimension of the pitch distance between neighboring contacts, so the dimension of the pitch distance between neighboring contacts should be as small as possible. During assembly, when the contacts 3 are loaded into the receiving passageways 210, 220 of the housing 2, the housing 2 is easily damaged. To prevent this damage, the contacts 3 are molded into the receiving passageways 210, 220 of the housing 2. The mold (not shown) is easily manufactured and includes an upper mold and a lower mold. FIGS. 5-6 show an assembled view of the housing 2 and the contacts 3 with carrier strips 3cafter insert molding. In an insert molding procedure, the contacts 3 are securely positioned within the molds, thereby preventing their displacement during high pressure injection of molten plastic resin into the mold cavity. The solder tails and the carrier strips 3cremain exposed to assure precise positioning. The carrier strips 3care easily separated from the contacts after molding because of V-shaped cutouts at the junction of each contact and carrier strip. The horizontal sections 32 of the contacts 3 are embedded in the receiving slots 210, 220 of the housing 2 with the solder tails 332 exposed out of the housing for soldering on a printed circuit board. The vertical sections 31 are exposed to the mating portion 200 of the receiving passageways 210, 220 and extend upwardly into the positioning apertures 202 of the housing 2. The horizontal section accessible from the top wall and the bottom wall of the insulative housing through the positioning aperture.

[0022] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.