Leadframe for a contact module and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-9246293-B2
Application number	US-201314069012-A
Country	US
Kind code	B2
Filing date	Oct 31, 2013
Priority date	Oct 31, 2013
Publication date	Jan 26, 2016
Grant date	Jan 26, 2016

Abstract

A leadframe for a contact module includes signal contacts arranged in pairs carrying differential signals. Each pair of signal contacts includes a first signal contact and a second signal contact. Each signal contact has a mating beam at an end thereof configured to be electrically connected to a corresponding header contact of a header assembly. Each mating beam includes a stem and a branch extending from the stem. A first paddle extends from the stem and a second paddle extends from the branch. In an initial, stamped orientation, the mating beams are stamped such that the mating beams of the first and second signal contacts within the same pair of signal contacts are angled non-parallel to one another.

First claim

What is claimed is:

1. A leadframe for a contact module, the leadframe comprising:
signal contacts arranged in pairs carrying differential signals, each pair of signal contacts comprising a first signal contact and a second signal contact, each signal contact having a mating beam at an end thereof, each mating beam configured to be electrically connected to a corresponding header contact of a header assembly, each mating beam comprising a stem and a branch extending from the stem, each mating beam comprising a first paddle extending from the stem and a second paddle extending from the branch, wherein, in an initial stamped orientation, the mating beams are stamped such that the mating beams of the first and second signal contacts within the same pair of signal contacts are angled non-parallel to one another.

2. The leadframe of claim 1 , wherein a centerline is defined between the mating beams of the first and second signal contacts within the same pair, the first paddle of the mating beam associated with the first signal contact extending along a first paddle axis angled oblique with respect to the centerline, the first paddle of the mating beam associated with the second signal contact extending along a second paddle axis angled oblique with respect to the centerline.

3. The leadframe of claim 2 , wherein the first and second paddle axes are angled inward at approximately equal angles relative to the centerline.

4. The leadframe of claim 1 , wherein a centerline is defined between the mating beams of the first and second signal contacts within the same pair, the first paddle of the mating beam associated with the first signal contact extending along a first paddle axis angled oblique with respect to the centerline, the second paddle of the mating beam associated with the first signal contact extending along a second paddle axis generally parallel to the first paddle axis.

5. The leadframe of claim 1 , wherein the mating beams are arranged on a tight pitch, wherein if the mating beams were not angled inward, the mating beams of adjacent pairs of signal contacts would overlap.

6. The leadframe of claim 1 , wherein a centerline is defined between the mating beams of the first and second signal contacts within the same pair, the first paddles arranged interior of the second paddles closer to the centerline, the second paddles having exterior edges facing outward away from the centerline, the exterior edges of the second paddles being angled oblique with respect to the centerline.

7. The leadframe of claim 1 , wherein the second paddles are outside of the first paddles, adjacent second paddles of mating beams of signal contacts of different pairs being angled away from each other as the mating beams extend to ends of the mating beams.

8. The leadframe of claim 1 , wherein the branch and second paddle of each mating beam are folded over the stem and first paddle of the corresponding mating beam such that the first and second paddles are parallel to one another and define a socket configured to receive the corresponding header contact.

9. The leadframe of claim 8 , wherein the mating beams are pressed outward to a final, formed orientation wherein each of the first and second paddles are parallel to one another.

10. A method of manufacturing a leadframe comprising:
providing a leadframe by stamping a metal blank to include pairs of signal contacts having mating beams that are non-parallel to each other, wherein said providing a leadframe comprises stamping the metal blank to include the mating beams each having a stem and a branch extending from the stem, each mating beam having a first paddle extending from the stem and a second paddle extending from the branch, said providing a leadframe comprises stamping the metal blank such that the first and second paddles of each mating beam are angled inward toward a centerline between the mating beams of the pair of signal contacts; and
forming the mating beams into a final form, the mating beams having a parallel alignment in the final form.

11. The method of claim 10 , wherein said forming the mating beams comprises folding the branch and the second paddle over the stem and the first paddle such that a socket is defined between the first and second paddles, the socket being configured to receive a header contact of a header assembly.

12. The method of claim 11 , wherein said forming the mating beams comprises pressing the mating beams of the pair of signal contacts outward away from each other such that the sockets are parallel to a mating direction of the mating beam with a header contact.

13. The method of claim 10 , wherein said forming the mating beams comprises pressing the mating beams of each pair of signal contacts outward away from each other such that the mating beams are parallel to each other.

14. The method of claim 10 , further comprising removing a connecting portion between the stems of the mating beams of the pair of signal contacts to allow the stems to be pressed outward away from each other.

15. A receptacle assembly comprising:
a receptacle housing configured to be mated with a header assembly; and
contact modules received in the receptacle housing, the contact modules each comprising:
a dielectric frame having a front and opposite first and second sides; and
a leadframe held by the dielectric frame, the leadframe having signal contacts arranged in pairs carrying differential signals, the signal contacts being generally arranged along a leadframe plane parallel to and between the first and second sides, the signal contacts having mating beams at ends thereof, each mating beam extending forward of the dielectric frame to be electrically connected to a corresponding header contact of the header assembly in a mating direction, each mating beam comprising a stem and a branch, each mating beam comprising a first paddle extending from the stem and a second paddle extending from the branch;
wherein the mating beams are stamped in an initial, stamped orientation such that the mating beams within the same pair of signal contacts are angled toward one another and such that the mating beams are angled away from the mating beams of any immediately adjacent pair of signal contacts, the branch and second paddle of each mating beam being folded over the stem and first paddle such that the first and second paddles are parallel to one another and define a socket for the corresponding header contact of the header assembly, the mating beams being pressed to a final, formed orientation such that each of the first and second paddles are parallel to the mating direction.

16. The receptacle assembly of claim 15 , wherein a centerline is defined between the mating beams of the signal contacts within the same pair, the first paddle of the mating beam associated with a first signal contact within a pair extending along a first paddle axis angled oblique with respect to the centerline, the first paddle of the mating beam associated with a second signal contact within the pair extending along a second paddle axis angled oblique with respect to the centerline.

17. The receptacle assembly of claim 16 , wherein the first and second paddle axes are angled inward at approximately equal angles relative to the centerline.

18. The receptacle assembly of claim 15 , wherein a centerline is defined between the mating beams of the signal contacts within the same pair, the first paddle extending along a first paddle axis angled oblique with respect to the centerline, the second paddle associated with such first paddle extending along a second paddl

Assignees

• Tyco Electronics Corp

Inventors

• Vino Iv Michael Joseph
• Graham Leo Joseph
• D Imperio Michael Christopher
• Trout David Allison
• Davis Wayne Samuel
• Yancey Rodney Timothy
• Mcclinton Jeffrey Byron

Classifications

• H01R13/6587

  for mounting on PCBs · CPC title

• H01R12/724

  containing contact members forming a right angle · CPC title

• H01R43/16 Primary

  for manufacturing contact members, e.g. by punching and by bending · CPC title

• Y10T29/49121

  Beam lead frame or beam lead device · CPC title