High-density electrical connector

Abstract

In various embodiments, a compact connector design can be provided, featuring a reduced board pitch (e.g., 1.80 mm, 1.50 mm, 1.27 mm, etc.) while still accommodating larger electrical conductors (e.g., 1.4 mm, 1.1 mm, 0.9 mm, etc.). In this way, the PCB footprint can be reduced (e.g., by 50% when using an interleaved connector configuration) while maintaining sufficient current carrying capacity (e.g., 2A, 3A, 4A, etc.). Additionally or alternatively, one or more other advantages can be achieved, such as robustness (e.g., vibration resistance), error prevention, construction flexibility, ease of manufacture, ease of assembly, and / or cost reduction.

Description

[0001] This application is a divisional application of Chinese Invention Patent Application No. 201980025001.2 entitled "High-Density Electrical Connector", filed on March 15, 2019. Background Technology

[0002] Many electrical devices are controlled and / or powered by printed circuit boards (PCBs). For example, in automobiles, electrical connectors can be used to connect LED lights to a PCB to control and / or power the LED lights. Such connectors may include electrical terminals configured to be crimped onto conductive lines (e.g., the wires of a cable connected to the LED lights) and / or contact pins configured to be soldered onto the PCB.

[0003] There has been a persistent trend towards miniaturization of components across many fields. This necessitates electrical connectors with high signal density. Furthermore, improved vibration resistance is required. For example, in automotive applications, it is desirable to prevent mating connectors from disengaging due to vibrations in the operating environment.

[0004] U.S. Patent Application Publication 2015 / 0050838 (hereinafter referred to as "'838 Publication"), among other things, illustrates examples of terminals for use in connectors. Such terminals can be securely crimped onto the wires of a cable. '838 Publication also illustrates a connector having a core and a housing, wherein the core and housing are attached to each other with a retaining force greater than the retaining force provided between the connector and the mating connector, such that the core and housing are prevented from being accidentally pulled apart when a user attempts to disconnect the two connectors. Summary of the Invention

[0005] In some embodiments, a terminal for use in a first electrical connector is provided, the terminal comprising: a mating end configured to receive a contact pin of a second electrical connector; a crimping end configured to crimp onto a wire; and an intermediate portion between the mating end and the crimping end, wherein: the terminal is elongated along a mating direction; and the intermediate portion includes a locking feature biased outward from a centerline of the terminal along the mating direction.

[0006] In some embodiments, an electrical connector is provided, comprising: a housing; a terminal position assurance (TPA) feature attached to the housing, the TPA feature being movable between a disengaged configuration and an engaged configuration; and a terminal inserted into a cavity in the housing, wherein: when the TPA feature is in the engaged configuration, a locking feature of the terminal engages the TPA feature to retain the terminal in the cavity.

[0007] In some embodiments, an electrical connector is provided, comprising: a housing; a terminal position assurance (TPA) feature attached to the housing, the TPA feature being movable between a split configuration and an engaged configuration; and a terminal inserted into a cavity in the housing, wherein: the TPA feature includes a protrusion; when the TPA feature is in the split configuration, the protrusion of the TPA feature is aligned with a wall of the cavity to allow the terminal to be inserted into the cavity; and the protrusion of the TPA feature has an angled profile configured to guide the terminal when the terminal is inserted into the housing when the TPA feature is in the split configuration.

[0008] In some embodiments, a first electrical connector is provided, including: a first housing; and a terminal position assurance (TPA) feature attached to the first housing, the TPA feature being movable between a split configuration and an engagement configuration, wherein: the first electrical connector is configured to mate with a second electrical connector having a second housing; and the TPA feature includes a latch configured to engage the second housing to secure the first electrical connector and the second electrical connector together in a mating configuration.

[0009] In some embodiments, an electrical connector is provided, comprising: a housing; and a clamping member having a first attachment feature, a second attachment feature, and a third attachment feature, wherein: the first attachment feature prevents lateral movement between the clamping member and the housing; the second attachment feature prevents vertical movement between the clamping member and the housing; and the third attachment feature is configured to attach to a printed circuit board (PCB) to secure the electrical connector to the PCB.

[0010] In some embodiments, a first electrical connector is provided, including: a first housing; and a connector position guarantee (CPA) feature attached to the first housing, the CPA feature being movable between a disengaged configuration and an engaged configuration, wherein: the CPA feature includes a first latch configured to attach the CPA feature to the first housing when the CPA feature is in the disengaged configuration; the first electrical connector is configured to mate with a second electrical connector having a second housing; the CPA feature includes a second latch configured to attach the CPA feature to the second housing when the CPA feature is in the engaged configuration; and the first housing is configured to prevent the CPA feature from moving to the engaged configuration when the first electrical connector and the second electrical connector are not fully engaged. Attached Figure Description

[0011] Figure 1A An illustrative connector 100 according to some embodiments is shown.

[0012] Figure 1B According to some embodiments Figure 1A An exploded view of the illustrative connector 100 is shown.

[0013] Figure 2A An illustrative electrical terminal 200 is shown according to some embodiments.

[0014] Figure 2B Illustrations are shown according to some embodiments Figure 2A The illustrative rolls 212a, 212b, 214a and 214b are in a crimped configuration.

[0015] Figure 3A -F respectively illustrate illustrative connectors 300A-F according to some embodiments.

[0016] Figure 4A -D illustrates some embodiments. Figure 1B The illustration shows a cross-sectional view of socket 130.

[0017] Figure 5A -B illustrates some embodiments Figure 1B A further cross-sectional view of the illustrative socket 130 shown.

[0018] Figure 6A Illustrations are shown according to some embodiments Figure 1B The illustrated socket 130 is shown in a bottom view, with a portion cut off to show the illustrative locking feature of the inserted terminal.

[0019] Figure 6B It shows Figure 6A A magnified view of region 602.

[0020] Figure 7 Illustrations are shown according to some embodiments Figure 1B Another cross-sectional view of the illustrative socket 130 shown.

[0021] Figure 8 Illustrations are shown according to some embodiments Figure 1B Another cross-sectional view of the illustrative socket 130 shown.

[0022] Figure 9A An illustrative connector 900A according to some embodiments is shown.

[0023] Figure 9B An illustrative connector 900B according to some embodiments is shown.

[0024] Figure 10 Illustrative plug housings 1002 and 1004 according to some embodiments are shown.

[0025] Figure 11A An illustrative plug 1100 according to some embodiments is shown.

[0026] Figure 11B Illustrations are shown according to some embodiments Figure 11A A cross-sectional view of the illustrative plug 1100.

[0027] Figure 12A An illustrative connector 1200 according to some embodiments is shown.

[0028] Figure 12B Illustrations are shown according to some embodiments Figure 12A A cross-sectional view of the illustrative connector 1200.

[0029] Figure 12C Contacts according to some embodiments are shown. Figure 12A -B's illustrative protrusion 1241's illustrative latch 1237.

[0030] Figure 12D The following are illustrated according to some embodiments: Figure 12A -B's illustrative protrusion 1241 deflection of the illustrative latch 1237.

[0031] Figure 12E Illustrations are shown according to some embodiments Figure 12A -B's illustrative CPA feature 1234 is in a joint configuration. Detailed Implementation

[0032] In various embodiments, a compact connector design can be provided, featuring a reduced board pitch (e.g., 1.80 mm, 1.50 mm, 1.27 mm, etc.) while still accommodating larger electrical conductors (e.g., 1.4 mm, 1.1 mm, 0.9 mm, etc.). In this way, the PCB footprint can be reduced (e.g., by 50% when using an interleaved connector configuration) while maintaining sufficient current carrying capacity (e.g., 2A, 3A, 4A, etc.). Additionally or alternatively, one or more other advantages can be achieved, such as robustness (e.g., vibration resistance), error prevention, construction flexibility, ease of manufacture, ease of assembly, and / or cost reduction.

[0033] Figure 1AAn illustrative connector 100 according to some embodiments is shown. In this example, connector 100 includes a cable interface 110 and a board interface 120. Cable interface 110 may be configured to receive one or more wires of a cable. For example, cable interface 100 may include an opening 115 into which electrical terminals can be inserted, wherein the terminals can be crimped onto the wires of the cable. Board interface 120 may be configured to establish an electrical connection with one or more traces on a PCB. For example, board interface 120 may include contact pins 125 configured to be soldered onto the PCB using any suitable technique such as surface mount device (SMD), lead dip solder paste (PiP), etc.

[0034] Figure 1B According to some embodiments Figure 1A An exploded view of the illustrative connector 100 is shown. In this example, connector 100 includes a socket 130 and a plug 140. Figure 1A The illustrative cable interface 110 and illustrative board interface 120 shown can be located at the socket 130 and plug 140, respectively.

[0035] In some embodiments, the socket 130 and plug 140 may be configured to mate with each other. Once mated, one or more electrical terminals of the socket 130 (e.g., terminal 132 in the insertion opening 115) may be electrically connected to one or more corresponding contact pins (e.g., contact pin 125) of the plug 140. In some embodiments, terminal 132 may be crimped to the wires of a cable, and contact pin 125 may be soldered to a PCB. Thus, when the socket 130 and plug 140 mate with each other, an electrical connection can be established between the wires and the conductive traces on the PCB.

[0036] exist Figure 1B In the example shown, plug 140 includes a cavity 142 configured to receive receptacle 130. Contact pins 125 may be retained in plug 140 such that when receptacle 130 is inserted into cavity 142, mating ends of contact pins 125 form an electrical connection with mating ends of terminal 132. Alternatively or additionally, plug 140 may include one or more features (e.g., clamping member 144) configured to secure plug 140 to a PCB.

[0037] exist Figure 1BIn the example shown, receptacle 130 includes a connector position guarantee (CPA) feature 134 and a terminal position guarantee (TPA) feature 136. In some embodiments, CPA feature 134 may be in at least two configurations, such as a split configuration and an engaged configuration. When receptacle 130 is not mated with any plug, CPA feature 134 may be in a split configuration and may prevent it from moving to an engaged configuration. When receptacle 130 is mated with a plug (e.g., plug 140), CPA feature 134 may be allowed to move to an engaged configuration, in which CPA feature 134 prevents receptacle 130 and plug 140 from disengaging (e.g., due to vibration in the operating environment). In some embodiments, TPA feature 136 may be engaged to prevent one or more terminals (e.g., terminal 132) from shifting within receptacle 130 (e.g., due to vibration in the operating environment). Additionally or alternatively, TPA feature 136 may be used to ensure that an electrical connection is established only when the terminals are in the desired position.

[0038] Figure 2A An illustrative electrical terminal 200 is shown according to some embodiments. Terminal 200 can be used with any suitable connector, such as… Figure 1A -B illustrates the connector 100. For example, terminal 200 can be used as... Figure 1B The illustrative terminal 132 is shown.

[0039] exist Figure 2A In the example, terminal 200 includes a crimp end 210 and a mating end 220. The crimp end 210 may be configured to crimp onto the wires of a cable. For example, the crimp end 210 may include one or more rolls / creeps (e.g., 212a and 212b) configured to crimp onto an insulating portion of the cable and / or one or more rolls / creeps (e.g., 214a and 214b) configured to crimp onto a stripped portion of the cable, where the insulation has been removed and the conductive wires are exposed. Figure 2B Illustrations are shown according to some embodiments Figure 2A The illustrative rolls 212a, 212b, 214a and 214b are in a crimped configuration.

[0040] In some embodiments, spools 212a and 212b may be offset relative to each other, such that during crimping, spools 212a and 212b may hold the insulation portion of the cable in different positions along the length of the cable, which can improve holding force. Additionally or alternatively, spools 214a and 214b may be elongated along the length of the terminal 200 to provide a larger contact area between the terminal 200 and the wire to which the terminal 200 is crimped (and thus improve electrical connection). The inventors have recognized and are aware that one or more of these techniques can be used to improve vibration resistance (e.g., in automotive applications).

[0041] exist Figure 2A In the example, mating terminal 220 includes components configured to engage with corresponding contact pins (e.g., Figure 1A -B illustrates the contact beam 222 that mates with the illustrative contact pin 125. For example, the contact beam 222 may be a box beam configured to receive the contact pin 125. However, it should be understood that aspects of this disclosure are not limited to the use of a box beam, as other mating contact configurations may also be applicable.

[0042] exist Figure 2A In the example, terminal 200 includes an intermediate portion 230 between crimp end 210 and mating end 220. In some embodiments, intermediate portion 230 may include locking feature 232 configured to engage one or more features of receptacle 130 to, for example, retain terminal 200 in a desired position within receptacle 130. For example, locking feature 232 may be biased outward from centerline of terminal 200 and may fit into a corresponding recess in receptacle 130 to prevent terminal 200 from shifting (e.g., due to vibrations in the operating environment).

[0043] Alternatively, the intermediate portion 230 may include a blocking feature 234 configured to interact with the TPA feature (e.g., Figure 1B The illustrative TPA feature 136) is shown in the diagram. For example, it is combined as follows. Figure 4C As explained, when the TPA feature is in the engagement configuration, the protrusion of the TPA feature can contact the blocking feature 234, thereby preventing the terminal 200 from shifting.

[0044] The inventors have recognized and acknowledged the need to provide different connector configurations for different applications. For example, it is desirable to provide connectors with different configurations (e.g., top latch vs. side latch, staggered vs. side-by-side, single-row vs. double-row, etc.) but capable of receiving terminals of the same design (e.g., Figure 2A (Illustrative terminal 200 shown). This can simplify manufacturing and / or installation. Furthermore, the tooling cost for manufacturing terminals can be high relative to the cost of the terminals themselves, and the overall cost can be reduced by amortizing the pin tooling cost across a large number of terminals. Therefore, it is desirable to provide a terminal design that can be used in many different connector configurations. However, it should be understood that aspects of this disclosure are not limited to the use of a universal terminal design.

[0045] Figure 3A -F respectively illustrate illustrative connectors 300A-F according to some embodiments. For example, each connector 300A-F can be configured to interact with having Figure 2A Use the terminals shown in the illustrative design together.

[0046] exist Figure 3A In the example shown, connector 300A includes a socket with two terminals 302A and 304A and a plug with two pins 312A and 314A. Terminals 302A and 304A can be arranged in an interleaved configuration. For example, terminal 302A can be offset relative to terminal 304A in both the horizontal and vertical directions, and the same can be done with pins 312A and 314A. In this way, the horizontal distance between pins 312A and 314A can be reduced while maintaining the total distance between pins 312A and 314A (the square root of the sum of the squares of the horizontal and vertical distances). Therefore, the board pitch can be reduced while still allowing the use of sufficiently large conductors to carry large currents.

[0047] In this disclosure, the "vertical" direction can be a direction orthogonal to the PCB on which the connector is mounted, and the "horizontal" direction can be a direction parallel to the PCB. Furthermore, if the first feature is vertically offset relative to the second feature and is farther from (or closer to) the PCB than the second feature, then the first feature of the connector can be said to be "above" (or "below") the second feature of the connector. Similarly, the "top" of the connector can face away from the PCB, and the "bottom" of the connector can face the PCB.

[0048] Back Figure 3A For example, the receptacle of connector 300A includes a latch 322A (mostly obscured in this view), and the plug of connector 300A includes an opening 324A configured to engage with the latch 322A. The latch 322A and the opening 324A may be located on top of connector 300A and can engage with each other when the receptacle mates with the plug. When engaged, the latch 322A and the opening 324A prevent the receptacle and plug from disengaging (e.g., due to vibrations in the operating environment).

[0049] exist Figure 3B In the example shown, connector 300B is similar to Figure 3A The illustrative connector 300A shown, except that the latch 322B (mostly obscured in this view) and the corresponding opening 324B can be arranged on the side of the connector 300B, rather than on the top of the connector 300B. This side latch can be used in applications where vertical space is limited and / or access from above is restricted.

[0050] exist Figure 3C In the example shown, connector 300C is similar to Figure 3AThe illustrative connector 300A shown is configured with terminals 302C and 304C side-by-side rather than staggered, and the same applies to pins 312C and 314C. For example, terminals 302C and 304C can be located in the same horizontal row, as can pins 312C and 314C. This side-by-side configuration can be used in applications with limited vertical space. Furthermore, using different configurations in the same environment reduces the likelihood of mating connectors that are not intended to be mated together.

[0051] exist Figure 3D In the example shown, connector 300D is similar to Figure 3B The illustrative connector 300B shown is configured with terminals 302D and 304D side-by-side rather than staggered, and the same applies to pins 312D and 314D. For example, terminals 302D and 304D can be in the same horizontal row, and so can pins 312D and 314D.

[0052] exist Figure 3E In the example shown, connector 300E is similar to Figure 3A The illustrative connector 300A shown is different from connector 300E, where the mating direction between the plug 302E and the socket 304E is vertical rather than horizontal.

[0053] exist Figure 3F In the example shown, connector 300F has two rows of terminals arranged horizontally and two corresponding rows of contact pins arranged horizontally. For example, a top row 302F and a bottom row 304F may be present. In this example, the terminals in the top row 302F may be oriented such that one or more engagement features (e.g., Figure 2A The illustrative locking feature 232 and illustrative blocking feature 234 shown can be oriented upwards to engage the top TPA feature, while the terminals in the bottom row 304F can be oriented such that one or more engaging features (e.g., Figure 2A The illustrative locking feature 232 and illustrative blocking feature 234 shown may face downwards to engage the bottom TPA feature. However, it should be understood that aspects of this disclosure are not limited to any particular orientation of the terminals, nor to the use of any TPA feature.

[0054] Figure 4A -C illustrates some embodiments Figure 1B The illustration shows a cross-sectional view of socket 130. Figure 4A In the example, the housing 402 of the socket 130 includes elongated cavities 404 and 406, which are configured to receive terminals 132 and 138, respectively. Terminal Position Assurance (TPA) feature 136 is present in... Figure 4AThe two are shown in a split configuration, with sufficient clearance in cavities 404 and 406 to allow insertion of terminals 132 and 138.

[0055] exist Figure 4B In the example, terminals 132 and 138 are fully inserted into cavities 404 and 406, respectively. TPA feature 136 can then be engaged to hold terminals 132 and 138 in their respective positions within housing 402. For example, in Figure 4C In the example, TPA feature 136 is pushed into housing 402 to engage terminals 132 and 138.

[0056] In some embodiments, TPA feature 136 may include one or more protrusions configured to engage one or more terminals in the insertion housing 402, respectively. For example, in Figure 4C In the example, TPA feature 136 includes a protrusion 408 configured to fit into a recess 412 formed in terminal 138, and a protrusion 410 configured to fit into a recess 414 formed in terminal 132. Protrusions 408 and 410 may have different heights. For example, protrusion 410 may be shorter than protrusion 408 because terminal 132 may be arranged in the bottom row of socket 130, while terminal 138 may be arranged in the top row.

[0057] In some embodiments, terminal 132 may include a terminal that is connected to a terminal. Figure 2A The illustrative blocking feature 234 shown is similar to the blocking feature 416 discussed below. When the TPA feature 136 is pushed into the housing 402, the protrusion 410 may be arranged adjacent to the blocking feature 416 of the terminal 132. In this engagement configuration, movement of the terminal 132 in the withdrawal direction causes the blocking feature 416 to move into contact with the protrusion 410, thereby preventing the terminal 132 from being withdrawn from the cavity 404.

[0058] Figure 4D Illustrations are shown according to some embodiments Figure 1B The diagram shows a cross-sectional view of the illustrative connector 100. In this example, the TPA feature 136 is in a split configuration and prevents the plug 140 from fully engaging with the receptacle 130. For example, as shown at 416, the TPA feature 136 in the split configuration can be vertically aligned with the lower edge of the plug 140, thereby blocking the plug 140. Once the TPA feature 136 is pushed upward to an engaged configuration, sufficient clearance is provided for the receptacle 130 to insert into the plug 140. In this way, an electrical connection can be established between the terminals of the receptacle 130 and the corresponding contact pins of the plug 140 only when the TPA feature 136 is in the engaged position, ensuring that the terminals of the receptacle are in the desired position when an electrical connection is established.

[0059] Figure 5A-B illustrates some embodiments Figure 1B A further cross-sectional view of the illustrative socket 130 is shown. Figure 5A The view shown in -B can be orthogonal to... Figure 4A The view shown in -C. Figure 5A In the example, TPA feature 136 is in a split configuration. For example, as shown at 502A, housing 402 may include two protrusions configured to engage with the protrusions of TPA 136. In some embodiments, when TPA feature 136 is in a split configuration, only one of the two protrusions of housing 402 (e.g., the lower protrusion) may engage with TPA feature 136. In this way, TPA feature 136 can be attached to housing 402 while leaving sufficient clearance for insertion of terminals (e.g., illustrative terminals 132 and 138).

[0060] In some embodiments, when TPA feature 136 is in an engagement configuration (e.g., as...) Figure 5B When the housing 402 is in use, the two protrusions can engage with the TPA feature 136 (e.g., as shown in 502B). In this way, the protrusions of the TPA feature 136 (e.g., illustrative protrusions 408 and 410) can be fitted into the corresponding recesses of the inserted terminals (e.g., illustrative terminals 132 and 138) to hold the inserted terminals in their corresponding positions.

[0061] In some embodiments, TPA feature 136 may include one or more recesses (e.g., recess 504) configured to receive a locking feature of the corresponding insertion terminal (e.g., Figure 2A The illustrative locking feature 232 is shown. For example, in Figure 5B In the example shown, when the corresponding terminal is correctly inserted, the locking feature can be vertically aligned with the recess 504, and when the TPA feature 136 is pushed upward to the engagement position, the recess 504 can be fitted onto the locking feature.

[0062] Figure 6A Illustrations are shown according to some embodiments Figure 1B The illustrated socket 130 is shown in a bottom view, with a portion cut off to show the illustrative locking feature of the inserted terminal. Figure 6B It shows Figure 6A A magnified view of region 602.

[0063] exist Figure 6AIn the example shown in -B, each of housing 402 and TPA feature 136 has one or more recesses configured to receive a locking feature of an inserted terminal. For example, housing 402 may have a recess (e.g., recess 606) configured to receive a locking feature of a terminal inserted at the top row (e.g., locking feature 608T), while TPA feature 136 may have a recess (e.g., recess 604) configured to receive a locking feature of a terminal inserted at the bottom row (e.g., locking feature 608B).

[0064] The inventors have recognized and realized that, contrary to the notion that all recesses are provided at housing 402, the spacing between terminals (and thus the board pitch) can be reduced by providing one or more recesses at TPA feature 136. However, it should be understood that aspects of this disclosure are not limited to having any recess at TPA feature 136 to receive a locking feature of an inserted terminal, or are not limited at all to the use of any TPA feature.

[0065] Figure 7 Illustrations are shown according to some embodiments Figure 1B Another cross-sectional view of the illustrative socket 130 is shown. In this example, the protrusion 410 of the TPA feature 136 has a sloping / ramped top profile 702, which is configured to facilitate the sliding of the terminal 132 into the cavity 404. For example, the sloping top profile 702 can prevent the terminal 132 from being damaged due to jamming during insertion.

[0066] Figure 8 Illustrations are shown according to some embodiments Figure 1B Another cross-sectional view of the illustrative socket 130 is shown. In this example, TPA feature 136 has a tapered side profile 802, which is configured to facilitate the sliding of the terminal into a cavity adjacent to the tapered side profile 802. For example, the tapered side profile 802 can prevent the terminal 132 from being damaged due to jamming during insertion.

[0067] Figure 9A An illustrative connector 900A according to some embodiments is shown. In this example, connector 900A has a receptacle with a latch 902A and a plug with an opening 904A configured to engage with the latch 902A. The latch 902A and the opening 904A can engage with each other when the receptacle and the plug mate. When engaged, the latch 902A and the opening 904A can prevent the receptacle and the plug from disengaging (e.g., due to vibration in the operating environment).

[0068] exist Figure 9A In the example, connector 900A also includes TPA feature 906A, which can be similar to Figure 1BIllustrative TPA feature 136 in the example. For example, TPA feature 906A can be configured to retain a terminal inserted into a socket of connector 900A.

[0069] Figure 9B An illustrative connector 900B according to some embodiments is shown. Connector 900B may be similar to... Figure 9A The illustrative connector 900A shown may have a single row of terminals, but connector 900B may also have two rows of terminals. Furthermore, in some embodiments, connector 900B may have two TPA features instead of one TPA feature. For example, bottom TPA feature 906B may be configured to engage terminals in the bottom row, and top TPA feature 908B may be configured to engage terminals in the top row.

[0070] exist Figure 9B In the example, connector 900B includes a receptacle with a latch 902B and a plug with an opening 904B configured to engage with the latch 902B. The latch 902B and the opening 904B can engage with each other when the receptacle and plug mate. When engaged, the latch 902B and the opening 904B prevent the receptacle and plug from disengaging (e.g., due to vibrations in the operating environment). However, with... Figure 9A The illustrative latch 902A in the example differs from that in which latch 902A is located at the socket housing. Figure 9B In the example, latch 902B is located at the top TPA feature 908B.

[0071] The inventors have recognized and realized that this can be achieved by adding a top TPA feature (e.g.) Figure 9B (Example) instead of the socket housing (e.g.) Figure 9A (Example) The presence of latches simplifies molding operations. For example, the number of mold slides can be reduced, thereby lowering manufacturing costs. However, it should be understood that aspects of this disclosure are not by any means limited to any particular location for the latches, or to the use of any particular latch.

[0072] Figure 10Illustrative plug housings 1002 and 1004 according to some embodiments are shown. In this example, plug housings 1002 and 1004 are configured to attach to each other. For example, plug housing 1002 may include a tongue 1006, and plug housing 1004 may include a similar tongue (obscured in this view). Plug housing 1004 may include a recess 1008, and plug housing 1002 may include a similar recess (obscured in this view). The tongue of plug housing 1004 and the recess of plug housing 1002 may be configured to slide engage with each other, thereby attaching plug housings 1002 and 1004 to each other. In this way, multiple desired electrical connections can be provided by attaching two or more connectors together.

[0073] exist Figure 10 In the example, the tongue of plug housing 1004 and the groove of plug housing 1002 form a dovetail joint, which can provide improved tensile strength. However, it should be understood that aspects of this disclosure are by no means limited to the use of any particular technique for connecting multiple connectors together, or to the use of the connectors being connected.

[0074] Figure 11A An illustrative plug 1100 according to some embodiments is shown. The plug 1100 can be used in any suitable connector, such as... Figure 1A -B illustrates the connector 100. For example, plug 1100 can be used as... Figure 1B The illustrative plug 140 is shown.

[0075] exist Figure 11A In the example shown, plug 1100 has a housing 1105 which has a receptacle configured to receive a socket (e.g., Figure 1B The illustrative socket 130 shown has a cavity 1142. For example, one or more contact pins of contact pin 1125 may be retained in the housing 1105 such that when the socket is inserted into the cavity 1142, the mating ends of the contact pins 1125 form an electrical connection with the mating ends of the socket terminals (e.g., Figure 1B (Illustrative terminal 132 shown).

[0076] In some embodiments, the plug 1100 may include one or more features configured to secure the plug 1100 to a PCB. Figure 11A In the example shown, plug 1100 includes clamping members 1144 configured to secure plug 1100 and PCB. For example, each vertical edge of clamping member 1144 may be configured to slide into a corresponding vertical recess, such as recess 1110, formed in housing 1005. In this way, once clamping member 1144 is secured to PCB, lateral movement of plug 1100 relative to PCB (e.g., along the x or y direction) can be prevented.

[0077] Alternatively or alternatively, as shown at 1115, the clamping member 1144 may include one or more beams, such as beam 1120, which are configured to apply a spring force against the housing 1105. Figure 11B Illustrations are shown according to some embodiments Figure 11A A cross-sectional view of the illustrative plug 1100 is provided. In this example, beam 1120 has an inclined end configured to engage with flange 1130 formed on the sidewall of the housing, thereby applying a downward spring force against housing 1105. Thus, once clamping member 1144 is secured to the PCB, vertical (e.g., along the z-direction) movement of plug 1100 relative to the PCB can be prevented.

[0078] Although Figure 11A Not visible in section -B, clamping members similar to clamping member 1144 can be secured to the opposite side of housing 1105 in a similar manner. These clamping members can together hold plug 1100 in place regardless of vibrations in the operating environment (e.g., in automotive applications). However, it should be understood that aspects of this disclosure are not by any means limited to any particular design for clamping members, or to the use of any clamping member. Figure 12A An illustrative connector 1200 according to some embodiments is shown. Connector 1200 may be similar to... Figure 1A The illustrated connector 100 may include a socket 1230 and a plug 1240 configured to mate with each other.

[0079] In some embodiments, connector 1200 may include a connector position assurance (CPA) feature configured to provide an indication of whether the receptacle 1230 and plug 1240 are properly mating with each other. For example, in Figure 12A In the example shown, connector 1200 includes CPA feature 1234, which is movable between a split configuration and a mating configuration.

[0080] Figure 12B Illustrations are shown according to some embodiments Figure 12A A cross-sectional view of the illustrative connector 1200. In this view, the socket 1230 and the plug 1240 partially mate, and the CPA feature 1234 is in a separated configuration.

[0081] In some embodiments, CPA feature 1234 may be attached to socket 1230. For example, in Figure 12AIn the example shown in -B, CPA feature 1234 includes a first latch 1235 configured to engage with receptacle 1230. The first latch 1235 may be made of a resilient material and may be configured to apply a spring force against receptacle 1230, thereby preventing CPA feature 1234 from disengaging from receptacle 1230. Alternatively or additionally, the end of the first latch 1235 may have a protrusion configured to engage with a corresponding protrusion 1236 formed on the housing of receptacle 1230, thereby preventing CPA feature 1234 from disengaging from receptacle 1230.

[0082] In some embodiments, when the socket 1230 is not fully engaged with the plug 1240, the CPA feature 1234 can be prevented from moving into the engagement configuration. For example, in Figure 12A In the example shown in -B, CPA feature 1234 includes a second latch 1237, and a protrusion 1238 is formed on the housing of socket 1230 to provide a stop for the second latch 1237, thereby preventing CPA feature 1234 from moving into the engagement configuration.

[0083] In some embodiments, when the socket 1230 is fully engaged with the plug 1240, the CPA feature 1234 may be allowed to move into the engagement configuration. For example, in Figure 12A In the example shown in -B, the second latch 1237 may be made of an elastic material, and a protrusion 1241 may be formed on the housing of the plug 1240 such that when the socket 1230 is inserted into the plug 1240, the protrusion 1241 on the plug 1240 causes the second latch 1237 to deflect from the protrusion 1238 on the socket 1230. Once the second latch 1237 has passed the protrusion 1238 on the socket 1230, the CPA feature 1234 can be fully pushed into the socket 1230.

[0084] Figure 12C Contacts according to some embodiments are shown. Figure 12A -B's illustrative protrusion 1241 and illustrative latch 1237. In this example, the protrusion 1241 formed on the plug 1240 has an inclined surface 1242 configured to guide the latch 1237. When the socket 1230 is inserted into the plug 1240 along the mating direction D, the end portion of the second latch 1237 can slide along the inclined surface 1242, which can cause the second latch 1237 to deviate from the protrusion 1238 formed on the socket 1230. (In Figure 12C In the middle, protrusion 1241 obscures protrusion 1238, making it invisible.

[0085] Figure 12D The following are illustrated according to some embodiments: Figure 12A-The illustrative protrusion 1241 of -B deflects the illustrative latch 1237. In this example, the second latch 1237 just over the protrusion 1238 formed on the socket 1230. (In Figure 12C In the middle, protrusion 1241 obscures protrusion 1238, making it invisible. Once the second latch 1237 passes over protrusion 1238, the second latch 1237 can enter channel 1239, thereby allowing CPA feature 1234 to be fully pushed into socket 1230.

[0086] Figure 12E Illustrations are shown according to some embodiments Figure 12A -B's illustrative CPA feature 1234 is in an engaged configuration. In this configuration, the CPA feature 1234 is fully pushed into the socket 1230, and the end portion of the second latch 1237 can engage the protrusion 1241 formed on the plug 1240, thereby preventing the socket 1230 and the plug 1240 from disengaging (e.g., due to vibration in the operating environment).

[0087] The techniques described herein can be used in connectors with configurations different from those described above. For example, the techniques described herein can be used in mezzanine connectors or backplane connectors.

[0088] Such changes, modifications, and improvements are intended to be part of this disclosure and are intended to fall within the spirit and scope of the invention. Furthermore, while advantages of the invention have been pointed out, it should be understood that not every embodiment of the invention will include every described advantage. In some cases, some embodiments may not achieve any of the features described herein as advantageous. Therefore, the foregoing description and figures are merely illustrative.

[0089] Various aspects of the present invention can be used alone, in combination, or in various arrangements not specifically discussed in the foregoing embodiments. Therefore, the application of the present invention is not limited to the details and arrangements of the components described herein or shown in the accompanying drawings. For example, aspects described in one embodiment can be combined with aspects described in other embodiments in any way.

[0090] The use of ordinal terms such as “first,” “second,” and “third” in claims to modify claim elements does not imply that one claim element has any priority, rank, or order relative to another claim, or the chronological order of the actions of the method. Rather, it is merely used as a marker to distinguish one claim element with the same name from another element with the same name (but using ordinal terms), thereby differentiating claim elements.

[0091] All definitions used and defined herein should be understood as control dictionary definitions, definitions incorporated by reference in other documents, and / or the general meaning of the defined terms.

[0092] The indefinite articles “a” and “an” used in the specification and claims, unless explicitly stated otherwise, shall be understood to mean “at least one”.

[0093] As used herein in the specification and claims, in a list referring to one or more elements, the phrase "at least one" shall be understood to mean that at least one element is selected from any one or more elements in the list of elements, but does not necessarily include at least one of each element specifically listed in the list of elements, and does not exclude any combination of elements in the list of elements. This definition also allows for the optional presence of elements other than those specifically identified in the list of elements referred to by the phrase "at least one," whether related to or unrelated to those specifically identified elements.

[0094] The phrase “and / or” as used herein in the specification and claims should be understood to mean “one or two” of the elements so combined, that is, in some cases the elements are combined and in others the elements are separate. Multiple elements listed by “and / or” should be interpreted in the same way, that is, “one or more” of the elements so connected. In addition to the elements specifically identified by the “and / or” clause, other elements may optionally be present, whether related to or unrelated to those specifically identified elements. Thus, as a non-limiting example, in one embodiment, when used in conjunction with open-ended language such as “comprising,” a reference to “A and / or B” may refer only to A (optionally including elements other than B); in another embodiment, only to B (optionally including elements other than A); in yet another embodiment, both A and B (optionally including other elements); and so on.

[0095] As used herein in the specification and claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when terms in a list are separated, “or” or “and / or” should be interpreted as inclusive, i.e., including at least one, more than one, and (optionally) additional terms not listed in the list of elements. Unless a term is explicitly indicated to the contrary, such as “only one” or “exactly one”, or when used in the claims, “consisting of” means including only exactly one element in the list of elements. In general, the term “or” as used herein should only be interpreted as indicating an exclusive alternative (i.e., “one or the other, but not both”) before exclusive terms (such as “any one,” “one of,” “only one of,” or “exactly one of”). When used in the claims, “consisting substantially of” should have the ordinary meaning used in the field of patent law.

[0096] Furthermore, the wording and terminology used herein are for descriptive purposes and should not be considered limiting. The use of “comprising,” “including,” or “having,” “containing,” “involving,” and variations thereof in this document is intended to cover the terms listed thereafter and their equivalents, as well as any additional terms.

Claims

1. An electrical connector, comprising: case; A terminal position assurance (TPA) feature attached to the housing, the TPA feature being movable between a split configuration and an engaged configuration; and The terminals inserted into the cavity in the housing, wherein: The TPA feature includes protrusions; When the TPA feature is in the separated configuration, the protrusion of the TPA feature is aligned with the wall of the cavity to allow the terminal to be inserted into the cavity; The protrusion of the TPA feature has an inclined profile, which is configured to guide the terminal when the terminal is inserted into the housing when the TPA feature is in the separated configuration; The wall includes a first wall; The cavity includes a second wall orthogonal to the first wall; The second wall includes a gap, wherein when the TPA feature is in the separated configuration, the gap in the second wall is occupied by a portion of the TPA feature; and The portion of the TPA feature occupying the gap in the second wall has a tapered profile, the tapered profile being configured to guide the terminal when the terminal is inserted into the housing when the TPA feature is in the separated configuration.

2. The electrical connector according to claim 1, characterized in that: When the TPA feature is in the engagement configuration, the protrusion of the TPA feature protrudes into the cavity to prevent the terminal from being pulled out of the cavity.

3. The electrical connector according to claim 1, characterized in that: The portion of the TPA feature includes the first portion of the TPA feature; The cavity includes a third wall opposite to the second wall; The third wall includes a gap, which is occupied by a second portion of the TPA feature when the TPA feature is in a split configuration; as well as The second portion of the TPA feature occupying the gap in the third wall has a tapered profile, which is configured to guide the terminal when the terminal is inserted into the housing when the TPA feature is in the separated configuration.

4. A terminal for a first electrical connector, the terminal comprising: The mating end is configured to receive a contact pin of a second electrical connector; A crimping end, the crimping end being configured to be crimped onto a wire; as well as In the intermediate portion between the mating end and the crimping end, the intermediate portion includes a base and a first wall and a second wall extending from the base, wherein: The terminal is elongated along the mating direction; The intermediate portion includes a blocking feature extending inward toward the centerline of the terminal in a direction perpendicular to the mating direction; The intermediate portion includes a locking feature that extends from the distal portion of the first wall; The first wall and the second wall are arranged on opposite sides of the centerline of the terminal along the mating direction; and The first wall extends further from the base than the second wall.

5. The terminal according to claim 4, characterized in that: The blocking feature is configured to contact a protrusion of the first electrical connector when the terminal is inserted into the first electrical connector, and to prevent the terminal from being pulled out of the first electrical connector.

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