Universal electrical connector

Abstract

An electrical connector includes a universal plug body, a plurality of electrical contacts disposed within the universal plug body, and a printed circuit board (PCB) coupled to the universal plug. The PCB includes a plurality of conductive features configured to electrically connect the plurality of electrical contacts to a plurality of terminals. Different PCB types can be used with the universal plug body to adapt to different power and data applications using the universal connector body.

Description

Technical Field

[0001] This specification generally relates to electrical connectors, methods for assembling electrical connectors, and more specifically to universal electrical connectors for a variety of different input power types. Background Technology

[0002] Electrical connector systems typically include different connector shapes, sizes, and dimensional specifications for different applications. Summary of the Invention

[0003] In a first aspect of this disclosure, an electrical connector is provided. The electrical connector includes a universal plug body, a plurality of electrical contacts disposed within the universal plug body, and a printed circuit board (PCB) coupled to the universal plug body. The PCB includes a plurality of conductive features configured to electrically connect the plurality of electrical contacts to a plurality of terminals.

[0004] In an embodiment of the first aspect, the PCB is a PCB type selected from a plurality of PCB types, each PCB type including a plurality of conductive features configured to electrically connect a plurality of electrical contacts to a plurality of corresponding terminals, wherein each PCB type includes a different number or a different layout of terminals than each other PCB type.

[0005] In an embodiment of the first aspect, the connector further includes a plurality of terminals electrically coupled to conductive features of the PCB.

[0006] In an embodiment of the first aspect, a conductive feature electrically couples a first terminal in the terminal to a first two or more electrical contacts.

[0007] In an embodiment of the first aspect, the conductive feature electrically couples the second terminal in the terminal to a second two or more electrical contacts, and / or the conductive feature electrically couples the second terminal in the terminal to one of the electrical contacts not in the two or more electrical contacts.

[0008] In an embodiment of the first aspect, the connector further includes an electrically insulating cover coupled to the PCB, wherein the electrical contacts are coupled to the PCB at a first side of the PCB, and the cover is coupled to a second side of the PCB opposite to the first side.

[0009] In an embodiment of the first aspect, the connector further includes a grounding contact disposed within the universal plug body and not in electrical contact with the PCB.

[0010] In an embodiment of the first aspect, the connector further includes a fastener disposed on the outer surface of the connector for securing the connector to a mating connector.

[0011] In the first aspect of the embodiment, each electrical contact is disposed in a corresponding C-shaped recess in the plug body.

[0012] In a second aspect of this disclosure, a method for assembling an electrical connector is provided. The method includes providing a universal plug body and inserting a plurality of electrical contacts into the plug body. The method further includes selecting a printed circuit board (PCB) from a plurality of PCB types, each PCB type including a corresponding plurality of conductive features configured to electrically connect the plurality of electrical contacts to corresponding plurality of terminals, wherein each PCB type includes a different number or arrangement of terminals than each other PCB type. The method also includes coupling the plurality of electrical contacts to the conductive features of the selected PCB.

[0013] In a second aspect of the implementation, the method further includes coupling a plurality of terminals to conductive features of the PCB.

[0014] In a second aspect of the implementation, the conductive feature electrically couples a single terminal to two or more electrical contacts.

[0015] In a second aspect of the implementation, the conductive feature electrically couples the second terminal in the terminal to a second two or more electrical contacts, and / or the conductive feature electrically couples the second terminal in the terminal to one of the electrical contacts not in the two or more electrical contacts.

[0016] In a second aspect of the implementation, the method further includes coupling an electrically insulating cover to a PCB, wherein an electrical contact is coupled to the PCB at a first side of the PCB, and the cover is coupled to a second side of the PCB opposite to the first side.

[0017] In a second aspect of the implementation, the method further includes inserting a grounding contact into the plug body, wherein the grounding contact is not positioned to make electrical contact with the PCB, and coupling a grounding wire to the grounding contact.

[0018] In a third aspect of this disclosure, a universal electrical connector system is provided. The electrical connector system includes a first connector comprising a first plug body, a first plurality of electrical contacts disposed in the first plug body, and a first printed circuit board (PCB) coupled to the first plurality of electrical contacts. The first PCB includes a first plurality of conductive features configured to electrically connect the first plurality of electrical contacts to a first plurality of terminals. The electrical connector system also includes a second connector comprising a second plug body identical to the first plug body, a second plurality of electrical contacts disposed in the second plug body, and a second PCB coupled to the second plurality of electrical contacts. The second PCB includes a second plurality of conductive features configured to electrically connect the second plurality of electrical contacts to the second plurality of terminals. The second plurality of terminals differs in number from the first plurality of terminals, and / or the second plurality of conductive features differs in construction from the first plurality of conductive features.

[0019] In a third aspect of the implementation, the system also includes mating universal connectors configured to mate individually with the first universal connector and the second universal connector.

[0020] In a third embodiment, the mating universal connector is configured to be individually secured to the first universal connector and the second universal connector using one or more fixing screws or integrated latches.

[0021] In a third aspect of the implementation, each of the first plug body and the second plug body includes a corresponding plurality of C-shaped recesses, wherein each of the first plurality of electrical contacts and the second plurality of electrical contacts is disposed in the corresponding C-shaped recess.

[0022] In a third aspect of the embodiment, the system further includes a third connector comprising a third plug body identical to the first plug body, a third plurality of electrical contacts disposed in the third plug body, and a third PCB coupled to the third plurality of electrical contacts. The third PCB includes a third plurality of conductive features configured to electrically connect the third plurality of electrical contacts to a third plurality of terminals. The third plurality of terminals differs in number from the first plurality of terminals and the second plurality of terminals, and / or the third plurality of conductive features differs in construction from the first plurality of conductive features and the second plurality of conductive features. Attached Figure Description

[0023] Figure 1 and Figure 2 This is a perspective view of an exemplary universal connector system.

[0024] Figure 3 and Figure 4 This is a perspective view of an exemplary general-purpose connector assembly.

[0025] Figure 5 This is a perspective view of an exemplary universal connector.

[0026] Figure 6 This is an exploded view of the internal components of an exemplary generic connector.

[0027] Figure 7 This is an end view of an exemplary PCB assembly that can be used with a universal connector.

[0028] Figure 8 This is a perspective view of an exemplary PCB assembly that can be used with a universal connector.

[0029] Figure 9 This is an end view of an exemplary PCB assembly that can be used with a universal connector.

[0030] Figure 10This is a perspective view of an exemplary PCB assembly that can be used with a universal connector.

[0031] Figure 11 This is an end view of an exemplary PCB assembly that can be used with a universal connector.

[0032] Figure 12 This is a perspective view of an exemplary PCB assembly that can be used with a universal connector.

[0033] Figure 13 It is along Figure 11 The line 13-13 in the middle is cut off Figure 11 A cross-sectional view of the PCB assembly.

[0034] Figure 14 This is a perspective view of an exemplary generic connector assembly.

[0035] Figure 15 This is a circuit diagram illustrating an exemplary arrangement of connectors for digital data transmission.

[0036] Figure 16 This is a flowchart illustrating an exemplary method for manufacturing and assembling a universal connector.

[0037] Figure 17 This is a block diagram illustrating an exemplary universal connector system.

[0038] Figure 18 This is an illustrated view of an exemplary implementation of a user computing environment. Detailed Implementation

[0039] The following description of exemplary methods and apparatus is not intended to limit the scope of the description to the precise form detailed herein. Rather, the following description is intended to be illustrative so that others may follow its teachings.

[0040] Figure 1 and Figure 2 A universal connector system 100 is shown, which includes a male universal connector 102 and a female universal connector 104. Figure 3 and Figure 4These are front and rear perspective views of the universal connector 102, respectively, omitting the overmolded portion of the connector housing. In some embodiments, the connector system 100 can be used to connect a power distribution unit (PDU), uninterruptible power supply (UPS), or other electronic equipment 106 to an AC power source or other input power source. In such embodiments, a female universal connector 104 can be disposed on or therein of the PDU, UPS, or other electronic equipment to receive input power. The male universal connector 102 can be coupled to a cable configured to transmit power from a power source. In some embodiments, universal connectors 102, 104 can be used to transmit data from a second device to electronic equipment 106. Universal connectors 102, 104 can be coupled together to provide power and / or data connectivity to electronic equipment 106. In some embodiments, electronic equipment 106 can be or may include one or more servers or server racks.

[0041] The male connector 102 may include a plug body 108 and a connector housing 110. In some embodiments, the connector housing 110 may be or may be included in a through-molding on the plug body 108 and the cable 111. The plug body 108 may include a plurality of recesses 1121, 1122, 1123, 1124, 1125, 1126 (which may be individually referred to as recess 112 or collectively as recess 112) and corresponding connector contacts 1141, 1142, 1143, 1144, 1145, 1146 (which may be individually referred to as contact 114 or collectively as contact 114) disposed in each recess 112. In some embodiments, the recess 112 may be generally C-shaped. In such embodiments, the contact 114 may be disposed on the upper or lower surface of an internal protrusion within the recess 112.

[0042] The male connector plug body may also include a grounding recess 116, which includes connector contacts 118 to be coupled to ground. In some embodiments, the grounding recess 116 and the contacts 118 may be configured to be substantially perpendicular to each C-shaped recess 112.

[0043] The female connector 104 may include a plug body 120 configured to be directly attached to an electronic device 106. The female connector plug body 120 may include a plurality of C-shaped protrusions 1221, 1222, 1223, 1224, 1225, 1226 configured to mate with C-shaped recesses 1121, 1122, 1123, 1124, 1125, 1126 on the male connector 102. Electrical contacts 1241, 1242, 1243, 1244, 1245, 1246 (each in...) Figure 2(The markings are hidden by the protrusions) can be provided on the upper or lower surface of each C-shaped protrusion 122 so as to connect to the electrical contact 112 of the male connector 102 when the male connector 102 and the female connector 104 mate with each other.

[0044] The female connector plug body 120 may also include a grounding protrusion 126, which includes a connector contact 128 to be coupled to ground. In some embodiments, the grounding protrusion 126 and the contact 128 may be configured to be substantially perpendicular to each C-shaped protrusion 112. The grounding protrusion 126 and the contact 128 may be configured to mate with the grounding recess 116 and the contact 118 of the male connector 102 when the male connector 102 and the female connector 104 mate with each other.

[0045] One or more fasteners may be provided on the male connector and / or female connector for securing the male connector 102 and the female connector 104 to each other. For example, the male connector 102 may include two retaining screws 130 on opposite outer surfaces of the connector, and the female connector may include threaded holes 132 for receiving the retaining screws 130. In another embodiment, an integrated latch may be provided on opposite outer surfaces of the plug body.

[0046] Figure 1 and Figure 2 The system 100 includes six contacts 114 on six C-shaped recesses 112 and six contacts 124 on six C-shaped protrusions 122, as well as a single ground contact 118, 128 on each connector 102, 104. In other embodiments, different numbers of contacts 114, 124, and corresponding numbers of recesses 112 and protrusions 122 may be provided. Furthermore, while in the illustrated embodiment all recesses 112 and protrusions 122 (except for grounding recesses 116 and protrusions 126) have the same size, shape, and orientation as each other, in other embodiments, the size, shape, or orientation of the recesses may differ from each other, and the size, shape, or orientation of the protrusions may differ from each other.

[0047] refer to Figure 4The male connector 102 may include a printed circuit board (PCB) 134 and a plurality of terminals 136 for coupling with an input line. Terminals 136 and contacts 114 can be electrically coupled to each other via the PCB 134. Specifically, the PCB 134 may include a plurality of conductive features 138 (not all conductive features 138 are labeled), to which contacts 114 and terminals 136 can be electrically coupled. In some embodiments, each contact 114 can be electrically coupled to a single corresponding terminal 136 via the conductive features 138 of the PCB 134. In some embodiments, multiple contacts 114 can be coupled to a single terminal 136 via the conductive features 138 of the PCB 134. The conductive features 138 of the PCB 134 may include vias, pins, pads, wire traces, etc.

[0048] like Figure 4 As shown, PCB 134 can be disposed within plug body 108. In other embodiments, PCB 134 can alternatively be disposed within another housing portion or body portion of connector 102, such as a through-molding portion.

[0049] In an embodiment, terminal 136 may include one or more lugs or other terminal structures. Each terminal 136 may provide a corresponding electrical contact for a power line or data line.

[0050] Using the conductive feature 138 of PCB 134 to connect terminal 136 to plug contact 114 advantageously allows the use of plug bodies 108, 120 of the same size specification for many different input types. For example, Figure 1 and Figure 2 The same plug body 108, 120 can be used for DC power, single-phase AC power, three-phase AC power, and / or one or more data signal lines. Therefore, IT and other computer hardware professionals and businesses can use a single plug size specification for a variety of applications.

[0051] Figure 5 This is a perspective view of a second embodiment of the universal connector 102'. Except as described herein, the universal connector 102' is identical to the universal connector 102. The universal connector 102' includes a connector 114', wherein half-connectors 1142', 1144', 1146' are disposed on the lower exposed surface of the C-shaped recess (and in...). Figure 5 (The middle one is shielded), while other contacts 1141', 1143', and 1145' are located on the upper exposed surface of the C-shaped recess. Furthermore, the universal connector 102' may include an integrated latch 140 or other fastener located on the opposing outer surface of the plug body 108' for connection to a mating female connector.

[0052] Figure 6This is an exploded view of the internal component assembly 600 of the universal connector 102'. Assembly 600 includes multiple (e.g., six) plug contacts 1141', 1142', 1143', 1144', 1145', 1146', a PCB 602, and multiple pad connectors 604 (one of which is in…) Figure 6 (marked in the middle), electrical insulation cover 606, multiple terminals 1361, 1362, 1363, 1364 and multiple fasteners 608 (one of which is in Figure 6 (Marked in the middle).

[0053] like Figure 6 As shown, the plug contacts can be arranged in two or more orientations. For example, three plug contacts 1141', 1143', and 1145' can be arranged in a first orientation, while the other three plug contacts 1142', 1144', and 1146' can be arranged in a second orientation opposite to the first orientation (e.g., rotated 180 degrees from the first orientation). In other embodiments, such as Figure 2 and Figure 3 As shown, all plug contacts 1141', 1142', 1143', 1144', 1145', and 1146' can be arranged in the same orientation. Furthermore, although six plug contacts 1141', 1142', 1143', 1144', 1145', and 1146' are shown, any number of plug contacts 114' can be provided depending on specific size specifications and application requirements.

[0054] Figure 6 The plug contact 114' includes a corresponding protrusion 610 (one of which is marked in Figure 6 (in the middle), which helps to secure the contacts within the plug body 108', which will be discussed below. Figure 13 It is described in the context of a similar "turning point" feature.

[0055] PCB 602 may include multiple conductive features 138. Figure 6 The PCB shown includes four sets of conductive features 1381, 1382, 1383, and 1384. Conductive feature 138 includes a first set of conductive features 1381 electrically coupling a contact 1141' to a first terminal location, a second set of conductive features 1382 electrically coupling a second contact 1143' to a second terminal location, a third set of conductive features 1383 electrically coupling a third contact 1145' to a third terminal location, and a fourth set of conductive features 1384 electrically coupling the remaining three contacts 1142', 1144', and 1146' to a fourth terminal location. PCB 602 may include a plurality of holes 612 (two of which 6122 and 6125 are marked), each hole for receiving a corresponding plug contact 114'. The plug contact 114' can be inserted into a first side of PCB 602 during assembly.

[0056] A pad connector 604 may be provided to couple a terminal location to a corresponding terminal 136. In some embodiments, the pad connector 604 may be internally threaded. The pad connector 604 may be located at a terminal location on the PCB 602 and electrically coupled to a terminal location on the PCB 602. The pad connector 604 may be conductive.

[0057] An insulating cover 606 may be disposed on the second side of PCB 602 opposite to plug contact 114'. The insulating cover 606 may cover the entire second side of PCB 602. The insulating cover may include a plurality of holes 614 (one of which is in…) Figure 6 (marked in the middle), the pad connector 604 can extend through the plurality of holes 614.

[0058] Terminal 136 can be secured to pad connector 604 using fastener 608. For example, fastener 608 can be a screw and can be screwed into pad connector 604. Therefore, terminal 136 can be electrically coupled to plug contact 114' through pad connector 604 and through conductive feature 138 of PCB 602.

[0059] The conductive feature 138 of PCB 602 connects terminal 136 to contact 114'. Figure 6 The arrangement allows different PCB layouts to be used for different terminal layouts located on the same plug and having the same plug contact configuration. Figures 7 to 13 Several implementations of PCBs with different numbers of input terminals are shown. These different PCBs may be referred to as PCB types herein.

[0060] Figure 7 and Figure 8 A first embodiment 700 and a second embodiment 800 for a PCB type with dual-terminal input are shown. Both embodiments 700 and 800 of the dual-terminal PCB type are configured to be electrically coupled to six contacts 114 or 114' and two power or data terminals 136. Each embodiment 700 and 800 of the dual-terminal PCB type includes a first conductive feature group 702, 802 that electrically couples three contacts 114, 114' to a first terminal 1361, and a second conductive feature group 704, 804 that electrically couples another three contacts 114, 114' to a second terminal 1362. The first dual-terminal PCB 700 also includes contacts ( Figure 7 (Not shown in the diagram), terminal 706, and conductive feature 708 for grounding. Conversely, the second two-terminal PCB 800 includes a cutout 806 on the PCB. Ground wires, contacts, or other grounding connections can bypass the PCB through the cutout 806.

[0061] Figure 9 and Figure 10 A first embodiment 900 and a second embodiment 1000 for a PCB type with three-terminal input are shown. Both embodiments 900 and 1000 of the three-terminal PCB type are configured to be electrically coupled to six contacts 114 or 114' or three power terminals or data terminals 136. Each embodiment of the three-terminal PCB types 900 and 1000 includes a first set of conductive features 902, 1002 electrically coupling two contacts to a first terminal, a second set of conductive features 904, 1004 electrically coupling two other contacts to a second terminal, and a third set of conductive features 906, 1006 electrically coupling the last two contacts to a third terminal. The first three-terminal PCB also includes contact terminals 908 and conductive features 910 for grounding. In contrast, the second three-terminal PCB 1000 includes a cutout 806 on the PCB. Ground wires, contacts, or other grounding connections can bypass the PCB through the cutout 806.

[0062] Figure 11 and Figure 12 A first embodiment 1100 and a second embodiment 1200 for a PCB type for four-terminal input are shown. Both embodiments of the four-terminal PCB types 1100 and 1200 are configured to be electrically coupled to six contacts 114 or 114' and four power or data terminals 136. Each embodiment of the four-terminal PCB types 1100 and 1200 includes a first conductive feature group 1102, 1202 electrically coupling one contact 114, 114' to a first terminal 1361, a second conductive feature group 1104, 1204 electrically coupling a second contact 114, 114' to a second terminal 1362, a third conductive feature group 1106, 1206 electrically coupling a third contact 114, 114' to a third terminal 1363, and a fourth conductive feature group 1108, 1208 electrically coupling the remaining three contacts 114, 114' to a fourth terminal 1364. The first four-terminal type PCB 1100 also includes contacts, terminals 706, and conductive features 708 for grounding. In contrast, the second four-terminal type PCB 1200 includes a cutout 806 on the PCB. Ground wires, contacts, or other grounding connections can bypass the PCB through the cutout 806.

[0063] Figure 13 It is along Figure 11The image shows a cross-sectional view of the assembly including the first four-terminal PCB 1100, taken by line 13-13. Each contact 114 may include a longitudinal bend 1302. The bend 1302 may abut against a vertical inner surface 1304 of the plug body 108 and may help prevent longitudinal movement of the contact 114 in the assembled connector. Each contact 114 may be inserted through a portion (up to and including all) of a hole 1306 in the PCB 1100. The hole 1306 may be configured to receive the contact 114 and may include a portion of a set of conductive features that electrically couples the contact 114 to terminals 136. The plug body 108 may define a recess 1308 within each C-shaped recess 112 for each contact 114, the recess 1308 being configured to receive an accessible portion of the contact 114 for electrical connection with a mating connector. The size and shape of the recess 1308 may be designed such that the accessible surface of the contact 114 is flush with the front lip of the plug body 108.

[0064] Figure 14 It has Figure 8 The rear perspective view of the internal assembly 1400 of the two-terminal connector of the second two-terminal PCB 800 is shown. The insulating cover 1402 of the connector assembly may include a hole 1404 that aligns with a cutout on the PCB 806 in the assembled connector for ground bypass.

[0065] As mentioned above, connector systems can be used to transmit power and / or data. Figure 15 This is a circuit diagram illustrating an exemplary arrangement 1500 of connectors for digital data transmission. Figure 15 The arrangement 1500 shown can be used with a four-terminal connector system (e.g., using...). Figure 9 and Figure 10 The PCB types shown are 900 and 1000.

[0066] The data transmission arrangement 1500 may include three terminals 1361, 1362, and 1363 for data transmission and a fourth terminal 1364 for grounding. Of the three terminals 1361, 1362, and 1363 for data transmission, the first terminal 1361 and the third terminal 1363, along with the associated first and third transmission lines, can be used for signal transmission, and the second transmission line can be used for neutral voltage. In the receiver connector, a pull-up resistor 1502 can be coupled to the first, second, and third terminal lines 1361, 1362, and 1363. A microcontroller, electronic control unit (ECU), or other processing unit 1504 can be coupled to the first, second, and third terminal lines of the receiver connector to read data from the three transmission lines.

[0067] Figure 15The schematic diagram is merely one example of a data transmission scheme that can be used with the connector system according to this disclosure. Many other data transmission schemes can utilize a universal connector plug body and use PCB type to define the terminal layout and quantity according to this disclosure.

[0068] Figure 16 This is a flowchart illustrating an exemplary method 1600 for manufacturing and assembling electrical connectors. For example, this method can be used to manufacture and assemble PCBs using the PCB types and other components disclosed herein. Figure 1-3 One of the connectors, 5 or 13.

[0069] Method 1600 may include, at block 1602, adding conductive features on each of a plurality of circuit boards to define a plurality of circuit board types. Adding conductive features may include printing wire traces, vias, pads, and other features on the circuit boards. The plurality of circuit board types may include a corresponding plurality of intended terminal numbers. Except for the number and configuration of vias and holes for coupling other components to the circuit boards, the plurality of circuit boards may be identical (before printing) and therefore may be identical in size and shape. As described below, the plurality of circuit boards may each have the same number and configuration of holes for coupling plug contacts to the circuit board. The conductive features of each PCB may include multiple sets of conductive features, each set electrically coupling one or more plug contact holes to a single contact pad. Each PCB type may include a corresponding plurality of conductive features configured to electrically connect a plurality of electrical contacts to a corresponding plurality of terminals, and each PCB type may include a different number or layout of terminals than each other PCB type.

[0070] Method 1600 may further include, at block 1604, selecting a desired circuit board from a variety of circuit board types. The selected circuit board will become the main body for further assembly.

[0071] Method 1600 may further include, at block 1606, electrically coupling a plurality of pad connectors to a conductive feature of a selected PCB. In embodiments, each pad connector may be electrically coupled to a contact pad on the PCB. The number of pad connectors may be equal to the number of terminals disposed on the connectors. In some embodiments, the pad connectors may be coupled to the rear side of the PCB. In some embodiments, the pad connectors may be internally threaded. In some embodiments, the pad connectors may be surface mount (SMT) type and may be soldered to the PCB.

[0072] Method 1600 may further include coupling an insulating cap to a PCB at block 1608. The insulating cap may be coupled to the rear side of the PCB. In some embodiments, the insulating cap may be coupled to the PCB above the pad connector. In some embodiments, the insulating cap may include multiple holes through which the pad connector may extend. In some embodiments, the insulating cap may have substantially the same shape as the PCB and thus may cover the entire rear side of the PCB except for the pad connector. The insulating cap may include holes located outside the PCB envelope for a ground wire to pass through.

[0073] Method 1600 may further include, at block 1610, coupling a plurality of terminals to a PCB (e.g., to a conductive feature of the PCB). In some embodiments, respective terminals may be coupled to each pad connector. Terminals may be coupled to pad connectors using fasteners (e.g., screws screwed into the internal threads of the pad connector). In embodiments, each terminal may be configured to accommodate a data line or a power line.

[0074] Method 1600 may further include coupling a plurality of plug contacts to the PCB at block 1612. In some embodiments, the number of plug contacts may be greater than the number of terminals. In some embodiments, each terminal may be coupled to one or more plug contacts via conductive features of the PCB. The plug contacts may be coupled to the front side of the PCB. In some embodiments, the plug contacts may be inserted into plug contact holes in the PCB and soldered to the PCB.

[0075] Method 1600 may further include, at block 1614, providing a universal plug body and coupling plug contacts to the universal plug body. For example, the plug contacts may be inserted into the plug body. Regardless of the PCB type selected at block 1604, the universal plug body may have the same size and shape. The universal plug body may include multiple recesses and / or protrusions, each plug contact having a corresponding recess or protrusion. The universal plug body may also include a recess or protrusion for a ground contact, and block 1614 may include, for example, coupling a ground contact to the universal plug body by inserting a ground contact into the plug body.

[0076] Method 1600 may further include, at block 1616, coupling a corresponding wire to each terminal. Each wire may be a data line or power line for a suitable configuration (e.g., measuring instrument) for the desired application. In some embodiments, the wire may be inserted into a cable body, or the cable body may be formed around the wire. Block 1616 may also include coupling a ground wire to a ground contact and such that the ground wire passes through a ground hole in an insulating cover. The ground wire may be coupled to an assembly without placing it in electrical contact with the PCB.

[0077] Method 1600 may also include molding the connector body over the coupling point of the wire and terminal at block 1618, or otherwise coupling the connector body to the plug body.

[0078] Method 1600 can be repeated in boxes 1604-1618 to assemble various different connector types using the same plug body.

[0079] Figure 17 This is a block diagram of an exemplary universal connector system 1700. The connector system 1700 may include a first connector 1702 and a second connector 1704 that mates with the first connector 1702. As described below, the first connector 1702 may be identical to connector 102 or connector 102', except that it includes a sensor 1706. In some embodiments, the second connector may be connector 104.

[0080] Connector 1702 may include six contacts 1141, 1142, 1143, 1144, 1145, and 1146 and sensor 1706. Five of the contacts, 1142, 1143, 1144, 1145, and 1146, may be electrically coupled to an input power supply 1708 (e.g., via a PCB as described herein). Sensor 1706 may be disposed within the plug body and may be electrically coupled to the sixth contact 1141. Sensor 1706 may be, for example, a thermistor or other sensor configured to output a signal indicating a condition within the connector. In some embodiments, sensor 1706 may be directly coupled to contact 1141. In other embodiments, sensor 1706 may be coupled to contact 1141 via a PCB.

[0081] The first contact 1241 of mating connector 1704 can output to processor 1710, which can receive the output signal from sensor 1706 and analyze the signal to determine the condition of connectors 1702 and 1704. For example, if sensor 1706 is a thermistor, processor 1710 can analyze the thermistor's output to determine whether connectors 1702 and 1704 are in thermal runaway or other overheating conditions. Other contacts of mating connectors can provide device power 1712 to the electronic device. In some embodiments, the input power can power processor 1710 (e.g., processor 1710 can be a processor of the electronic device).

[0082] Figure 18This is a schematic diagram of an example user computing environment, including a general-purpose computing system environment 1800, such as a desktop computer, laptop computer, smartphone, tablet computer, or any other such device capable of executing instructions (e.g., those stored in a non-transitory computer-readable medium). The various computing devices disclosed herein may resemble computing system 1800 or may include some components of computing system 1800. For example, Figure 17 The connector system 1700 may include or be used with one or more data servers or data server racks, which may include one or more computing components of environment 1800. Furthermore, although described and illustrated in the context of a single computing system 1800, those skilled in the art will also understand that the various tasks described below can be practiced in a distributed environment having multiple computing systems 1800 linked via a local area network or wide area network, wherein executable instructions may be associated with and / or executed by one or more of the multiple computing systems 1800.

[0083] In its most basic configuration, the computing system environment 1800 typically includes at least one processing unit 1802 and at least one memory 1804, which can be linked via a bus 1806. Depending on the exact configuration and type of the computing system environment, the memory 1804 can be volatile (e.g., RAM 1810), non-volatile (e.g., ROM 1808, flash memory, etc.), or some combination of both. The computing system environment 1800 may have additional features and / or functions. For example, the computing system environment 1800 may also include additional storage (removable and / or non-removable), including but not limited to, disk or optical disc drives, tape drives, and / or flash drives. Such additional storage devices can be accessed by the computing system environment 1800 by means of, for example, a hard disk drive interface 1812, a disk drive interface 1814, and / or an optical disc drive interface 1816. As will be understood, these devices, respectively linked to system bus 1806, allow reading from and writing to hard disk 1818, reading from or writing to removable disk 120, and / or reading from or writing to removable optical disk 1822 (e.g., CD / DVD ROM or other optical media). The drive interface and its associated computer-readable media allow for the non-volatile storage of computer-readable instructions, data structures, program modules, and other data of computing system environment 1800. Those skilled in the art will further understand that other types of computer-readable media capable of storing data can be used for the same purpose. Examples of such media devices include, but are not limited to, magnetic tape cartridges, flash memory cards, digital optical discs, Bernoulli tape cartridges, random access memory, nanodrives, memory sticks, other read / write and / or read-only memories, and / or any other methods or techniques for storing information such as computer-readable instructions, data structures, program modules, or other data. Any such computer storage medium may be part of computing system environment 1800.

[0084] Multiple program modules can be stored in one or more memory / media devices. For example, a Basic Input / Output System (BIOS) 1824, containing basic routines such as those that facilitate the transfer of information between components within the computing system environment 1800 during startup, can be stored in ROM 1808. Similarly, RAM 1810, hard disk drive 1818, and / or peripheral memory devices can be used to store computer-executable instructions, including an operating system 1826, one or more application programs 1828 (e.g., which may include temperature detection or other sensor readout functions disclosed herein), other program modules 1830, and / or program data 1822. Furthermore, the computer-executable instructions can be downloaded to the computing environment 1800 as needed, for example, via a network connection.

[0085] End users can input commands and information into the computing system environment 1800 through input devices such as keyboard 1834 and / or pointing device 1836. Although not shown, other input devices may include microphones, joysticks, game controllers, scanners, etc. These and other input devices are typically connected to the processing unit 1802 via peripheral interface 1838, which is coupled to bus 1806. Input devices may be connected directly or indirectly to processor 1802 via interfaces such as parallel ports, game ports, FireWire, or Universal Serial Bus (USB). To view information from the computing system environment 1800, monitor 1840 or other types of display devices may also be connected to bus 1806 via an interface such as video adapter 1832. In addition to monitor 1840, the computing system environment 1800 may also include other peripheral output devices, such as speakers and printers, not shown.

[0086] The computing system environment 1800 can also utilize logical connections to one or more computing system environments. Communication between the computing system environment 1800 and remote computing system environments can be exchanged via another processing device (e.g., a network router 1842 responsible for network routing). Communication with the network router 1842 can be performed via a network interface component 1844. Therefore, within such a network environment (e.g., the Internet, the World Wide Web, a local area network, or other similar wired or wireless networks), it should be understood that program modules described relative to the computing system environment 1800 or parts thereof can be stored in the memory storage device of the computing system environment 1800.

[0087] The computing system environment 1800 may also include positioning hardware 1846 for determining the location of the computing system environment 1800. In some cases, the positioning hardware 1846 may include (by way of example only) a GPS antenna, an RFID chip or reader, a WiFi antenna, or other computing hardware that can be used to capture or transmit signals that can be used to determine the location of the computing system environment 1800.

[0088] While certain embodiments have been described in this disclosure, it should be understood that the claims are not intended to limit them to these embodiments except as expressly recited in the claims. Rather, this disclosure is intended to cover alternatives, modifications, and equivalents that may be included within the spirit and scope of this disclosure. Furthermore, numerous specific details are set forth in the detailed description of this disclosure to provide a thorough understanding of the disclosed embodiments. However, it will be apparent to those skilled in the art that systems and methods consistent with this disclosure can be practiced without these specific details. In other instances, well-known methods, processes, components, and circuits have not been described in detail so as not to unnecessarily obscure various aspects of this disclosure.

[0089] Some portions of the detailed description in this disclosure have been presented in terms of processes, logic blocks, operations, and other symbolic representations of operations on data bits within the memory of a computer or digital system. These descriptions and representations are the most effective means employed by those skilled in the art of data processing to convey the main content of their work to others skilled in the art. Processes, logic blocks, operations, etc., are conceived herein and generally as self-consistent sequences of steps or instructions that lead to desired results. These steps are steps that require physical operations on physical quantities. Typically, but not necessarily, these physical operations take the form of electrical or magnetic data capable of being stored, transferred, combined, compared, and otherwise manipulated in a computer system or similar electronic computing device. For convenience, and with reference to common usage, and to various embodiments of the present disclosure, such data is referred to as bits, values, elements, symbols, characters, terms, numbers, etc.

[0090] However, it should be remembered that these terms should be interpreted as referring to physical operations and quantities, and are merely convenient labels that should be further interpreted according to the terminology commonly used in the art. Unless otherwise specifically stated, it is clear from the discussion herein that it should be understood that throughout the discussion of this embodiment, the use of terms such as “determine” or “output” or “transmit” or “record” or “locate” or “store” or “display” or “receive” or “identify” or “utilize” or “generate” or “provide” or “access” or “check” or “notify” or “transmit” refers to the actions and processes of a computer system or similar electronic computing device that operates and converts data. Data is represented as physical (electronic) quantities within the registers and memories of a computer system, and is converted into other data similarly represented as physical quantities within the memory or registers of a computer system, or other such information storage, transmission, or display devices described herein or otherwise understood by those skilled in the art.

[0091] Although certain example methods and apparatuses have been described herein, the scope of this patent is not limited thereto. Rather, this patent covers all methods, apparatuses, and articles of manufacture that fall fully within the scope of the appended claims, either literally or under the doctrine of equivalents.

Claims

1. An electrical connector, comprising: A plug body, the plug body including a plurality of C-shaped recesses; A plurality of electrical contacts are disposed within the plug body, wherein each of the plurality of electrical contacts is disposed in a corresponding C-shaped recess in the plug body; A printed circuit board (PCB) coupled to the plug body includes multiple conductive features configured to electrically connect multiple electrical contacts to multiple terminals; and A grounding contact is disposed in the plug body and does not make electrical contact with the printed circuit board.

2. The electrical connector of claim 1, wherein the PCB is a PCB type selected from a plurality of PCB types, each PCB type including a corresponding plurality of conductive features configured to electrically connect the plurality of electrical contacts to a corresponding plurality of terminals, wherein each PCB type includes a different number or layout of terminals than each other PCB type.

3. The electrical connector of claim 1 further includes a plurality of terminals electrically coupled to the conductive features of the PCB.

4. The electrical connector of claim 1, wherein the conductive feature electrically couples a first terminal of the terminals to a first two or more electrical contacts of the electrical contacts.

5. The electrical connector according to claim 4, characterized in that: One or more of the following: The conductive feature electrically couples the second terminal in the terminal to two or more second electrical contacts in the electrical contacts; or The conductive feature electrically couples the second terminal of the terminal to one of the electrical contacts that is not among the two or more electrical contacts.

6. The electrical connector of claim 1, further comprising an electrically insulating cover coupled to the PCB, wherein the electrical contact is coupled to the PCB at a first side of the PCB, and the cover is coupled to a second side of the PCB opposite to the first side.

7. The electrical connector according to claim 1 further includes a fastener disposed on the outer surface of the connector for securing the connector to a mating connector.

8. A method for assembling an electrical connector, the method comprising: A plug body is provided, the plug body including a plurality of C-shaped recesses; Multiple electrical contacts are inserted into the plug body, wherein each of the multiple electrical contacts is disposed in a corresponding C-shaped recess in the plug body; Select a printed circuit board (PCB) from a plurality of PCBs of a plurality of PCB types, each PCB type including a plurality of corresponding conductive features configured to electrically connect a plurality of electrical contacts to a plurality of corresponding terminals, wherein each PCB type includes a different number or layout of terminals than each other PCB type; The plurality of electrical contacts are coupled to the conductive features of the selected PCB; as well as An electrically insulating cover is coupled to the PCB, wherein the electrical contacts are coupled to the PCB at a first side of the PCB, and the cover is coupled to a second side of the PCB opposite to the first side.

9. The method of claim 8, further comprising coupling the plurality of terminals to the conductive features of the PCB.

10. The method of claim 8, wherein the conductive feature electrically couples a single terminal of the terminal to two or more of the electrical contacts.

11. The method according to claim 10, characterized in that: One or more of the following: The conductive feature electrically couples the second terminal in the terminal to two or more second electrical contacts in the electrical contacts; or The conductive feature electrically couples the second terminal of the terminal to one of the electrical contacts that is not among the two or more electrical contacts.

12. The method according to claim 8, further comprising: Insert a grounding contact into the plug body, wherein the grounding contact is not positioned to make electrical contact with the printed circuit board; as well as Couple the grounding wire to the grounding contact.

13. An electrical connector system, comprising: The first connector includes: First plug body; The first plurality of electrical contacts disposed in the first plug body; and The first printed circuit board (PCB), the first printed circuit board (PCB) and the First plurality of electrical contacts are coupled, the first printed circuit board (PCB) includes first plurality of conductive features, the first plurality of conductive features being configured to electrically connect the first plurality of electrical contacts to first plurality of terminals; and The second connector includes: The second plug body is the same as the first plug body; The second plurality of electrical contacts are disposed in the second plug body; and A second PCB, coupled to the second plurality of electrical contacts, includes a second plurality of conductive features configured to electrically connect the second plurality of electrical contacts to the second plurality of terminals, wherein one or more of the following are included: The second plurality of terminals differs in number from the first plurality of terminals; or The second plurality of conductive features are structurally different from the first plurality of conductive features; Each of the first plug body and the second plug body includes a corresponding plurality of C-shaped recesses, wherein each of the first plurality of electrical contacts and the second plurality of electrical contacts is disposed in the corresponding C-shaped recess.

14. The electrical connector system of claim 13, further comprising: A mating connector, the mating connector being configured to mate individually with the first connector and the second connector.

15. The connector system of claim 14, wherein the mating connector is configured to be individually secured to the first connector and the second connector using one or more fixing screws or integrated latches.

16. The electrical connector system of claim 13, further comprising a third connector, the third connector comprising: The third plug body is the same as the first plug body; The third plurality of electrical contacts are disposed in the third plug body; and A third PCB, coupled to the third plurality of electrical contacts, includes a third plurality of conductive features configured to electrically connect the third plurality of electrical contacts to a third plurality of terminals, wherein one or more of the following: The third plurality of terminals differs in number from the first plurality of terminals and the second plurality of terminals; or The third plurality of conductive features are structurally different from the first plurality of conductive features and the second plurality of conductive features.

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