Contact organizer for plug connector

Abstract

The invention relates to a contact organizer for a plug connector. A plug connector includes a plug housing extending between a front portion and a rear portion. The front portion is configured to mate with a headstock housing. The plug housing includes a contact channel extending longitudinally between a front portion and a rear portion. The plug connector includes a contact received in the contact channel. The contact includes a receptacle at a mating end of the contact configured to receive a pin contact of the header housing. The contacts are arranged in an array having a plurality of rows and a plurality of columns. The plug connector includes a contact organizer coupled to a front portion of the plug housing. The contact organizer has apertures therethrough aligned with corresponding contact channels. The contact organizer has a guide feature configured to center the needle contacts in the bore to align the needle contacts with the receptacle.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 596,498, filed on November 6, 2023, and entitled “CONTACT ORGANIZER FOR A PLUGCONNECTOR,” the subject matter of which is incorporated herein by reference in its entirety. Technical Field

[0002] The subject matter herein relates generally to electrical connector systems. Background Art

[0003] Electrical connectors are used in electronic systems to provide electrical signal transmission between various components. Connectors typically include arrays of pin and socket contacts that must be precisely aligned to establish reliable electrical connections. However, conventional connector designs often encounter challenges involving accurate alignment of contacts, resulting in intermittent or unstable electrical connections. In addition, damage to the contacts may occur during mating if the contacts are not properly aligned. Some known connectors rely on precise machining techniques to help align the contacts, which can add complexity and cost to the connector manufacturing process. In addition, such solutions may not always provide a robust remedy for alignment issues, particularly in situations where the connectors need to mate in challenging environments or under dynamic conditions.

[0004] There remains a need for a robust and cost-effective solution for aligning contacts of electrical connectors during mating. Summary of the invention

[0005] In one embodiment, a plug connector is provided, and the plug connector includes a plug housing extending between a front portion and a rear portion. The front portion is configured to mate with a header housing. The plug housing includes a contact channel extending longitudinally between the front portion and the rear portion. The plug connector includes a contact received in the contact channel. The contact includes a socket at the mating end of the contact, which is configured to receive the pin contact of the header housing. The contacts are arranged in an array having multiple rows and columns. The plug connector includes a contact organizer coupled to the front portion of the plug housing. The contact organizer has a hole passing therethrough that is aligned with the corresponding contact channel. The contact organizer has a guiding feature that is configured to center the pin contact in the hole to align the pin contact with the socket.

[0006] In another embodiment, a plug connector is provided, and the plug connector includes a plug housing extending between a front portion and a rear portion. The front portion is configured to mate with a header housing. The plug housing includes a contact channel extending longitudinally between the front portion and the rear portion. The plug connector includes a contact received in the contact channel. The contact includes a socket at a mating end of the contact, which is configured to receive a pin contact of the header housing. The socket has a distal edge configured to receive the pin contact. The contacts are arranged in an array having multiple rows and columns. The plug connector includes a contact organizer coupled to the front portion of the plug housing. The contact organizer has a hole aligned with a corresponding contact channel therethrough. The contact organizer has a cap extending into the hole. The cap is overhung on the distal end of the socket. The contact organizer has a guide feature in front of the cap, which is configured to center the pin contact in the hole to align the pin contact with the socket.

[0007] In another embodiment, an electrical connector system is provided, and the electrical connector system includes a header connector having a header housing, the header housing having a channel for holding pin contacts in an array having multiple rows and columns. The header housing includes a shield at the mating end of the header connector, which forms a cavity. The pin contacts extend into the cavity. The electrical connector system includes a plug connector mating with the header connector. The plug connector includes a plug housing for holding contacts in an array having multiple rows and columns. The plug housing extends between a front and a rear portion. The front portion is configured to be inserted into the cavity of the header housing. The plug housing includes a contact channel for receiving corresponding contacts. The contact includes a socket at the mating end of the contact, which is configured to receive the corresponding pin contact. The plug connector includes a contact organizer connected to the front of the plug housing. The contact organizer has a hole aligned with the corresponding contact channel passing therethrough. The contact organizer has a guiding feature configured to center the pin contact in the hole to align the pin contact with the socket during mating. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a front perspective view of an electrical connector system according to an exemplary embodiment.

[0009] Figure 2 is a rear perspective view of an electrical connector system according to an exemplary embodiment.

[0010] Figure 3 is an exploded front perspective view of an electrical connector system according to an exemplary embodiment.

[0011] Figure 4 is an exploded rear perspective view of an electrical connector system according to an exemplary embodiment.

[0012] Figure 5 is a perspective view of a plug connector according to an exemplary embodiment.

[0013] Figure 6 is an exploded perspective view of a plug connector according to an exemplary embodiment.

[0014] Figure 7 is a cross-sectional view of a portion of a plug connector according to an exemplary embodiment.

[0015] Figure 8 is a perspective view of a header connector according to an exemplary embodiment.

[0016] Fig. 9 is a cross-sectional view of a portion of a header connector according to an exemplary embodiment.

[0017] Fig.10 is a cross-sectional view of a portion of a header connector according to an exemplary embodiment.

[0018] Fig.11 is a cross-sectional view of an electrical connector system showing a plug connector partially mated with a header connector according to an exemplary embodiment.

[0019] Fig.12 is a cross-sectional view of a portion of an electrical connector system showing a plug connector partially mated with a header connector according to an exemplary embodiment.

[0020] Fig.13 is a perspective view of a header connector according to an exemplary embodiment.

[0021] Fig.14 is a cross-sectional view of a portion of a header connector according to an exemplary embodiment.

[0022] Fig.15 is a perspective view of a header connector according to an exemplary embodiment.

[0023] Fig.16 is a cross-sectional view of a portion of a header connector according to an exemplary embodiment.

[0024] Fig.17 is a perspective view of a header connector according to an exemplary embodiment.

[0025] Fig.18 is a cross-sectional view of a portion of a header connector according to an exemplary embodiment.

[0026] Fig.19 is a perspective view of a plug connector according to an exemplary embodiment.

[0027] Fig. 20 is a cross-sectional view of a portion of a plug connector according to an exemplary embodiment.

[0028] Fig.21is a perspective view of a plug connector according to an exemplary embodiment.

[0029] Fig. 22 is a cross-sectional view of a portion of a plug connector according to an exemplary embodiment.

[0030] Fig.23 is a top view of a portion of a plug connector according to an exemplary embodiment. DETAILED DESCRIPTION

[0031] Figure 1 is a front perspective view of an electrical connector system 100 according to an exemplary embodiment. Figure 2 is a rear perspective view of the electrical connector system 100 according to an exemplary embodiment. Figure 3 is an exploded front perspective view of an electrical connector system 100 according to an exemplary embodiment. Figure 4 is an exploded rear perspective view of the electrical connector system 100 according to an exemplary embodiment.

[0032] The electrical connector system 100 includes a plug connector 200 and a header connector 300, which are configured to mate together to electrically connect a first member 102 and a second member 104. In various embodiments, the plug connector 200 is electrically connected to the first member 102 through a wire 106 (only one is shown in the figure). However, the plug connector 200 may be electrically connected to the first member 102 through a circuit board (not shown). In various embodiments, the header connector 300 is electrically connected to the second member 104 through a wire 108 (only one is shown in the figure). However, the header connector 300 may be electrically connected to the second member 104 through a circuit board (not shown). In the illustrated embodiment, the plug connector 200 and the header connector 300 are cable connectors terminated to the ends of the cables or wires 106, 108. In other various embodiments, the plug connector 200 and / or the header connector 300 may be board connectors mounted to a circuit board.

[0033] In an exemplary embodiment, the header connector 300 can be physically mounted to the second member 104. For example, the header connector 300 can be mounted to the second member 104 using fasteners, latches, clips, welding or other attachment means. In an exemplary embodiment, the plug connector 200 can be physically mounted to the first member 102. For example, the plug connector 200 can be mounted to the first member 102 using fasteners, latches, clips, welding or other attachment means. When the first member 102 is mated with the second member 104, the plug connector 200 can be mated with the header connector 300. In an example, the electrical connector system 100 is part of an appliance (such as a coffee machine). The plug connector 200 can be integrated with a removable member of the appliance, and when the removable member is coupled to the appliance, the removable member is mated to the header connector 300. For example, the plug connector 200 can be integrated into a drawer or a cup or a water container, which can be removed from the appliance and is configured to be inserted back into the appliance during operation of the appliance. When such a removable component is inserted back into the appliance, the plug connector 200 mates with the header connector 300. In alternative embodiments, the electrical connector system 100 can be used in other types of appliances. In other alternative embodiments, the electrical connector system 100 can be used in other applications other than appliances, such as automotive applications, industrial applications, computer applications, network applications, vehicles, machines, devices, or other types of applications in which two electrical connectors mate to electrically connect corresponding components.

[0034] The plug connector 200 includes a plurality of contacts 202 ( Figure 3 ), which is configured to be terminated to the wire 106 (or a circuit board in a board mount application). The plug connector 200 includes a plug housing 210 that holds the contact 202. In an exemplary embodiment, the contact 202 is a socket contact that has a socket 204 at the mating end of the contact 202. In an exemplary embodiment, the plug connector 200 includes a contact organizer 260 that is configured to position the contact 202 within the plug housing 210. The contact organizer 260 is used to guide the mating of the contacts of the header connector 300 with the contacts 202 of the plug connector 200. The contact organizer 260 prevents the contacts 202 from being stubbed during mating to prevent damage to the contacts 202.

[0035] The header connector 300 includes a plurality of pin contacts 302 ( Figure 4 ), which is configured to terminate to the wire 108 (or circuit board in board mounting applications). The header connector 300 includes a header housing 310 that holds the pin contacts 302. In an exemplary embodiment, the pin contacts 302 include pins at the mating ends of the pin contacts 302 that are configured to be received in the receptacles 204 of the contacts 202. The pins are configured to be guided into the receptacles 204 by the contact organizer 260.

[0036] Figure 5 is a perspective view of a plug connector 200 according to an exemplary embodiment. Figure 6 is an exploded perspective view of a plug connector 200 according to an exemplary embodiment. Figure 6 The contacts 202 are shown arranged in a plug housing 210. The contact organizer 260 is shown ready to mate with the plug housing 210.

[0037] The plug housing 210 is made of a dielectric material, such as a plastic material. The plug housing 210 may be an injection molded component. The plug housing 210 extends between a front portion 212 and a rear portion 214. The plug housing 210 has a first end 216 and a second end 218 opposite to the first end 216. The plug housing 210 includes a first side portion 220 and a second side portion 222 opposite to the first side portion 220. The side portions 220, 222 extend between the ends 216, 218. In an exemplary embodiment, the side portions 220, 222 are planar and parallel to each other. The ends 216, 218 may be planar. However, in an alternative embodiment, the ends 216, 218 are curved between the sides 220, 222. In an exemplary embodiment, the plug housing 210 is elongated end to end. For example, the side portions 220, 222 are longer than the ends 216, 218. In various embodiments, the plug housing 210 is generally oval-shaped, such as a racetrack shape. However, in alternative embodiments, the plug housing 210 may have other shapes, such as a rectangular shape.

[0038] In an exemplary embodiment, the plug housing 210 includes a base 230 and a contact block 232 extending from the base 230 toward the front 212. The base 230 may be located at the rear 214. In various embodiments, the base 230 may be mounted to a structure or component. For example, the plug housing 210 may include a mounting element 234 extending from the base 230. In the illustrated embodiment, the plug housing 210 includes a mounting element 234 located at the ends 216, 218. In alternative embodiments, the mounting element 234 may be located at other locations. The mounting element 234 can be used to fix the plug housing 210 to another structure or component. Optionally, the mounting element 234 can be used to fix the plug connector 200 to the header connector 300. The mounting element 234 may include an opening therethrough, the opening receiving a fastener or other fixing element.

[0039] In an exemplary embodiment, the plug housing 210 includes one or more guide features 236 to guide the mating with the header connector 300. In the illustrated embodiment, the guide feature 236 is a guide post extending forward from the base 230. The guide post may be cylindrical. Alternatively, the guide post may be truncated, such as a semi-cylindrical shape. In the illustrated embodiment, the guide feature 236 is located at the ends 216, 218. In alternative embodiments, other positions are possible. Optionally, the guide feature 236 may be the frontmost portion of the plug connector 200, so that the guide feature 236 is the first element of the plug connector 200 that mates with the header connector 300. In various embodiments, the guide feature 236 is conical at the distal end to help align the plug connector 200 with the header connector 300. For example, the guide feature 236 includes an introduction surface at its distal end. The guide feature 236 may have a smaller diameter at the tip and a larger diameter along the column. The guide features 236 may be used to guide mating in various directions, such as side-to-side and / or end-to-end.

[0040] In an exemplary embodiment, the plug housing 210 includes one or more alignment features 238 to align the plug housing 210 with the header connector 300. In the illustrated embodiment, the alignment features 238 include grooves formed along the sides 220, 222 that receive complementary protrusions of the header connector 300 to position the plug connector 200 relative to the header connector 300 when mated to the header connector 300. The grooves may be V-shaped grooves. However, in alternative embodiments, the grooves may have other shapes. The alignment features 238 may be used to align the plug connector 200 relative to the header connector 300 in various directions, such as side to side and / or end to end. In an exemplary embodiment, the alignment features 238 are positioned along the plug housing 210 for keying with the header connector 300. For example, the alignment features 238 may prevent the plug connector 200 from mating with the header connector 300 in an improper orientation. In various embodiments, the positioning and / or spacing of the alignment features 238 along the sides 220, 222 provide a keyed fit with the header connector 300. Optionally, the number of alignment features 238 along the first side 220 may differ from the number of alignment features 238 along the second side 222.

[0041] In an exemplary embodiment, the contact block 232 of the plug housing 210 includes a contact channel 240 passing therethrough. The contact channel 240 receives the corresponding contact 202 of the plug connector 200. The contact channel 240 is open at the front 212 and / or the rear 214 to receive the contact 202. In various embodiments, the contact channel 240 is cylindrical to receive the contact 202. In alternative embodiments, the contact channel 240 may have other shapes, such as rectangular. In an exemplary embodiment, the contact channel 240 is arranged in multiple rows and columns. For example, in the illustrated embodiment, the plug housing 210 includes two rows of contact channels 240, each row including fifteen columns of contact channels 240. The rows are oriented parallel to the sides 220, 222. Optionally, the columns may be oriented perpendicular to the sides 220, 222. However, in alternative embodiments, the rows of contact channels 240 may be offset such that the contact channels 240 in adjacent rows are staggered for more closely positioning the contact channels 240 and the contacts 202 within the plug housing 210. Alternatively, the plug housing 210 may include more or fewer rows and / or columns of contact channels 240. In an exemplary embodiment, the contacts 202 are loaded into the contact channels 240 from the rear through the rear 214 (such as through the base 230). In an alternative embodiment, the contacts 202 may be loaded into the contact channels 240 from the front through the front 212. In an exemplary embodiment, the mating ends of the contacts 202 are located forward of the front 212 of the plug housing 210. The mating ends of the contacts 202 are configured to be received in the contact organizer 260, wherein the contact organizer 260 is coupled to the front 212 of the plug housing 210.

[0042] The contact organizer 260 is configured to be coupled to the plug housing 210. In an exemplary embodiment, the contact organizer 260 is separate and discrete from the plug housing 210 and is coupled to the plug housing 210 to cover the mating ends of the contacts 202. The contact organizer 260 is made of a dielectric material, such as a plastic material. The contact organizer 260 may be an injection molded component.

[0043] The contact organizer 260 extends between an outer side 262 at the front of the contact organizer 260 and an inner side 264 at the rear of the contact organizer 260. The inner side 264 faces the plug housing 210. The inner side 264 can be connected to the front 212 of the plug housing 210. In the illustrated embodiment, the contact organizer 260 is generally rectangular with opposite sides and opposite ends. In alternative embodiments, other shapes are possible. In an exemplary embodiment, the contact organizer 260 includes alignment features 268 along opposite sides of the contact organizer 260. The alignment features 268 are configured to align with the alignment features 238 of the plug housing 210. The alignment features 268 can be shaped and positioned to complement the alignment features 238 to receive corresponding alignment features of the header connector 300 to ensure that the plug connector 200 is properly matched with the header connector 300.

[0044] In an exemplary embodiment, the contact organizer 260 includes latches 265, 266 at opposite ends of the contact organizer 260. The latches 265, 266 are configured to latchably couple to the plug housing 210 to secure the contact organizer 260 to the plug housing 210. For example, the latches 265, 266 may be received in latch recesses 245, 246 at the ends 216, 218 of the contact block 232. The latch recesses 245, 246 may be formed in the guide feature 236. In various embodiments, the latches 265, 266 and the latch recesses 245, 246 are keyed for keying the contact organizer 260 to the plug housing 210. For example, the latches 265, 266 may have different widths that are configured to be received in corresponding latch recesses 245, 246 in a single orientation. For example, the wider of the two latches 265, 266 may not be received in the wrong latch recess. In a permanent embodiment, other types of pull-up features may be used. In addition, other types of fixing features may be used to fix the contact organizer 260 to the plug housing 210, such as fasteners, clips or other fixing devices.

[0045] The contact organizer 260 includes holes 270 passing through the contact organizer 260 between the outer side 262 and the inner side 264. The holes 270 are configured to receive corresponding contacts 202. The holes 270 are arranged in an array complementary to the array of the contact channels 240. The holes 270 are configured to align with the contact channels 240 to receive the contacts 202. The holes 270 are open at the inner side 264 and the outer side 262. The holes 270 receive the mating ends of the contacts 202 at the inner side 264. At the outer side 262, the holes 270 are configured to receive the contacts 302 of the header connector 300 to guide the mating of the pin contacts 302 of the header connector 300 with the contacts 202. In an exemplary embodiment, the holes 270 are sized and shaped to align the pin contacts 302 and the contacts 202 during mating to prevent collision and / or damage to the contacts during mating.

[0046] Figure 7 is a cross-sectional view of a portion of plug connector 200 according to an exemplary embodiment. Figure 7 A contact organizer 260 is shown coupled to the plug housing 210 . Figure 7 A plurality of contacts 202 are shown in the contact channels 240 of the plug housing 210 and the apertures 270 of the contact organizer 260 .

[0047] Each contact 202 extends between a mating end 206 and a termination end 208. In the illustrated embodiment, the socket 204 is disposed at the mating end 206. The socket 204 is configured to receive a corresponding pin contact 302 of the header connector 300. In an exemplary embodiment, the socket 204 is cylindrical. The socket 204 extends to a distal end 205. The termination end 208 opposite to the mating end 206 is configured to terminate to a corresponding wire 106. In an exemplary embodiment, the termination end 208 includes a crimp barrel 209 configured to be crimped to the end of the wire 106. In an alternative embodiment, the termination end 208 may include an insulation displacement contact. In other alternative embodiments, the termination end 208 may include a welding pad or a soldering pad configured to be welded or soldered to the end of the wire 106. In other alternative embodiments, the termination end 208 may be configured to terminate to a circuit board. For example, the welding pad or the soldering pad may be welded or soldered to a circuit of a circuit board. In other alternative embodiments, the terminating end 208 may include a compliant pin configured to be press-fit into a plated through-hole of a circuit board.

[0048] In an exemplary embodiment, the contact 202 includes a securing feature 203 for securing the contact 202 in the plug housing 210. In the illustrated embodiment, the securing feature 203 includes a latch or barb extending from one or more sides of the contact 202. The securing feature 203 is configured to engage a shoulder 242 in the contact channel 240 to retain the contact 202 in the contact channel 240. The securing feature 203 engages the shoulder 242 to prevent the contact 202 from being pulled out or withdrawn from the contact channel 240. In the illustrated embodiment, the shoulder 242 is located in front of a retaining portion 244 of the contact channel 240. The retaining portion 244 has a smaller diameter than other portions of the contact channel 240. The retaining portion 244 is used to orient the contact 202 in the contact channel 240. For example, the retaining portion 244 can be used to center the contact 202 in the contact channel 240. Optionally, the contact 202 may have a limited amount of floating movement within the contact channel 240, such as to align the contact 202 with the pin contact 302 during mating. For example, the contact 202 may be allowed to tilt or pivot a small amount in one or more directions (e.g., side to side and / or end to end) to align with the pin contact 302 during mating. The securing feature 202 may be deflectable to allow a limited amount of floating movement of the contact 202 in the contact channel 240. The securing feature 203 is flexible and tends to center the contact 202 in the contact channel 240.

[0049] In an exemplary embodiment, the contact channel 240 includes an expanded portion 241 behind the retaining portion 244. The expanded portion 241 has a larger diameter than the retaining portion 244. The expanded portion 241 can be oversized to receive the end of the wire 106. The terminating end 208 of the contact 202 is located in the expanded portion 241. The expanded portion 241 is located at the rear 214 of the plug housing 210. The expanded portion 241 can define a cable channel or wire channel that receives the end of the wire 106. The contact channel 240 has a first diameter along the retaining portion 244, a second diameter along the front portion in front of the shoulder 242, and a third diameter along the expanded portion 241. The first diameter can be the smallest diameter along the contact channel 240. The third diameter along the expanded portion can be the largest diameter of the contact channel 240.

[0050] In an exemplary embodiment, the plug housing 210 includes a housing wall 250 located between the contact channels 240. The housing wall 250 separates the contacts 202 from each other, such as to prevent shorting between the contacts 202. The housing wall 250 has a peripheral edge 252 surrounding the perimeter of the contact channels 240. The peripheral edge 252 is located at the front 212 of the plug housing 210. Optionally, the housing wall 250 is chamfered at the peripheral edge 252.

[0051] The contact organizer 260 is coupled to the front portion 212 of the plug housing 210. For example, the inner side 264 of the contact organizer 260 is coupled to the front portion 212 of the plug housing 210. The holes 270 are aligned with the contact channels 240. In an exemplary embodiment, the contact organizer 260 includes a separation wall 272 between the holes 270. The separation wall 272 separates the holes 270 and the contacts 202 located in the holes 270 from each other, such as to prevent shorting of the contacts 202. The separation wall 272 is coupled to a corresponding housing wall 250 of the plug housing 210. In an exemplary embodiment, the separation wall 272 includes a notch 274 along the inner side 264, which receives the peripheral edge 252 of the housing wall 250. In an exemplary embodiment, the notch 274 system helps position the contact organizer 260 relative to the plug housing 210. For example, the notch 274 can be used to align the contact organizer 260 side to side and / or end to end relative to the plug housing 210. For example, the flanges 276, 278 extend along both sides of the recess 274 to abut against the peripheral edge 252 of the housing wall 250. The flanges 276, 270 may be angled or chamfered to receive the chamfered peripheral edge 252, which helps center the contact organizer 260 relative to the plug housing 210. The flanges 276, 278 overlap the peripheral edge 252 to increase the creepage distance between the contacts 202, such as by eliminating a straight path between the contacts 202 at the interface between the contact organizer 260 and the plug housing 210.

[0052] In an exemplary embodiment, the holes 270 have a variable diameter along the length of the holes 270. For example, at the bottom of the contact organizer 260, each hole 270 includes a large diameter section 280. The hole 270 includes a reduced diameter section 282 above (e.g., in front of) the large diameter section 280. In an exemplary embodiment, the separating wall 272 of the contact organizer 270 includes a neck region 284 that defines the reduced diameter section 282. The separating wall 272 contracts inwardly to reduce the diameter of the hole 270 along the reduced diameter section 282. The neck region 284 is used to center the socket 204 of the contact 202 in the hole 270. For example, when the contact organizer 260 is coupled to the front 212 of the plug housing 210, the contact 202 is initially loaded into the large diameter section 280. The diameter of the large diameter section 280 is greater than the diameter of the socket 204 to gather the socket 204 in the hole 270. When the contact organizer 260 is lowered onto the plug housing 210, the neck region 284 centers the contact 202 in the hole 270. Optionally, the diameter of the hole 270 along the reduced diameter section 282 may be approximately equal to but slightly larger than the receptacle 204 to allow the receptacle 204 to be easily loaded into the hole 270 while ensuring that the receptacle 204 is centered within the hole 270. In an exemplary embodiment, the diameter of the hole 270 along the reduced diameter section 282 is less than the diameter of the contact channel 240 of the plug housing 210. As such, the contact organizer 260, rather than the plug housing 210, controls the positioning of the contacts 202 (e.g., end to end and / or side to side).

[0053] In an exemplary embodiment, the contact organizer 260 includes a cap 290 at the front of the contact organizer 260. The cap 290 extends into the hole 270. The cap 290 depends on the distal end 205 of the contact 202. The cap 290 has an introduction surface 292, which is used to guide the pin contact 302 of the header connector 300 into the hole 270. The introduction surface 292 is angled or tapered so that the diameter of the hole 270 is larger at the outer surface 262 and the diameter is narrower at the inner edge 294 of the cap 290. The cap 290 includes an inwardly facing flange. The flange 296 extends between the inner edge 294 and the neck area 284. The flange 296 faces the distal end 205 of the contact 202. The flange 296 covers the contact 202 to prevent the contact 202 from moving forward in the hole 270. The contact 202 is captured between the flange 296 and the shoulder 242. In an exemplary embodiment, the contact organizer 260 has a diameter at the inner edge 294 of the cap 290 that is smaller than the diameter of the socket 204. For example, the flange 296 overhangs the distal end 205 of the contact 202 to prevent the pin contact 302 from hitting the end of the contact 202 during mating. The diameter at the inner edge 294 is larger than the diameter of the pin contact 302 to allow the pin contact 302 to pass through the cap 290 into the socket 204. The cap 290 guides the pin contact 302 into the socket 204.

[0054] Figure 8 is a perspective view of a header connector 300 according to an exemplary embodiment. Fig. 9 is a cross-sectional view of a portion of header connector 300 according to an exemplary embodiment. Fig. 9 The header housing 310 is shown with the pin contacts 302 removed to illustrate the header housing 310 .

[0055] The header housing 310 is made of a dielectric material such as a plastic material. The header housing 310 may be an injection molded component. The header housing 310 extends between a front portion 312 and a rear portion 314. The header housing 310 has a first end 316 and a second end 318 opposite to the first end 316. The header housing 310 includes a first side portion 320 and a second side portion 322 opposite to the first side portion 320. The side portions 320, 322 extend between the ends 316, 318. In an exemplary embodiment, the side portions 320, 322 are planar and parallel to each other. The ends 316, 318 may be planar. However, in an alternative embodiment, the ends 316, 318 are curved between the sides 320, 322. In an exemplary embodiment, the header housing 310 is elongated end to end. For example, the side portions 320, 322 are longer than the ends 316, 318. In various embodiments, the header housing 310 is generally oval-shaped, such as a racetrack shape. However, in alternative embodiments, the header housing 310 may have other shapes, such as a rectangular shape.

[0056] In an exemplary embodiment, the header housing 310 includes a base 330 and a shield 332 extending from the base 330 toward the front 312. The shield 332 forms a cavity 333, which is configured to receive the plug connector 200. The cavity 333 is sized and shaped to receive the plug housing 210. The base 330 may be located at the rear 314. In various embodiments, the base 330 may be mounted to a structure or component. For example, the header housing 310 may include a mounting element 334 extending from the base 330. In the illustrated embodiment, the header housing 310 includes a mounting element 334 located at the ends 316, 318. In alternative embodiments, the mounting element 334 may be located at other locations. The mounting element 334 can be used to fix the header housing 310 to another structure or component. Optionally, the mounting element 334 can be used to fix the header connector 300 to the plug connector 200. The mounting element 334 may include an opening therethrough, which receives a fastener or other fixing element.

[0057] In an exemplary embodiment, the header housing 310 includes one or more guide features 336 to guide the mating with the header connector 300. The guide features 336 can be used to guide the mating in various directions (such as side to side and / or end to end). In the illustrated embodiment, the guide features 336 are openings. The openings 336 can be disposed in the shield 332 and / or the base 330. The openings 336 can extend forward from the base 330. The openings 336 can be cylindrical. However, the openings 336 can have other shapes. For example, the openings 336 can be semi-cylindrical with at least one flat side. In the illustrated embodiment, the guide features 336 are located at the ends 316, 318. In alternative embodiments, other positions are possible.

[0058] In an exemplary embodiment, the header housing 310 includes one or more alignment features 338 to align the header housing 310 with the header connector 300. In the illustrated embodiment, the alignment features 338 include protrusions along the sides 320, 322, which are configured to cooperate with the alignment features 238 of the plug housing 210 to position the header connector 300 relative to the plug connector 200 when mated to the plug connector 200. The protrusions 338 may extend from the shield 332 into the cavity 333. The protrusions 338 may be V-shaped. However, in alternative embodiments, the protrusions 338 may have other shapes. The alignment features 338 can be used to align the header connector 300 relative to the plug connector 200 in various directions, such as side to side and / or end to end. In an exemplary embodiment, the alignment features 338 are positioned along the header housing 310 for keying with the header connector 300. For example, the alignment features 338 can prevent the header connector 300 from mating with the plug connector 200 in an improper orientation. In various embodiments, the positioning and / or spacing of the alignment features 338 along the sides 320, 322 provide a keyed fit with the plug connector 200. Optionally, the number of alignment features 338 along the first side 320 can be different than the number of alignment features 338 along the second side 322.

[0059] In an exemplary embodiment, the base 330 of the header housing 310 includes a contact channel 340 passing therethrough. The contact channel 340 receives the corresponding contact 302 of the header connector 300. The contact channel 340 is open at the front 312 and / or the rear 314 to receive the contact 302. In various embodiments, the contact channel 340 is cylindrical to receive the contact 302. In alternative embodiments, the contact channel 340 may have other shapes, such as rectangular. In an exemplary embodiment, the contact channel 340 is arranged in multiple rows and columns. For example, in the illustrated embodiment, the header housing 310 includes two rows of contact channels 340, each row including fifteen columns of contact channels 340. The rows are oriented parallel to the side portions 320, 322. Optionally, the header housing 310 may include more or fewer rows and / or columns of contact channels 340. In an exemplary embodiment, the contacts 302 are loaded from the rear through the rear portion 314 into the contact channels 340. In an exemplary embodiment, the mating ends of the contacts 302 are located forward of the base 330. The mating ends of the contacts 302 are configured to be inserted into the receptacles 204 of the contacts 202 of the plug connector 200.

[0060] Fig.10 is a cross-sectional view of a portion of header connector 300 according to an exemplary embodiment. Fig.10 A plurality of contacts 302 are shown in contact channels 340 of the header housing 310 .

[0061] Each pin contact 302 extends between a mating end 306 and a termination end 308. In the illustrated embodiment, the pin 304 is disposed at the mating end 306. The pin 304 is configured to be received in the socket 204 of the contact 202 of the plug connector 200. In an exemplary embodiment, the pin 304 is generally cylindrical and is bent at the top to form a plug end at the tip of the pin 304. The termination end 308 opposite the mating end 306 is configured to terminate to a corresponding wire 108. In an exemplary embodiment, the termination end 308 includes a crimp barrel 309 configured to be crimped to the end of the wire 108. In an alternative embodiment, the termination end 308 may include an insulation displacement contact. In other alternative embodiments, the termination end 308 may include a soldering pad or a soldering pad configured to be welded or soldered to the end of the wire 108. In other alternative embodiments, the termination end 308 may be configured to terminate to a circuit board. For example, the soldering pad or the soldering pad may be welded or soldered to a circuit of a circuit board. In other alternative embodiments, the terminating end 308 may include a compliant pin configured to be press-fit into a plated through-hole of a circuit board.

[0062] In an exemplary embodiment, the pin contact 302 includes a securing feature 303 for securing the pin contact 302 in the header housing 310. In the illustrated embodiment, the securing feature 303 includes a latch or barb extending from one or more sides of the contact 302. The securing feature 303 is configured to engage a shoulder 342 in the contact channel 340 to hold the pin contact 302 in the contact channel 340. The securing feature 303 engages the shoulder 342 to prevent the pin contact 302 from being pulled out or withdrawn from the contact channel 340. The securing feature 303 can be used to orient the pin contact 302 in the contact channel 340, such as to center the pin contact 302 in the contact channel 340. Optionally, the pin contact 302 can have a limited amount of floating movement within the contact channel 340, such as to align the contact 302 with the contact 202 during mating. For example, the pin contact 302 may be allowed to tilt or pivot a small amount in one or more directions (e.g., side to side and / or end to end) to align with the contact 202 during mating. The securing feature 302 may be deflectable to allow a limited amount of floating movement of the pin contact 302 in the contact channel 340. The securing feature 303 is flexible and tends to center the pin contact 302 in the contact channel 340.

[0063] In an exemplary embodiment, the header housing 310 includes a housing wall 350 between the contact channels 340. The housing wall 350 separates the contacts 302 from each other, such as to prevent short circuits between the contacts 302. The housing wall 350 has a peripheral edge 352 surrounding the perimeter of the contact channel 340. The peripheral edge 352 is located at the front 312 of the base 330. Optionally, the peripheral edge 352 is chamfered. The peripheral edge 352 can be inserted into the contact organizer 260, such as into a corresponding hole 270 in the contact organizer 260.

[0064] Fig.11 is a cross-sectional view of the electrical connector system 100 showing the plug connector 200 partially mated with the header connector 300 according to an exemplary embodiment. Fig.12 is a cross-sectional view of a portion of the electrical connector system 100 showing the plug connector 200 partially mated with the header connector 300 according to an exemplary embodiment. Fig.11 and Fig.12 The pin contacts 302 of the header connector 300 are shown aligned with the contacts 202 of the plug connector 200 .

[0065] In an exemplary embodiment, the contact organizer 260 positions the contacts 202 for mating with the pin contacts 302. For example, the contact organizer 260 centers each contact 202 in a corresponding contact channel 240 and a corresponding hole 270. The neck region 284 centers the contact 202 in the hole 270. The neck region 284 centers the contact 202 under the cap 290. The flange 296 of the cap 290 depends from the distal end 205 of the socket 204 to ensure that when the pin contact 302 passes through the inner edge 294 of the cap 290, the pin contact 302 is directly inserted into the socket 204. In an exemplary embodiment, the contact organizer 260 positions the pin contact 302 for mating with the contact 202. For example, the cap 290 guides the pin contact 302 into the socket 204. The cap 290 depends from the contact 202 to prevent the pin 304 from impinging on the distal end 205 of the receptacle 204 during mating.

[0066] Fig.13 is a perspective view of a header connector 300 according to an exemplary embodiment. Fig.14 is a cross-sectional view of a portion of header connector 300 according to an exemplary embodiment. Fig.13 The header housing 310 is shown with the pin contacts 302 removed to illustrate the header housing 310 .

[0067] In an exemplary embodiment, the header connector 300 includes an insert 360 that is loaded into the header housing 310 to position the pin contacts 302. The insert 360 is used to center the pin contacts 302 in the contact channels 340, such as to reduce the risk of collision during mating with the contacts 202. The insert 360 reduces the amount of floating movement of the pin contacts 302 in the contact channels 340 to reduce the risk of collision during mating with the contacts 202. In the illustrated embodiment, the insert 360 is separate and discrete from the header housing 310 and is coupled to the header housing 310. In the illustrated embodiment, the inserts 360 are separate and discrete from each other, such as individual inserts 360 received in corresponding contact channels 340.

[0068] Fig.15 is a perspective view of a header connector 300 according to an exemplary embodiment. Fig.16 is a cross-sectional view of a portion of header connector 300 according to an exemplary embodiment. Fig.15 The header housing 310 is shown with the pin contacts 302 removed to illustrate the header housing 310 .

[0069] In an exemplary embodiment, the header connector 300 includes an insert 360 that is loaded into the header housing 310 to position the pin contacts 302. In the illustrated embodiment, the inserts 360 are formed on a common carrier 362. For example, each of the inserts 360 is integral with the carrier 362. For example, the inserts 360 can be formed by a molded component. The carrier 362 is coupled to the base 330, wherein the inserts 360 extend into the contact channels 340 to engage the pin contacts 302. The inserts 360 reduce the amount of floating movement of the pin contacts 302 in the contact channels 340 to reduce the risk of collision during mating with the contacts 202.

[0070] Fig.17 is a perspective view of a header connector 300 according to an exemplary embodiment. Fig.18 is a cross-sectional view of a portion of header connector 300 according to an exemplary embodiment.

[0071] In an exemplary embodiment, the header connector 300 includes a contact retainer 364 for retaining the position of the pin contact 302 in the header housing 310. In the illustrated embodiment, the contact retainer 364 is a film or sheet having an opening that receives the pin 304 of the pin contact 302. The contact retainer 364 may be movable in the cavity 333. For example, the contact retainer 364 may be movable in the cavity 333 during mating with the plug connector 200. For example, when the plug connector 200 is mated with the header connector 300, the contact retainer 364 may slide down along the pin 304. The contact retainer 364 may initially be positioned near the distal end of the pin 304, but slides down along the pin 304 during mating to rest against the base 330. The contact retainer 364 reduces the amount of floating movement of the pin contact 302 in the contact channel 340 to reduce the risk of collision during mating with the contact 202.

[0072] Fig.19 is a perspective view of a plug connector 200 according to an exemplary embodiment. Fig. 20 is a cross-sectional view of a portion of plug connector 200 according to an exemplary embodiment. Fig.19 The plug housing 210 is shown with the contacts 202 removed to illustrate the plug housing 210. The contact organizer 260 is shown coupled to the plug housing 210. The shape of the contact organizer 260 is similar to Figure 7 In the illustrated embodiment, the plug housing 210 is larger than the contact organizer shown in FIG. Figure 7 2. The plug housing 210 in the embodiment shown in FIG. 2 is taller. For example, the contact block 232 is positioned in front of the distal ends 205 of the contacts 202. In the illustrated embodiment, the cap 290 extends into the contact channel 240. The cap 290 can engage the distal ends 205 of the contacts 202. The cap 290 overhangs the distal ends 205 of the contacts 202 to protect the ends of the contacts 202 and prevent the pin contacts 302 from being struck when the pin contacts 302 are inserted into the receptacle 204.

[0073] Fig.21 is a perspective view of a plug connector 200 according to an exemplary embodiment. Fig. 22 is a cross-sectional view of a portion of plug connector 200 according to an exemplary embodiment. Fig.23 is a top view of a portion of plug connector 200 according to an exemplary embodiment.

[0074] In an exemplary embodiment, the plug connector 200 is not provided with a contact organizer ( Figure 7). The plug housing 210 includes features for centering the contacts 202 and / or the pin contacts 302 to prevent collisions. For example, the plug housing 210 includes a centering finger 254 extending from the housing wall 250 into the contact channel 240. The centering finger 254 is functionally equivalent to a cap of the contact organizer 260. For example, the centering finger 254 reduces the diameter of the opening that receives the pin contact 302 to center the pin contact 302 and reduce collisions of the pin contact 302 on the socket 204 during mating. The centering finger 254 depends from the distal end 205 of the contact 202 to ensure that the pin contact 302 is received in the socket 204 to prevent collisions.

[0075] It will be understood that the above description is intended to be illustrative rather than restrictive. For example, the embodiments described above (and / or aspects thereof) may be used in combination with each other. In addition, without departing from the scope of the present invention, many modifications may be made to adapt specific situations or materials to the teachings of the present invention. The dimensions, material types, orientations of various components, and the number and position of various components described herein are intended to define the parameters of certain embodiments, and are by no means restrictive, but are merely exemplary embodiments. Upon reviewing the above description, many other embodiments and modifications within the spirit and scope of the claims will be apparent to those skilled in the art. Therefore, the scope of the present invention should be determined with reference to the attached claims together with the full scope of equivalents granted by such claims. In the attached claims, the terms "including" and "wherein" are used as the plain English equivalents of the corresponding terms "including" and "wherein". In addition, in the following claims, the terms "first", "second", and "third", etc. are used only as marks, and are not intended to impose numerical requirements on their objects. Furthermore, the following claim limitations are not written in a means-plus-function format and are not intended to be interpreted under 35 U.S.C. § 112(f) unless and until such claim limitations expressly use the phrase "means for..." followed by a recitation of the function without additional structure.

Claims

1. A plug connector, comprising: a plug housing extending between a front portion and a rear portion, the front portion being configured to mate with the header housing, the plug housing including a contact channel extending longitudinally between the front portion and the rear portion; contacts received in the contact channels, the contacts including receptacles at mating ends of the contacts, the receptacles configured to receive pin contacts of the header housing, the contacts being arranged in an array having a plurality of rows and columns; as well as A contact organizer coupled to the front of the plug housing has holes therethrough aligned with corresponding contact channels, the contact organizer having guide features configured to center the pin contacts in the holes to align the pin contacts with the receptacles.

2. The plug connector according to claim 1, wherein: The contact organizer is separate and discrete from the plug housing and is coupled to the plug housing.

3. The plug connector according to claim 1, wherein: The contacts extend forward of the front portion of the plug housing into the apertures of the contact organizer.

4. The plug connector according to claim 1, wherein: The bore has a variable diameter along a central axis of the bore.

5. The plug connector according to claim 1, wherein: Each hole has a reduced diameter section having a diameter that is larger than a pin diameter of a corresponding pin contact but smaller than a diameter of a corresponding socket.

6. The plug connector according to claim 1, wherein: The contact organizer includes a cap extending into the aperture, the cap depending from a distal end of the socket.

7. The plug connector according to claim 1, wherein: Each aperture includes an inwardly converging neck region in which the distal end of the corresponding socket is located to center the socket in the aperture.

8. The plug connector according to claim 1, wherein: The contact includes a retaining feature that engages the plug housing to position the contact in the contact channel, the retaining feature being flexible to allow a limited amount of floating movement of the contact in the contact channel.

9. The plug connector according to claim 1, wherein: The plug housing includes a housing wall, which is located between the contact channels and has a peripheral edge surrounding the periphery of the contact channels. The contact organizer includes a separation wall between the holes, and the separation wall includes a groove at the inner surface of the contact organizer, which receives the corresponding peripheral edge of the housing wall to position the contact organizer relative to the plug housing.

10. The plug connector according to claim 1, wherein: The contact organizer includes a latch latchably coupled to the plug housing.

11. The plug connector according to claim 1, wherein: The contact organizer and the plug housing include polarization features to orient the contact organizer relative to the plug housing.

12. The plug connector according to claim 1, wherein: The plug housing includes a guide feature extending forward of the front portion of the plug housing to interface with the header housing and position the header housing relative to the plug housing during mating.

13. The plug connector according to claim 1, wherein: The contact channel has an inner diameter, and wherein the aperture has an inner diameter that is smaller than the inner diameter of the contact channel.

14. A plug connector, comprising: a plug housing extending between a front portion and a rear portion, the front portion being configured to mate with the header housing, the plug housing including a contact channel extending longitudinally between the front portion and the rear portion; contacts received in the contact channels, the contacts comprising receptacles at mating ends of the contacts, the receptacles configured to receive pin contacts of the header housing, the receptacles having distal edges configured to receive the pin contacts, the contacts being arranged in an array having a plurality of rows and columns; as well as a contact organizer coupled to the front portion of the plug housing, the contact organizer having holes therethrough aligned with corresponding contact channels, the contact organizer having caps extending into the holes, the caps depending from a distal end of the receptacle, the contact organizer having guide features forward of the caps, the guide features configured to center the pin contacts in the holes to align the pin contacts with the receptacles.

15. The plug connector according to claim 14, wherein: The bore has a variable diameter along a central axis of the bore.

16. The plug connector according to claim 14, wherein: Each hole has a reduced diameter section having a diameter that is larger than a pin diameter of a corresponding pin contact but smaller than a diameter of a corresponding socket.

17. The plug connector according to claim 14, wherein: The contact organizer includes a cap extending into the aperture, the cap depending from a distal end of the socket.

18. The plug connector according to claim 14, wherein: Each aperture includes an inwardly converging neck region in which the distal end of the corresponding socket is located to center the socket in the aperture.

19. An electrical connector system, comprising: a header connector having a header housing having channels for holding pin contacts in an array having a plurality of rows and columns, the header housing including a shroud at a mating end of the header connector, the shroud forming a cavity into which the pin contacts extend; as well as A plug connector that mates with the header connector, the plug connector comprising a plug housing that holds contacts in an array having multiple rows and columns, the plug housing extending between a front and a rear portion, the front portion being configured to be inserted into the cavity of the header housing, the plug housing comprising contact channels that receive corresponding contacts, the contacts comprising sockets at mating ends of the contacts, the sockets being configured to receive corresponding pin contacts, the plug connector comprising a contact organizer coupled to the front portion of the plug housing, the contact organizer having holes therethrough that are aligned with the corresponding contact channels, the contact organizer having a guide feature that is configured to center the pin contacts in the holes so as to align the pin contacts with the sockets during mating.

20. The electrical connector system of claim 19, wherein: The plug housing includes a guide feature extending forward of the front portion of the plug housing to interface with the header housing and position the header housing relative to the plug housing during mating.

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