High-speed, reinforced compact cable connector

Abstract

A compact connector that economically provides high signal integrity in harsh environments such as in automobiles, which may be a right angle connector. The connector may include a contact carrier position assurance component (CCPA) that ensures that the contact carrier is latched and remains latched in a design position, which improves signal integrity. The CCPA may hold the mating interface portion or contact carrier in a desired position relative to the mating direction, but may be narrow and fit into a narrow slot perpendicular to the mating direction of the connector so as to enable the connector to extend only a small distance beyond the mating face of the mating connector in the mating direction. Such a connector may also have a connector position assurance device that facilitates reliable operation of the connector.

Description

Technical Field

[0001] The present patent application relates generally to interconnection systems for interconnecting electronic components, such as those including electrical connectors, and more particularly to interconnection systems for use in harsh environments, such as in vehicles. Background Art

[0002] Electrical connectors are used in many electronic systems. It is often easier and more cost-effective to manufacture a system as separate electronic assemblies that can be connected together using electrical connectors. Connectors can be used to interconnect components so that these components can operate together as part of a system. For example, connectors can be mounted on printed circuit boards within two components that are connected by mating connectors. In other systems, it may not be feasible to connect these printed circuit boards by directly mating connectors on two printed circuit boards. For example, when assembling a system, these printed circuit boards may be spaced very far apart, making it impossible to achieve a direct connection between the connectors mounted on the printed circuit boards.

[0003] In some systems, connections between components can be made via cables. The cables can be terminated with connectors that mate with connectors mounted on a printed circuit board. In this way, connections can be made between components by inserting a connector that is part of a cable assembly into a connector mounted on the printed circuit board. In other system architectures, a connector that terminates a cable can mate with another connector that terminates another cable.

[0004] An example of a system in which components are connected by cables is a modern automobile. For example, an automobile includes electronic control units (ECUs) for controlling various vehicle systems, such as those for the engine, transmission (TCU), safety systems, emission controls, lighting, advanced driver assistance systems (ADAS), entertainment systems, navigation systems, and cameras. These ECUs can be manufactured as separate components and connected via one or more vehicle networks formed by cables routed between the components. To simplify automobile manufacturing, the components can be manufactured separately and then connected via cables terminated with connectors that enable connection to mating connectors that terminate other cables or circuit boards attached to the components.

[0005] Automobiles present a harsh environment for electrical connectors. Vehicles vibrate, which can cause connectors to become unmated and stop functioning altogether. Even if vibrations don't completely prevent connector operation, they can still introduce electrical noise, which can interfere with the operation of electronic devices connected via interconnects, including connectors. For example, noise can be caused by relative movement of components within the connector, which can alter the connector's electrical characteristics. These changes in electrical characteristics, in turn, cause changes in the signal passing through the interconnect, a form of noise that can interfere with processing of the underlying signal.

[0006] In an automotive environment, electrical noise can also be caused by automotive components that generate electromagnetic radiation. This radiation can couple to the conductive structures of the connector, thereby generating noise on any signals passing through those conductive structures. In a car, any of several components can generate electromagnetic radiation, such as spark plugs, alternators, or power switches. Noise can be particularly destructive to high-speed signals, such as those used to communicate data over the car's network. Summary of the Invention

[0007] The concepts disclosed herein can be implemented as an electrical connector comprising: (i) a housing (120) comprising a chamber and a first opening (128); (ii) a contact carrier comprising a mating portion extending in a first direction and a cable mounting portion extending in a second direction transverse to the first direction, (iii) wherein: (a) the mating portion is positioned within the chamber of the housing and engaged to the housing; (b) the mating portion includes a tab (146); and (c) a position assurance feature (130) configured to latch in a closed position, the closed position being within the first opening of the housing, and the position assurance feature engaging the tab (146) of the contact carrier in the closed position to retain the contact carrier within the chamber of the housing such that the position assurance feature engages the contact carrier between the tab (146) and the cable mounting portion.

[0008] Optionally, the first opening may include a channel extending in a second direction, and optionally, the position assurance component may be configured to slide in the channel between an open position and a closed position; and latch to the housing in the open position. Optionally, the second direction is substantially perpendicular to the first direction. That is, the electrical connector may be a right-angle connector. Optionally, the position assurance component (130) may include a tab (136) configured to abut a tab (146) of the contact carrier when the position assurance component is in the closed position. Optionally, the position assurance component may include (i) a base (652), (ii) a first arm (650A), and (iii) a second arm (650B), the first arm and the second arm extending from the base and configured to latch to the housing; wherein the tab (136) extends from the base. Optionally, the tab (136) of the position assurance component is thinner than the first arm and the second arm.

[0009] In another aspect, an electrical connector may include: (i) a housing (120) including a chamber, a first opening (128), and a latch (122); and (ii) a contact carrier including a mating portion extending in a first direction and a cable mounting portion extending in a second direction transverse to the first direction, (iii) wherein: (a) the mating portion is located in the chamber of the housing, (b) the contact carrier includes a protrusion; and (c) the latch (122) engages the protrusion to latch the contact carrier in the chamber of the housing; and (iv) a position assurance member (130) positioned in the first opening of the housing and configured to slide to a closed position in which the position assurance member prevents withdrawal of the contact carrier from the chamber of the housing.

[0010] Optionally, the housing may include an insulating housing (160), and the latch may include an arm integrally molded with the insulating housing. Optionally, the electrical connector may further include: (i) a conductive housing (150); (ii) wherein the contact carrier includes (a) an insulating housing including a channel and a contact disposed within the channel; and (b) the conductive housing including a protrusion of the contact carrier. Optionally, the conductive housing is a die-cast component; and the conductive housing includes an integrally formed portion of the die-cast component.

[0011] In another aspect, a cable assembly includes: (i) a cable including a conductor; (ii) an electrical connector (100) including: (a) an outer housing (120) including a chamber; (b) a conductive housing (150) at least partially positioned within the chamber of the outer housing, including a portion having the chamber; (c) an insulating housing including a channel disposed within the chamber of the conductive housing; and (d) a contact including a mating portion disposed within the channel of the insulating housing and a tail portion attached to the conductor of the cable, wherein the conductive housing further includes a tail portion (152) configured to support the cable.

[0012] Optionally, the cable assembly may further include (i) an integral sheet comprising a first portion that at least partially surrounds the tail and the cable. Optionally, the integral sheet comprises an outer ferrule; the electrical connector further comprises an inner ferrule disposed on the cable; and the first portion of the integral sheet at least partially surrounds the tail, the cable, and the inner ferrule. Optionally, the cable comprises a jacket and a shield; the cable shield extends beyond the jacket and is disposed between the inner ferrule and the outer ferrule. Optionally, the tail comprises a stepped portion extending toward the cable; and an end of the cable shield is between the stepped portion and the cable jacket and in contact with the stepped portion and the cable jacket. Optionally, the inner ferrule comprises a first portion having a circular cross-section and a second portion having an elliptical cross-section; and the first portion of the integral sheet at least partially surrounds the tail, the cable, and the first portion of the inner ferrule such that the shield is located between the inner ferrule and the outer ferrule and in contact with the inner ferrule and the outer ferrule over substantially the entire circumference of the first portion of the inner ferrule. Optionally, the integral sheet includes a second portion; and the second portion at least partially surrounds the cable at a position offset relative to the tail portion.

[0013] Optionally, the cavity of the conductive housing includes an inlet; the integral sheet includes a third portion covering the inlet. Optionally, the conductive housing includes at least one embossment that retains the third portion to the conductive housing. Optionally, the third portion includes a flat portion and an embossed area offset from the flat portion. Optionally, the mating portion of the contact is elongated in a first direction, and the tail extends in a second direction perpendicular to the first direction; the conductor of the cable includes a distal portion extending in the second direction within the conductive housing; and the distal portion of the conductor is adjacent to the embossed area of the third portion. Optionally, the embossed area extends into the cavity of the conductive housing; and the inner ferrule is sleeved outside the cavity of the conductive housing.

[0014] In another aspect, a housing subassembly for an electrical connector includes (i) an insulating housing (120) having a latch and a channel; and (ii) a connector position assurance device (CPA) (110) disposed within the channel, (iii) wherein: (a) the CPA includes: (1) a compliant arm including a protrusion (112) extending therefrom; and (2) a distal portion; and (b) the insulating housing further includes a stop (729) disposed within the channel and configured to engage a cam surface of the protrusion to force the protrusion into a predetermined position; and (c) the housing subassembly is configured such that a portion of the insulating housing blocks movement of the CPA within the channel beyond the predetermined position.

[0015] Optionally, the compliant arm is a first compliant arm, and the CPA further comprises a second compliant arm parallel to the first compliant arm. Optionally, the CPA further comprises: (i) a first cross member connecting a first end of the first compliant arm and a second compliant arm, and (ii) a second cross member connecting a second end of the first compliant arm and the second compliant arm opposite the first end. Optionally, the stopper may be a first stopper, and the protrusion is a first protrusion; the CPA comprises a second protrusion on the compliant arm; and the insulating housing comprises a second stopper disposed within the channel and configured to engage the second protrusion to block movement of the CPA within the channel in the first direction when the CPA is in an unlocked position in which the CPA is disengaged from the latch. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawings are not limited to the dimensions shown. For clarity, not every component is labeled in every view. In the drawings:

[0017] Figure 1 is a perspective view of an exemplary interconnection system including a board connector 100 and a cable connector 200 ′ mated to the board connector.

[0018] Figure 2A It can be used with Figure 1 FIG. 1 is an exploded perspective view of an exemplary right-angle cable connector 200 mated with the board connector 100 .

[0019] Figure 2B is a diagram showing a method for connecting the cable 300 to the Figure 2A An exemplary cable connector 200 is shown as a series of schematic diagrams illustrating exemplary steps in a method 200 of terminating a cable assembly.

[0020] Figure 2C is through Figure 2B FIG. 1 is a side view of a cable connector 200 formed by a manufacturing process.

[0021] Figure 3A is Figure 2B Magnified view of a cable with a ferrule and braid during a step of the manufacturing process.

[0022] Figure 3B yes Figure 3A A cross-sectional view of an exemplary cable along line AA.

[0023] Figure 3C yes Figure 3A A cross-sectional view of an exemplary cable along line BB.

[0024] Figure 3D yes Figure 2A 1 is a cross-sectional view of a portion of an exemplary cable connector 200 illustrating a portion of a cable termination.

[0025] Figure 4A is a perspective view of an exemplary dielectric housing and electrical contacts of a right-angle contact carrier of an exemplary cable connector 200 illustrating the housing.

[0026] Figure 4B yes Figure 4A A top cross-sectional view of an exemplary housing and electrical contacts.

[0027] Figure 4C Is equipped with TPA 170 Figure 4A A cross-sectional view of an exemplary housing and electrical contacts.

[0028] Figure 5A 、 Figure 5B and Figure 5C are perspective views of an exemplary right-angle contact carrier at successive steps in a manufacturing process, showing a conductive housing, a conductive housing with an insulative housing inserted therein, and contacts terminating a cable in the insulative housing, and contact carriers along the Figure 5B Cross-sectional view along line CC.

[0029] Figure 5D yes Figure 5C Cross-sectional view of an exemplary right-angle contact carrier.

[0030] Figure 6A is inserted into the housing subassembly Figure 5C A side perspective view of an exemplary contact carrier.

[0031] Figure 6B is a perspective view of a portion of an exemplary contact carrier.

[0032] Figure 6C is a cross-sectional view of an exemplary cable connector 200 in which the contact carrier is locked in place by a contact carrier position assurance feature (CCPA) 130 .

[0033] Figure 6D is a perspective view of an exemplary CCPA.

[0034] Figure 6E is a perspective view of an exemplary cable connector 200 showing a latch and a CCPA.

[0035] Figure 7A is an enlarged side view of a portion of an illustrative housing subassembly of a cable connector 200 having a connector position assurance feature (CPA).

[0036] Figure 7B yes Figure 7A A perspective view of an exemplary connector position assurance (CPA) component of FIG.

[0037] Figure 7CIt is taken along line 7C-7C Figure 7A sectional view of an exemplary cable connector housing subassembly of FIG. 1 , wherein the exemplary CPA is in a first unlocked position.

[0038] Figure 7D It is taken along line 7C-7C Figure 7A sectional view of an exemplary cable connector housing subassembly with the exemplary CPA in a second locked position.

[0039] Figure 7E yes Figure 7A A top perspective view of an exemplary housing subassembly of FIG. 1 with the CPA in a second locked position. DETAILED DESCRIPTION

[0040] The inventors have recognized and appreciated techniques for manufacturing connectors for providing high data rate transmission that can be manufactured economically while still operating reliably in the harsh environments presented by automobiles. For example, such connectors would be suitable for interconnecting components in automotive networks. These techniques can be applied to modular connector systems, in which a set of components can be combined to form a connector in any of a variety of configurations. By designing the connector components to be modular, the costs associated with manufacturing connectors of the type described herein can be reduced.

[0041] The inventors have recognized and appreciated various techniques that can be applied to components of connector systems to provide connections with high signal integrity (SI). SI improvements can be achieved by controlling the electrical characteristics of the signal path through the connector and / or by configuring the connector to operate efficiently despite the harsh automotive environment in which the connector is used. The techniques disclosed herein can provide mechanical and / or electrical stability to the electrical conductors within the connector. These techniques can be used to create a right-angle cable connector that is both rugged and compact while also providing high SI.

[0042] For example, a connector configuration can be formed by an insulating outer housing that establishes at least the mating interface of the connector. The insulating outer housing can provide a latching feature. The set of components can include an insulating outer housing in a complementary configuration that can be used to form two connector configurations that will mate and latch with each other. The insulating housing can include a cavity and a channel.

[0043] A cable connector can be assembled by inserting one or more contact carriers, each contact carrier terminating one or more cables into a cavity of an insulating housing. The contact carriers can have tabs that align with channels in the connector housing. Latch features of the insulating housing can engage with the contact carriers to retain the contact carriers within the housing. Optionally or additionally, a contact carrier position assurance component (CCPA) can ensure that the contact carriers of the connector are correctly positioned in the connector and remain correctly positioned during use of the connector, regardless of shock and vibration that might otherwise tend to move the contact carriers from their intended position. Ensuring that the contact carriers are securely held in their designed positions reduces impedance discontinuities in a pair of mated connectors and reduces vibration-induced noise.

[0044] The CCPA can have a design that facilitates simple and reliable manufacture of the connector. The CCPA can be latched to the insulating housing in any of a plurality of positions. For example, the plurality of positions can be an open position and a closed position. When the CCPA is in the open position, the CCPA can enable the contact carriers to be inserted into the insulating housing. Moving the CCPA to the closed position can lock those plurality of contact carriers in place.

[0045] For example, a connector configuration can be implemented as a right-angle connector to achieve compactness and fit within a confined space. The connector may include: a housing including a cavity and a first opening; a contact carrier including a mating portion extending in a first direction and a cable mounting portion extending in a second direction transverse to the first direction, such that the mating portion is positioned within the cavity of the housing and engaged to the housing; the mating portion including a tab; and a position assurance component configured to latch in a closed position, the closed position being within the first opening of the housing, and the position assurance component engaging the tab of the contact carrier in the closed position to retain the contact carrier within the cavity of the housing, such that the position assurance component engages the contact carrier between the tab and the cable mounting portion.

[0046] Another connector configuration may include: a shell comprising a chamber, a first opening, and a latch; and a contact carrier comprising a mating portion extending in a first direction and a cable mounting portion extending in a second direction transverse to the first direction, such that the mating portion is located in the chamber of the shell, the contact carrier comprising a protrusion; and the latch engaging the protrusion to latch the contact carrier in the chamber of the shell; and a position assurance component positioned in the first opening of the shell and configured to slide to a closed position, wherein the position assurance component blocks withdrawal of the contact carrier from the chamber of the shell in the closed position.

[0047] A cable assembly may include: a cable including a conductor; an electrical connector including: an outer shell including a chamber; a conductive shell including a portion having a chamber, the conductive shell being at least partially positioned within the chamber of the outer shell; an insulating shell including a channel disposed within the chamber of the conductive shell; a contact including a mating portion disposed within the channel of the insulating shell and a tail portion attached to the conductor of the cable, wherein the conductive shell further includes a tail portion configured to support the cable.

[0048] In addition, a subassembly for an electrical connector may include: an insulating shell including a latch and a channel; and a connector position assurance device (CPA) disposed within the channel such that the CPA includes: a compliant arm including a protrusion extending therefrom; and a distal portion; and the insulating shell also includes a stop portion disposed within the channel and configured to engage the protrusion to block movement of the CPA within the channel in a first direction when the CPA is in a locked position, in which position the CPA blocks movement of the latch; and the shell subassembly is configured such that when the CPA is in the locked position, a portion of the insulating shell blocks movement of the CPA within the channel in a second direction opposite to the first direction.

[0049] The techniques described herein can be used individually or in combination. These techniques are described below in conjunction with an interconnect system that can be used to establish physical connections between components in, for example, an automobile.

[0050] Figure 1 is a perspective view of an exemplary interconnect system including a board connector 100 and a cable connector 200' mated to the board connector. The interconnect system can be used to connect two electronic devices to each other. In some embodiments, the interconnect system 100 is used in high data rate transmission applications (e.g., in applications including ECUs of vehicles). In this example, the interconnect system includes the board connector 100 and the cable connector 200'. In this example, the cable connector 200' has an elongated orientation in which the cable 300 exits the housing of the connector 200' from the rear in a direction opposite to the direction along which the cable connector 200' is inserted into the board connector 100 for installation. Figure 1 The cable connector of the configuration shown may only be used in systems where there is a clearance space 101' in the front or board connector 100 that exceeds the length of the cable connector 200' by a sufficient distance to accommodate the cable 300 when it is bent at its minimum bend radius.

[0051] However, in some cases, the clearance space may not be sufficient to accommodate the cable connector 200' and the cable 300 without bending the cable 300 to a radius tighter than its minimum bend radius. For example, the board connector 100 may be mounted in a panel of the ECU adjacent to the wall of the car, so that the clearance space 101' is limited. In this case, a compact right-angle cable connector 200 (Figure 2) can be used. However, this compact connector can have a mating interface (mating interface) like the cable connector 200' to enable mating with the same board connector. Similarly, the compact cable connector can have a ruggedness and SI comparable to the connector 200' so that the performance of the system is not reduced by using the compact connector.

[0052] Figure 2A It can be with Figure 1 FIG2 is an exploded perspective view of an exemplary right-angle cable connector 200 mated with the board connector 100. The right-angle cable connector 200 may include a plug housing 120, which may be manufactured, for example, by injection molding of an insulating material (e.g., plastic or nylon). The cable connector 200 may also include a connector position assurance (CPA) member 110 engaged with the plug housing 120.

[0053] The cable connector 200 may further include a conductive housing 150. For example, the conductive housing 150 may be a die-cast component. In this example, the conductive housing has a forward portion 152 that extends into the opening of the plug housing 120 when the conductive housing 150 is inserted into the plug housing 120.

[0054] The cable connector 200 may also include one or more additional shielding members, shown here as a front shield 140. The front shield 140 may be assembled onto the forward portion 152 of the conductive housing 150 such that both the forward portion 152 of the conductive housing 150 and the front shield 140 extend into the opening of the plug housing 120 to further surround the electrical conductors 180. The shield 140 is electrically and mechanically coupled to the conductive housing 150 such that the shield 140 may also be grounded.

[0055] The front shield 140 can be assembled onto the forward portion 152 of the conductive housing 150 such that both the forward portion 152 of the conductive housing 150 and the front shield 140 extend into the opening of the plug housing 120. The front shield 140 can be formed from sheet metal to provide shielding and can include one or more features to provide one or more functions. For example, one or more features stamped into the sheet metal forming the front shield 140 can retain the front shield 140 to the conductive housing 150, mate the front shield 140 to corresponding conductive structures in the board connector 100, or provide one or more tabs for engaging with the CCPA 130.

[0056] Some of the components of the cable connector 200 can be assembled into a contact carrier, which can include electrical conductors 180 that can serve as signal conductors. In this example, the contact carrier is assembled with components that hold and shield the electrical conductors 180 and provide a controlled impedance environment for the electrical conductors 180. In this example, the conductive housing 150 forms a portion of the contact carrier.

[0057] In this example, a pair of electrical conductors 180 are shown so that the contact carrier is configured to transmit differential signals. In addition to transmitting one or more signals through the connector, the electrical conductor can have a mating contact portion at one end, a tail portion at the opposite end, and an intermediate portion between the mating contact portion and the tail portion. Thus, the electrical conductor can be used as a contact for the connector. In this example, the mating contact portion of the electrical conductor is shaped as a socket that can receive and mate with a mating contact portion shaped as a pin of a conductor (not shown) in the board connector 100. In other examples, the mating contact portion of the electrical conductor in the cable connector 200 can be shaped as a pin, a blade, or have other shapes.

[0058] In this example, the tail of the electrical conductor 180 is configured to be attached to a conductor within the cable 300. For example, the conductor within the cable 300 can be soldered to the tail of the electrical conductor 180. Figure 2A In the example shown, the mating contact portion and the tail portion of the electrical conductor 180 are connected by a middle portion bent at a right angle. As a result, the cable 300 terminated to the electrical conductor 180 extends from the connector 200 perpendicular to the mating direction, and the connector 200 can be inserted into the board connector 100 in this mating direction to achieve mating.

[0059] A ferrule 190 may also be included in the contact carrier to facilitate terminating the cable 300 to the contact carrier. Figure 2A 1, ferrule 190 is shown in an exploded state relative to its designed position. For example, ferrule 190 can be annular so that the conductors of cable 300 pass through the opening of ferrule 190. When ferrule 192 is installed, the shield of the cable can be folded over ferrule 190 and captured between ferrule 190 and outer ferrule 192.

[0060] The contact carrier may also include an insulating inner housing 160 that holds the mating contact portion of the electrical conductor 180. The shape and size of the insulator can be designed to receive the mating contact. For example, the contact 180 can be passed through an opening in the insulating inner housing 160. The insulating housing 160 can be inserted into a cavity within the conductive housing 150. In this way, the conductive housing 150 will at least partially surround the insulating inner housing 160 containing the electrical conductor 180.

[0061] The contact carrier may also include a terminal position assurance (TPA) member 170 that may be inserted into the insulative inner housing 160 to secure the electrical contact 180 within the insulative inner housing 160 .

[0062] The contact carrier may also include a mechanism for grounding the conductive housing 150. In this example, the outer ferrule 192 (which is Figure 2A The shield of the cable 300 can be connected to the conductive housing 150. By grounding the conductive housing 150, the conductive housing 150 can serve as a shield for the contact carrier including a pair of conductors 180 therein.

[0063] The cable connector 200 may also include a contact carrier position assurance assembly (CCPA) 130 that provides precise and stable positioning of the conductors (e.g., contacts 180). The CCPA 130 ensures that the contact carrier is latched and remains latched in the designed position. The contact carrier position assurance assembly can be slid to a closed position to lock the contact carrier in the designed position.

[0064] Figure 2B is a diagram showing a method for connecting the cable 300 to the Figure 2A The exemplary cable connector 200 shown is terminated to form a series of schematic diagrams of exemplary steps of a method 200 for manufacturing a cable assembly. Figure 2B In the example shown, the cable is first prepared for termination. For example, the cable may include one or more insulated conductors. In the example shown, the cable 300 includes two insulated conductors 250A and 250B that will eventually be attached to the contact 180. These conductors can be surrounded by one or more layers that provide the cable with desired electrical and / or mechanical properties. Some or all of these layers can be removed and / or exposed at one end of the cable so that they can be electrically and / or mechanically connected to a structure in the cable connector.

[0065] For example, the insulated conductors may be wrapped with foil. The foil may be a thin metal foil backed by a polymer such as polyester film. The foil may mechanically hold the insulated conductors together and / or provide electrical shielding to the insulated conductors and / or provide a conductive ground path through the cable.

[0066] Instead of or in addition to the foil, the cable can include a layer formed of a wire braid. The wire braid can provide mechanical integrity to the cable, shielding to the insulated conductors, and a ground path. In this example, a foil and a braid are used, with the foil forming the inner layer and the braid forming the outer layer.

[0067] The cable may include an outer layer forming a jacket for the cable. The jacket may be an insulating polymer that provides mechanical protection to the cable.

[0068] In step 202 , the jacket of the cable 300 is stripped, which in this example exposes the braid 304 and the foil underneath the braid.

[0069] In step 204, the inner ferrule 190 is threaded onto the cable and crimped into place. Figure 2B In the example shown, the ferrule 190 has two connected parts. The larger diameter part 190A is crimped onto a portion of the cable where the jacket is still in place. The smaller diameter part 190B is crimped onto the portion of the cable where the braid 304 is already exposed.

[0070] In step 206, the braid 304 in the portion of the cable that extends beyond the smaller diameter portion 190B is flipped back onto the ferrule 190. In this state, the outermost layer of the cable in the portion between the ferrule 190 and the end is foil.

[0071] In step 208, the foil in the portion of the cable extending beyond ferrule 190 is cut away to expose insulated conductors 250A and 250B. A portion 306 of the insulation at the ends of insulated conductors 250A and 250B may also be removed to expose the ends of the conductors of the cable.

[0072] In step 210, the contact 180 may be crimped to the exposed end of the conductor of the cable. Subsequently, the contact 180 may be bent so that the mating portion of the contact extends in a first direction and the tail portion of the contact to which the cable conductor is attached extends in a second direction perpendicular to the first direction.

[0073] In step 212 , the contacts 180 are inserted into the inner housing 160 . In step 214 , the TPA 170 is inserted into the inner housing 160 to secure the contacts 180 within the inner housing 160 .

[0074] In step 216, the conductive housing 150 is assembled onto the insulating housing 160. The conductive housing 150 includes a tail portion 152 that aligns with the portion of the cable 300 that includes the inner ferrule 190. Thus, the portion of the braid 304 that is folded over the ferrule 190 contacts the conductive housing 150 at the tail portion 152.

[0075] In step 218, the metal sheet forming the outer ferrule 192 is wrapped around the tail portion 152 and the inner ferrule 190. The sheet is crimped in place, thereby providing a mechanical connection of the cable to the conductive housing 150. Alternatively or additionally, the braid 304 may be electrically connected to the conductive housing 150 by this crimping operation.

[0076] As part of the assembly process, the opening in the conductive housing 150 (through which the insulating housing 160 is inserted) may be covered. Figure 2BIn the example shown, the metal sheet forming the outer ferrule 192 has a portion aligned with and covering the opening. In step 220, as shown, protrusions 154 are formed on each side of the conductive housing 150. For example, the protrusions 154 can be formed in a pounding operation and can hold the portion of the metal sheet forming the outer ferrule 192 to the conductive housing 150.

[0077] In step 220, the front shield 140 is positioned over the forward portion 152 of the conductive housing 150. Tabs or other features on the front shield 140 may engage with recesses or other complementary features on the conductive housing 150.

[0078] The cable connectors described herein can be assembled from housing subassemblies that can be assembled as part of the cable termination process or can be assembled at a different time and / or at a different location. For example, a connector manufacturer can include a housing subassembly as part of the cable termination process. Figure 2A 1 and 2. The connector assembly is provided as part of a kit of some or all of the connector components shown. Step 224 shows the assembly of the subassembly. In step 224, the CCPA 130 is slid into the plug housing 120 and latched to the plug housing 120 in a first position. In the state shown, the CCPA 130 is latched in a first open position in which the CCPA 130 will not block movement of the contact carrier into the housing 120. The CPA 110 is also slid into the plug housing 120 and latched in the open position. In the open position, the CPA 110 is held away from a latch member that is capable of latching the cable connector to the mating connector. In the open position, the latch member can be moved so that the cable connector can be latched and / or unlocked to the mating connector.

[0079] In step 226, the assembled contact carrier, including the front shield 140, conductive housing 150, inner housing 160, TPA 170, and contacts 180, is positioned within the right-angle plug housing 120. The latch members 122 on the plug housing 120 engage to contact the carrier assembly, thereby retaining the carrier assembly within the housing. The CCPA can be used to provide additional robustness, preventing the contact carrier from being withdrawn from the housing and providing an indication that the contact carrier is positioned in the intended position within the housing 120. In step 228, the CCPA 130 is slid within the plug housing 120 from its open position to a second, closed position. If the contact carrier is not fully seated in its designed position, portions of the contact carrier may obstruct the movement of the CCPA 130 as it slides toward the closed position. Therefore, if the contact carrier is not properly positioned, a force above a threshold may be required to slide the CCPA 130 to the closed position, and the high force may provide feedback to the user that the contact carrier is not properly positioned within the housing subassembly. Conversely, if the CCPA 130 is slid to the closed position, the CCPA 130 will interfere with tabs or other structures on the contact carrier, thereby securing the contact carrier within the plug housing 120 .

[0080] Figure 2C Shown by executing Figure 2B The steps of method 200 form a resulting cable assembly. Figure 2C One end of the cable assembly is shown. The opposite end of the cable assembly can be terminated in other ways, such as by another connector or by connecting directly to other electronic components through conductors within the cable 300.

[0081] Additional details of the construction and operation of these components of the cable assembly are shown in the following figures. Figure 3A A cable is shown having a first portion and a second portion with an inner ferrule 190 and a braid 304. Figure 2B As illustrated in step 206 of method 200 , braid 304 is flipped back. Figure 3B yes Figure 3A A cross-sectional view of a first portion of an exemplary cable along line AA. Figure 3C yes Figure 3A 8. A cross-sectional view of a second portion of an exemplary cable along line BB.

[0082] like Figure 3B As shown, the exemplary cable includes insulated conductors 250A and 250B surrounded by a first portion 190B of an inner ferrule 190 having an oval cross-section. Figure 3C As shown, the second portion of the exemplary cable includes insulated conductors 250A and 250B surrounded by a second portion 190A of the inner ferrule 190 having a circular cross-section.

[0083] Figure 3D is a cross-sectional view of a cable attachment to an exemplary cable connector. Figure 3D As shown, the conductive housing 150 includes a tail portion 152 that extends parallel to the axis of the cable 300. The tail portion 152 includes a step 153. In this example, the step 153 is located on the portion of the tail portion 152 that extends beyond the inner ferrule 190. In the illustrated state, the braid 304 is folded back over the ferrule 190 and can extend beyond the inner ferrule 190 so that the step 153 ensures that the conductive housing 150 is pressed against the braid 304 at the free end of the braid 304. In this example, the step 153 captures the braid 304 between the tail portion 152 and the jacket of the cable 300.

[0084] The additional structure of the outer hoop 192 is also Figure 3D . In this example, outer ferrule 192 has multiple sections integrally formed from a single sheet of metal. Section 192A contacts and is crimped around cable 300. For example, section 192A can press against the jacket of cable 300. Section 192A can provide a mechanical connection between the connector and the cable.

[0085] The second portion 192B surrounds the tail portion 152 of the cable, including a portion of the inner ferrule 190 and the conductive housing. In this example, portion 192B presses against the tail portion 152 over a portion of the circumference of the tail portion 152. Over the remainder of the circumference of the tail portion 152, portion 192B presses against the braid 304 that is folded back over the inner ferrule 190. Portion 192B can provide both a mechanical and electrical connection between the cable and the connector because portion 192B can attach the cable to the tail portion 152 and press the tail portion 152 of the conductive housing 150 into the braid 304, which creates an electrical connection.

[0086] The third portion 192C extends over the opening in the conductive housing 150 and may form a cover for the conductive housing 150 .

[0087] Figure 4A is a perspective view of an exemplary insulative inner housing 160 into which the electrical contacts 180 are inserted. In this example, the insulative inner housing 160 is L-shaped with channels extending in two orthogonal directions to receive the electrical contacts 180 after they have been bent, as described above in connection with step 210.

[0088] Figure 4A The electrical contact 180 is shown partially inserted into the inner housing 160 . Figure 4B1 is a top cross-sectional view showing the electrical contact 180 fully inserted into the inner housing 160. As can be seen, the electrical contact 180 has features that engage the inner wall 410 of the inner housing 160. The inner wall 410 has a hole through which the contact 180 is inserted. The contact 180 includes features that engage both sides of the wall 410 to lock the contact in an axial direction relative to the wall 410.

[0089] In this example, these features include spring fingers 412 cut out of the contact 180. The spring fingers 412 can be pressed into the body of the contact 180 to insert the contact 180 through the hole in the wall 410, and can pop outward on the second side of the wall to prevent the contact 180 from being withdrawn from the designed position through the hole. Alternatively or additionally, the contact 180 can have a dimple portion 182. The dimple portion fits within the notch 162 on the first side of the wall. The interference between the dimple portion and the first side of the wall prevents the contact 180 from being inserted beyond its designed position.

[0090] Figure 4C yes Figure 4A As shown in these figures, the dimple 182 is disposed in the notch 162. The engagement of the dimple and the notch also prevents the contact 180 from rotating from its designed orientation.

[0091] In this example, if Figure 4A As shown, the electrical contact 180 has a mating portion extending in a first direction and a tail portion extending in a second direction perpendicular to the first direction. The mating portion of the electrical contact 180 slides through the channel in the inner housing 160 so that the recessed portion 182 of the electrical contact 180 is disposed in the notch 162. Optionally, the contact carrier may further include a terminal position assurance member (TPA) 170 positioned to prevent the recessed portion 182 from being withdrawn from the notch 162. Figure 4B and Figure 4C In this example, the TPA 170 includes two compliant arms that latch beneath the shelf within an inner insulating housing.

[0092] 5A to 5D Further details of assembling the dielectric housing with the contacts 180 secured therein into the conductive housing 150 are shown. Figure 5A 、 Figure 5B and Figure 5Care perspective views of an exemplary right-angle contact carrier. As shown in these figures, the conductive housing 150 may have a chamber 510 for receiving the insulating housing. The conductive housing 150 may be open at the rear, providing an entrance into the chamber 510 through which the insulating housing can be inserted. The integral sheet of material forming the outer ferrule 192 may have a third portion 192C that covers the entrance after insertion into the insulating housing. Optionally, the conductive housing 150 may include at least one protrusion 154 extending into the entrance of the conductive housing 150, thereby removing the blocking portion 192C. The protrusion 154 may be formed, for example, by a strike that deforms the conductive housing 150 after the portion 192C is placed in place to cover the entrance. Alternatively, the conductive housing 150 may be formed with the protrusion 154, such as by die casting, before the portion 192C is placed over the entrance. In the latter case, the portion 192C can be slid into a position below the protrusion 154. Alternatively, the protrusion 154 may be positioned on the opposite side of the conductive housing 150, also as shown. Figure 5C shown.

[0093] The third portion of the unitary sheet may include a flat portion 155 and a region 142 offset relative to the flat portion, such as Figure 5C As shown. In this example, the region 142 can be formed by embossing the metal sheet. The embossed region 142 can improve the signal integrity in the electrical contact 180. Figure 5D As shown, Figure 5D In a cross-sectional view of an exemplary right-angle contact carrier, the knurled area 142 changes the spacing between the contact 180 and the portion 192C. When the outer ferrule 192 is grounded, the knurled area 142 changes the signal-to-ground spacing in a limited area of the contact 180. This configuration can compensate for impedance variations that would otherwise be caused by crimping the contact 180 to the conductor of the cable or other features that, without compensation, could result in impedance variations that would degrade signal integrity.

[0094] Optionally, the electrical contacts 180 of the cable 300 include distal portions that extend into the conductive housing 150 and are adjacent to the embossed area 142 of the third portion of the integral sheet, as shown in FIG. Figure 5B and Figure 5C Optionally, the embossed area 142 extends into the cavity 510 of the conductive housing 150 and the inner ferrule 170 is located outside of the cavity of the conductive housing.

[0095] Based on the foregoing description, it can be understood that, optionally, the integral sheet includes a first portion that at least partially surrounds the tail of the electrical contact 180 and the cable 300. Optionally, the integral sheet includes an outer ferrule 192. Optionally, the inner ferrule 190 is disposed on the cable 300. Preferably, the first portion of the integral sheet at least partially surrounds the tail of the electrical contact 180, the cable 300, and the inner ferrule 190. Optionally, the cable 300 includes a jacket 302 and a shield that may extend beyond the jacket and may be disposed between the inner ferrule 190 and the outer ferrule 192. Optionally, the tail of the electrical contact 180 includes a stepped portion that extends toward the cable 300, wherein an end of the cable shield is located between and in contact with the stepped portion and the cable jacket 302.

[0096] Optionally, a first portion of the unitary sheet at least partially surrounds the tail of the electrical contact 180, the cable 300, and the first portion of the inner ferrule 190, such that the shield is positioned between and in contact with the inner ferrule 190 and the outer ferrule 192 over substantially the entire circumference of the first portion of the inner ferrule 190. Optionally, the unitary sheet includes a second portion that at least partially surrounds the cable 300 at a position offset relative to the tail of the electrical contact 180.

[0097] Figure 6A is inserted into the housing subassembly 600 Figure 5C 1 is a side perspective view of an exemplary contact carrier. As shown in this figure, the contact carrier is an assembly having electrical contacts 180 that are shielded by the front shield 140, the conductive housing 150, and the outer ferrule 192 and terminated to the cable 300. The subassembly is inserted through the rear of the right-angle plug housing 120 to position the front shield 140 surrounding the mating contact portions of the contacts 180 at the mating interface of the connector. Figure 6A As further shown, the contact carrier includes a mating portion 610 extending in a first direction and a cable mounting portion 612 extending in a second direction transverse to the first direction such that the mating portion is positioned within a cavity of the right-angle plug housing 120 and engaged to the plug housing 120 via the latch 122 .

[0098] The housing subassembly 600 may include a contact carrier position assurance component (CCPA) 130. Figure 6A In the example shown, the CCPA is latched in the housing subassembly 600 in a first position in which a portion of the CCPA extends from the housing 120. The first position is an open position in which portions of the CCPA 130 that might block movement of the contact carrier into or out of the housing subassembly 600 are retracted a sufficient distance so as not to interfere with movement of the contact carrier.

[0099] Figure 6B yes Figure 6A A perspective view of a portion of an exemplary contact carrier. Figure 6B The front shield 140 is shown being held to the dielectric housing with the tabs 644 bent into the recesses 544 ( Figure 5A For example, the tabs 644 may be cut from a sheet of metal that is formed into the front shield 140. Although only one such tab is shown, the contact carrier may have two or more such features to retain the front shield 140 to the conductive housing 150.

[0100] The contact carrier may include one or more other features that position and / or secure the contact carrier in a designed position. For example, Figure 6B The contact carrier is shown to include tabs 146. When the mating portion 610 is inserted into the housing subassembly 600 into its designed position and the CCPA 130 is pushed into the closed position, the tabs 146 can engage the CCPA 130. In this example, the tabs 146 are formed as part of the conductive housing 150. For example, the conductive housing can be formed by die casting, and the tabs 146 can be formed as part of that operation. Alternatively, the tabs can be formed from the sheet metal used to form the front shield 140.

[0101] Figure 6C is a cross-sectional view of an exemplary cable connector 200 in which the contact carrier is locked in place by the CCPA 130. As can be seen in this example, the CCPA 130 is inserted into a channel within the housing 120. Figure 6C In the illustrated state, the CCPA 130 has been pushed further into the channel and is in a closed position. In this state, the tab 136 of the CCPA 130 is aligned with the tab 146 in the direction in which the contact carrier is inserted into or removed from the housing 120. When the CCPA is pushed into this second closed position after the contact carrier is inserted into the housing 120 to its designed position, the tab 136 interferes with the tab 146, thereby preventing the contact carrier from being removed from its position in the housing 120.

[0102] Figure 6D is a perspective view of an exemplary contact carrier position assurance (CCPA) component.

[0103] Figure 6E is a perspective view of an exemplary cable connector 200 showing a latch and a CCPA.

[0104] like Figures 6A to 6EAs shown, the mating portion 610 of the contact carrier optionally includes a tab 146, and the position assurance member 130 can be configured to latch in a closed position within the first opening 128 of the plug housing 120, with the position assurance member 130 engaging the tab 146 of the contact carrier in the closed position to retain the contact carrier within the cavity of the housing 120. Figure 6C and Figure 6D As shown, the position assurance member 130 can engage the contact carrier between the tab 146 and the cable mounting portion of the contact carrier. The first opening 128 may include a passage for accessing the position assurance member 130, and the position assurance member 130 can be configured to slide in the passage between an open position and a closed position. The position assurance member 130 can be configured to latch to the plug housing 120 in the open position and / or the closed position. The passage provided by the first opening 128 of the plug housing 120 for accessing the position assurance member 130 can extend in a direction substantially perpendicular to the direction of another passage 670 of the plug housing 120, which is configured to receive the mating portion 610 of the contact carrier.

[0105] like Figure 6D As shown, the position assurance member 130 may include a tab 136 that is configured to abut a tab 146 of the front shield 140 of the contact carrier when the position assurance member 130 is in the closed position. Figure 6D As further shown, the position assurance member 130 may include a base 652, a first arm 650A and a second arm 650B extending from the base 652 and configured to latch to the housing. Figure 6C and Figure 6D In the example shown, the tab 136 of the position assurance member 130 is thinner than the first arm 650A and the second arm 650B of the position assurance member 130. This configuration can result in a more compact connector. Figure 6D As further shown, the CCPA 130 has a first side and a second side opposite the first side. The CCPA 130 can be inserted into the dielectric housing 120 with the first side facing the cable mounting portion 612 of the contact carrier such that the tab 136 of the CCPA 130 is adjacent to the first side and offset relative to the second side. The tab 136 of the CCPA 130 can be configured to engage the contact carrier and retain the contact carrier within the cavity of the plug housing 120.

[0106] Alternatively, as Figure 7A and Figure 7E As shown, the insulating housing 120 may include a latch 700 configured to latch the cable connector 200 to a substrate such as a board connector 100 ( Figure 1) or a mating connector such as a . Cable connector 200 may include a connector position assurance component (CPA) 110 that is compact but still ensures that the connection between the cable connector 200 and the board connector is secure and reliable. The CPA 110 may be configured to slide between an open state and a closed state. The CPA 110 may be configured so that in the closed state, it blocks the latch 700 from being deflected in a direction that would unlock the cable connector 200 from the board connector 100. When the CPA 110 is in the open position, it does not interfere with the movement of the latch 700, thereby ensuring that the latch 700 is latched or unlocked.

[0107] Figure 7A FIG2 is an enlarged side view of a portion of the housing subassembly of the exemplary cable connector 200, illustrating the latch 700 and the CPA 110. In the illustrated state, the CPA 110 is in an open position. The upper surface 712 of the CPA 110 is offset relative to the distal end 710 of the latch 700. Thus, the latch 700 is not blocked from deflection by the CPA 110, enabling it to engage or disengage with a complementary latch feature in a mating connector.

[0108] exist Figure 7A In the illustrated state, CPA 110 can be retained in the open state by engagement of one or more features of CPA 110 with complementary engagement features on connector housing 120. For example, in the open state, member 730 fits within recess 702 in housing 120. In this example, the walls of recess 702 are generally perpendicular to direction 704, in which direction CPA 110 can slide within the channel of housing 120 between the unlocked and locked states, such that sliding CPA 110 in direction 704 without first removing member 730 from recess 702 would require a relatively large force. In this example, member 730 is located at the distal end of arms 732 and 734 and can flex when a force is applied to arms 732 and 734 in a downward direction 706. Thus, these engagement features can be disengaged by a user pressing member 730 in direction 706.

[0109] Figure 7A Other engagement features that may be used in place of or in addition to member 730 and recess 702 are also indicated. Alternatively or additionally, protrusion 112 may be included. Protrusion 112 is located on compliant arm 111. Figure 7AIn the open position shown, the forward-facing surface of the projection 112 abuts the stop 729 of the housing 120. The forward-facing surface is cammed so that if the CPA 110 is pressed forward with sufficient force, the camming surface will generate a lateral force that deflects the arm 111 until the projection 112 passes the stop 729. The CPA 110 can then slide forward until the member 730 abuts the wall 703 ( Figure 6C In this position, the projection 112 can pass over the stop 729, allowing the arm 111 to be released from its deflected state, wherein the projection 112 is located on the opposite side of the stop 729 (such as Figure 7D ). The protrusion 112 and the stop 729 may be configured such that when the protrusion 112 is on the opposite side of the stop 729, the CPA 110 is in its closed position, such as in Figure 7E , where surface 712 of the CPA 110 blocks movement of the distal end 710 in a direction for latching or unlatching from a mating connector.

[0110] The arm 111 can be sized such that the force required to apply to the CPA 110 along the sliding direction 704 to generate sufficient cam force at the interface between the protrusion 112 and the side of the stop 729 to deflect the arm 111 is above a threshold, but such that the force is not so low that it can be generated by a human user intending to slide the CPA 110 to the locked state when the member 730 is pressed to disengage from the recess 702 (if such engagement features are present).

[0111] Alternatively or additionally, protrusions 114 may be included on the CPA 110. For example, protrusion 714 is shown as being positioned when the CPA 110 is in Figure 7A The open (ie, unlocked) position shown abuts the stop 728. Figure 7BAs can be seen in FIG, protrusion 114 may have a surface that faces stop 728 perpendicular to sliding direction 704. Unlike protrusion 112, this surface generates little or no camming force in response to a force applied to CPA 110 to urge protrusion 114 toward stop 728. In this example, protrusion 114 and stop 728 are positioned so that they contact when CPA 110 is in its open position. Because little or no camming force is generated at this interface, little force is generated to prevent protrusion 114 from moving in a direction that would allow it to pass stop 728. Thus, protrusion 114 and stop 728 interact to prevent CPA 110 from moving rearward in sliding direction 704 sufficiently to be removed from housing 720. More specifically, to remove CPA 110 , a user may insert a tool into the opening between stops 728 and 729 to directly press arm 111 to deflect it enough to allow protrusion 114 to clear stop 728 .

[0112] Alternatively, a CPA as described herein can be operated with a bistable latching mechanism that tends to position the CPA in either an open (e.g., unlocked) or closed (e.g., locked) position. Such a bistable latching mechanism can urge the CPA 110 away from a position that is neither open nor closed. Preventing the CPA from assuming such a position can reduce operational errors that might otherwise occur due to improperly securing the connector to the mating connector. For example, because both sides of the protrusion 112 are chamfered, the force applied by the arm 111 to urge the protrusion 112 toward the stop 729 can generate a force that urges the protrusion 112 to one side or the other of the stop 729. Because the positions on one side or the other correspond to the open and closed positions of the CPA, this force is generated when the CPA is between the open and closed positions and urges the CPA into the open or closed position. Other features can prevent the CPA from being pressed further into the housing than the designed closed position and / or from being retracted from the housing beyond the designed open position. For example, the protrusion 114 interacting with the stop 728 can limit the withdrawal of the CPA 110 beyond the open position. Alternatively or additionally, the protrusion 112 and the wall 727 defining the channel in which the CPA 110 slides can cooperate to generate a cam force that forces the CPA 110 back to the designed locked position if the CPA 110 is over-inserted.

[0113] Alternatively or additionally, the structure described above can be used to provide audible feedback to the user. As described above, if the CPA 110 is between the open position and the closed position, the force generated by the interaction between the cam surface of the protrusion 112 and the stop 729 causes the arm 111 to deflect. When the CPA 110 slides to the closed or open position, the force can cease and the arm 111 can return to its undeflected state with sufficient force to produce a sound, such as a click, which can serve as audible feedback to the user that the CPA is in a predetermined position, such as the open position or the closed position.

[0114] Figure 7B yes Figure 7A A perspective view of an exemplary CPA 110 is shown. Figure 7B It is shown that the CPA 110 can be symmetrical so that the above combined Figure 7A The features discussed may be present on both sides of the connector housing. Figure 7C yes Figure 7A 7C-7C of the exemplary cable connector housing subassembly, wherein the exemplary CPA 110 is in the first unlocked position. In this view, the second arm 113 symmetrical to the arm 111 is visible. Figure 7D yes Figure 7A 7C-7C of the exemplary cable connector housing subassembly, wherein the exemplary CPA 110 is in the second locked position. Figure 7E yes Figure 7A 00140] A top perspective view of an exemplary cable connector housing subassembly with the CPA in a second locked position.

[0115] like Figure 7B and Figure 7C As shown, a connector position assurance device (CPA) 110 may include a first compliant arm 111 including a first protrusion 112 and a second protrusion 114 extending therefrom and may be disposed within a channel of an insulating housing 120. CPA 110 may also include a second compliant arm 113 that is parallel to first compliant arm 111 and also includes a first protrusion and a second protrusion. CPA 110 may also include a first cross member 115 connecting first ends of first compliant arm 111 and second compliant arm 113, and a second cross member 117 connecting second ends (opposite to the first ends) of first compliant arm 111 and second compliant arm 113.

[0116] Alternatively, as Figure 7A 、 Figure 7C 、 Figure 7D and Figure 7EAs shown, the insulating housing 120 may include a first stop 729 disposed within the channel and configured to engage the first protrusion 112 on the compliant arm 111 of the CPA 110. When the CPA 110 is in the locked position, movement of the CPA 110 in a second direction opposite to the first direction may be blocked within the channel of the insulating housing 120. Optionally, the insulating housing 120 may further include a second stop disposed within the channel and configured to engage the second protrusion 114 on the compliant arm 111 of the CPA 110 to block movement of the CPA in the first direction within the channel when the CPA is in the unlocked position in which the CPA is disengaged from the latch.

[0117] Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art.

[0118] For example, the contact carrier position assurance member 130 may include other types of latching features to engage the connector housing in the open position and / or the closed position.

[0119] As another example, the techniques described herein may be used in connectors having configurations other than those described above.

[0120] This optional connector configuration can be used with all or any suitable number of features described herein. In addition, it should be understood that all structures, materials, and construction techniques described herein can be used together, but in some embodiments, some or all of the structures, materials, or techniques can be omitted.

[0121] Such changes or modifications are intended to be part of this disclosure and are intended to be within the spirit and scope of the invention. Furthermore, although advantages of the invention have been indicated, it should be understood that not every embodiment of the invention will include every described advantage. Some embodiments may not implement any of the features described herein and in some cases as advantageous. Therefore, the foregoing description and accompanying drawings are intended to be examples only.

[0122] The various aspects of the present invention may be used alone, in combination, or in various arrangements not specifically discussed in the foregoing embodiments, and therefore their application is not limited to the details and arrangements of components set forth in the foregoing description or shown in the accompanying drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments.

[0123] The use of ordinal terms such as "first," "second," "third," etc. in the claims to modify claim elements does not in itself imply any priority, precedence, or order of one claim element with respect to another claim element, or a temporal order of acts of performing a method, but serves merely as a marker to distinguish one claim element having a particular name from another element having the same name (but using an ordinal term) to distinguish the claim elements.

[0124] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0125] Unless expressly stated otherwise, the indefinite articles "a" and "an" as used in this specification and claims should be understood to mean "at least one".

[0126] As used herein in the specification and claims, the phrase "at least one" with respect to a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but does not necessarily include at least one of each element specifically listed in the list of elements, and does not exclude any combination of elements in the list of elements. This definition also allows that elements may optionally be present in addition to the elements specifically identified in the list of elements to which the phrase "at least one" refers, whether related or unrelated to those elements specifically identified.

[0127] As used herein in the specification and claims, the phrase "and / or" should be understood to mean "either or both" of the elements so combined, i.e., elements that are present in combination in some cases and separately in other cases. Multiple elements listed with "and / or" should be interpreted in the same manner, i.e., "one or more" of the elements so combined. In addition to the elements specifically identified by the "and / or" clause, other elements may optionally be present, whether related or unrelated to those specifically identified. Thus, as a non-limiting example, when used in conjunction with open language such as "comprising"), a reference to "A and / or B" may, in one embodiment, refer only to A (optionally including elements other than B); in another embodiment, to only B (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements), etc.

[0128] As used herein in the specification and claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating the items in a list, "or" or "and / or" should be interpreted as inclusive, that is, including at least one of a plurality of elements or lists, but also including more than one, and optionally, additional unlisted items. Only terms that clearly indicate the opposite, such as "only one" or "exactly one", or when used in the claims, "consisting of..." will refer to including exactly one element in a plurality of elements or lists of elements. Generally, the term "or" as used herein will only be interpreted to indicate an exclusive alternative (i.e., "one or the other but not both") when preceded by an exclusive term, such as "either", "one", "only one" or "exactly one". When used in the claims, "consisting essentially of..." should have its ordinary meaning used in the field of patent law.

[0129] In addition, the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having," "containing," "involving," and variations thereof herein is intended to encompass the items listed thereafter and their equivalents as well as additional items.

Claims

1. An electrical connector (100), comprising: a housing (120) comprising a chamber and a first opening (128); A contact carrier comprising a mating portion extending in a first direction and a cable mounting portion extending in a second direction transverse to the first direction, wherein: the mating portion being positioned within the cavity of the housing and engaged to the housing; The mating portion includes a tab (146); as well as A position assurance member (130) is configured to latch in a closed position, the closed position being within the first opening of the housing, and the position assurance member engages the tab (146) of the contact carrier in the closed position to retain the contact carrier within the cavity of the housing such that the position assurance member engages the contact carrier between the tab (146) and the cable mounting portion.

2. The electrical connector according to claim 1, wherein: The first opening includes a channel extending in the second direction.

3. The electrical connector according to claim 2, wherein: The position assurance member is configured to slide in the channel between an open position and the closed position; and The position assurance component (130) is configured to latch to the housing in the open position.

4. The electrical connector according to claim 1, wherein: The second direction is substantially perpendicular to the first direction.

5. The electrical connector according to claim 1, wherein: The position assurance member (130) includes a tab (136), and the tab of the position assurance member is configured to abut the tab (146) of the contact carrier when the position assurance member is in the closed position.

6. The electrical connector according to claim 5, wherein: The position ensuring component includes: Base(652) a first arm (650A) and a second arm (650B) extending from the base and configured to latch to the housing; The tab (136) extends from the base.

7. The electrical connector according to claim 6, wherein: The tab (136) of the position assurance member is thinner than the first arm and the second arm.

8. The electrical connector according to claim 7, wherein: The position ensuring member has a first side and a second side opposite to the first side; The position ensuring member is positioned so that the first side faces the cable mounting portion; and The tab is adjacent the first side and offset relative to the second side.

9. The electrical connector according to claim 1, wherein: The contact carrier includes a shield, the shield (140) including the tab (146); and The position assurance feature includes a tab (136) configured to engage the tab to retain the contact carrier within the cavity of the housing.

10. The electrical connector according to claim 3, wherein: The contact carrier includes at least one electrical contact (180); The electrical connector is combined with a cable (300) comprising a jacket (302) surrounding at least one electrical conductor and a shielding layer between the jacket and the at least one electrical conductor.

11. The electrical connector according to claim 10, wherein: The electrical connector further comprises: A die-cast component including a tail portion (152); and wherein the die-cast member is attached to the cable, wherein the tail portion presses against the exposed portion of the shielding layer.

12. The electrical connector according to claim 10, wherein: The contact carrier includes an inner housing (160) having a notch (162); and The electrical contact (180) includes a recessed portion (182); and The dimple portion is provided in the notch.

13. The electrical connector according to claim 12, wherein: The contact carrier further includes a terminal position assurance feature positioned to block withdrawal of the socket portion from the notch.

14. The electrical connector according to claim 1, wherein: The electrical connector further comprises: A second position ensuring component (110), the second position ensuring component includes a first protrusion (112), wherein the shell further includes a shelf (729) having a first side and a second side, the first protrusion being positioned against the first side of the shelf of the second position ensuring component to fix the second position ensuring component in the shell.

15. The electrical connector according to claim 14, wherein: The second position assurance member (110) includes a second protrusion (114) positioned against the second side of the shelf of the second position assurance member to further secure the second position assurance member in the housing.

16. An electrical connector, comprising: a housing (120) comprising a chamber, a first opening (128), and a latch (122); as well as A contact carrier comprising a mating portion extending in a first direction and a cable mounting portion extending in a second direction transverse to the first direction, wherein: The matching portion is located in the cavity of the housing, The contact carrier includes a protrusion (144); and The latch (122) engages the protrusion to latch the contact carrier within the cavity of the housing; as well as A position assurance member (130) is positioned within the first opening of the housing and is configured to slide into a closed position in which it blocks withdrawal of the contact carrier from the cavity of the housing.

17. The electrical connector according to claim 16, wherein: The housing includes an insulating housing (160), and the latch includes an arm integrally molded with the insulating housing.

18. The electrical connector according to claim 17, wherein: The electrical connector further comprises: a conductive housing (150); wherein the contact carrier comprises an insulating housing, the insulating housing comprises a channel and a contact disposed in the channel; and The conductive housing includes the protrusion of the contact carrier.

19. The electrical connector according to claim 18, wherein: The conductive housing is a die-cast component; and The conductive housing comprises an integrally formed portion of the die cast component.

20. The electrical connector according to claim 16, wherein The first opening includes a channel extending in the second direction.

21. The electrical connector according to claim 20, wherein: The position assurance member is configured to slide in the channel between an open position and the closed position; and The position assurance component (130) is configured to latch to the housing in the open position.

22. The electrical connector according to claim 16, wherein: The second direction is substantially perpendicular to the first direction.

23. The electrical connector according to claim 16, wherein: The position assurance member (130) includes a tab (136), and the tab of the position assurance member is configured to abut the tab (146) of the contact carrier when the position assurance member is in the closed position.

24. The electrical connector according to claim 23, wherein: The position ensuring component includes: Base(652) a first arm (650A) and a second arm (650B) extending from the base and configured to latch to the housing; The tab (136) extends from the base.

25. The electrical connector according to claim 24, wherein: The tab (136) of the position assurance member is thinner than the first arm and the second arm.

26. The electrical connector according to claim 25, wherein: The position ensuring member has a first side and a second side opposite to the first side; the position ensuring member is positioned so that the first side faces the cable mounting portion; and The tab is adjacent the first side and offset relative to the second side.

27. The electrical connector according to claim 16, wherein: The contact carrier includes a shield, the shield (140) including the tab (146); and The position assurance member includes a tab (136), the tab of the position assurance member being configured to engage the tab of the shield to retain the contact carrier within the cavity of the housing.

28. The electrical connector according to claim 27, wherein: The contact carrier includes at least one electrical contact (180); The electrical connector is combined with a cable (300), the cable comprising a sheath (.) surrounding the at least one electrical contact, the sheath having an oval cross section.

29. The electrical connector according to claim 28, wherein: The electrical connector further comprises: a die-cast component including at least one step (153) positioned within the cavity of the housing; and Shielding components; The cable comprises a braid, and the stepped portion ensures that the die-cast component is pressed against the braid.

30. The electrical connector according to claim 29, wherein: The contact carrier includes an inner housing (160) having a notch (162); and The electrical contact (180) includes a recessed portion (182); and The dimple portion is provided in the notch.

31. The electrical connector according to claim 30, wherein: The contact carrier further includes a terminal position assurance feature positioned to block withdrawal of the socket portion from the slot.

32. The electrical connector according to claim 16, wherein: The electrical connector further comprises: A second position ensuring component (110), the second position ensuring component includes a first protrusion (112), wherein the shell further includes a shelf (729) having a first side and a second side, the first protrusion being positioned against the first side of the shelf of the second position ensuring component to fix the second position ensuring component in the shell.

33. The electrical connector according to claim 32, wherein: The second position assurance member (110) includes a second protrusion (114) positioned against the second side of the shelf of the second position assurance member to further secure the second position assurance member in the housing.

34. A cable assembly comprising: Cables including conductors; An electrical connector (100), comprising: an outer housing (120) comprising a chamber; a conductive housing (150) including a portion having a cavity (510), the conductive housing being at least partially positioned within the cavity of the outer housing; an insulating housing comprising a passage disposed within the chamber of the conductive housing; a contact comprising a mating portion disposed within the channel of the insulating housing and a tail portion attached to the conductor of the cable, The conductive housing further comprises a tail portion (152) configured to support the cable.

35. The cable assembly according to claim 34, wherein: The cable assembly further comprises: An integral sheet includes a first portion at least partially surrounding the tail portion and the cable.

36. The cable assembly according to claim 35, wherein: The integral sheet material includes an outer hoop; The electrical connector further includes an inner ferrule disposed on the cable; and The first portion of the unitary sheet at least partially surrounds the tail, the cable, and the inner ferrule.

37. The cable assembly according to claim 36, wherein: The cable includes a sheath and a shield; The shield of the cable extends beyond the jacket and is disposed between the inner ferrule and the outer ferrule.

38. The cable assembly according to claim 37, wherein: The tail portion includes a stepped portion extending toward the cable; An end portion of the shield of the cable is located between the stepped portion and the jacket of the cable and is in contact with the stepped portion and the jacket of the cable.

39. The cable assembly according to claim 37, wherein: The inner cuff includes a first portion having a circular cross-section and a second portion including an elliptical cross-section; and The first portion of the unitary sheet at least partially surrounds the tail, the cable, and the first portion of the inner ferrule such that the shield is positioned between and in contact with the inner and outer ferrules around substantially the entire circumference of the first portion of the inner ferrule.

40. The cable assembly according to claim 35, wherein: The integral sheet material includes a second portion; The second portion at least partially surrounds the cable at a position offset relative to the tail portion.

41. The cable assembly according to claim 40, wherein: The chamber of the conductive housing includes an inlet; The integral sheet includes a third portion covering the inlet.

42. The cable assembly according to claim 41, wherein: The conductive housing includes at least one protrusion that retains the third portion to the conductive housing.

43. The cable assembly according to claim 41, wherein: The third portion includes a planar portion and an embossed area offset relative to the planar portion.

44. The cable assembly according to claim 43, wherein: The mating portion of the contact is elongated in a first direction, and the tail portion extends in a second direction perpendicular to the first direction; the conductor of the cable including a distal portion extending in the second direction within the conductive housing; as well as The distal portion of the conductor is adjacent the embossed area of the third portion.

45. The cable assembly according to claim 44, wherein: an embossed area extending into the cavity of the conductive housing; and The inner ferrule is located outside the cavity of the conductive housing.

46. A housing subassembly for an electrical connector, comprising: an insulating housing (120) including a latch and a channel; as well as a connector position assurance device (CPA) (110) disposed within the passageway, in: The CPA includes: a compliant arm including a protrusion (112) extending therefrom, the protrusion including a cam surface; and distal portion; The insulating housing further includes a stop (729) disposed within the channel and configured to engage the cam surface of the protrusion to force the protrusion into a predetermined position; and The housing subassembly is configured such that a portion of the insulating housing blocks movement of the CPA within the channel beyond the predetermined position.

47. The housing subassembly of claim 46, wherein: The compliant arm is a first compliant arm; and The CPA also includes a second compliant arm parallel to the first compliant arm.

48. The housing subassembly of claim 47, wherein: The CPA further includes a first cross member connecting first ends of the first and second compliant arms and a second cross member connecting second ends of the first and second compliant arms opposite the first ends.

49. The housing subassembly of claim 46, wherein: The stopper is a first stopper, and the protrusion is a first protrusion; The CPA includes a second protrusion on the compliant arm; and The insulating housing includes a second stop disposed within the channel and configured to engage the second protrusion to block movement of the CPA within the channel in the first direction when the CPA is in an unlocked position in which the CPA is disengaged from the latch.

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