High-speed reinforced connector

Abstract

A modular connector that economically provides high signal integrity in harsh environments such as automobiles. The connector may include structures that provide precise and stable positioning of conductors such as contacts. These structures may include a contact carrier position assurance component (CCPA) that ensures that the contact carrier is latched and remains latched in a design position. The contact carrier position assurance member can slide to a closed position while locking the plurality of contact carriers into a design position. For a non-sealed connector, the CCPA may slide into the connector housing in a direction transverse to the direction in which the contact carrier is inserted into the housing. For a sealed connector, the CCPA may slide into a closed position in the same direction as the direction in which the contact carrier is inserted, thereby facilitating sealing 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) an insulating housing comprising a chamber and a channel; (ii) a position assurance component comprising an opening having a channel and a surface adjacent to the channel; and (iii) a contact carrier comprising a tab; wherein the position assurance component is slidably mounted in the insulating housing and is configured to slide between an open position and a closed position, wherein in the open position, the channel of the insulating housing, the channel of the position assurance component, and the tab on the contact carrier are aligned, and in the closed position, the surface of the position assurance component is aligned with the channel of the insulating housing.

[0008] On the other hand, an electrical connector may include: (i) an insulating housing including a chamber; (ii) a position assurance component including an opening and a surface; and (iii) a contact carrier having a tab (1611) and positioned within the chamber; wherein: the contact carrier extends through the opening of the position assurance component; and the position assurance component is positioned so that the surface interferes with the tab of the contact carrier to prevent the contact carrier from being withdrawn from the chamber of the insulating housing and the opening in the position assurance component.

[0009] In another aspect, an electrical connector subassembly may include (i) an insulating housing (1609) including a chamber (1622) having a channel (1628); (ii) a position assurance member (1630) including an opening (1631) having a channel (1626) and a surface adjacent to the channel; and wherein the position assurance member is slidably mounted in the insulating housing to slide between an open position and a closed position, wherein in the open position, the channel (1628) of the insulating housing (1609) and the channel (1626) of the position assurance member are aligned, and in the closed position, the surface of the position assurance member is aligned with the channel (1628) on the insulating housing (1609); and the position assurance member (1630) includes a latch configured to engage a complementary structure in the insulating housing when the position assurance member is in the open position.

[0010] On the other hand, a method of operating an electrical connector includes an insulating housing (1603) and a position assurance component (1650), the insulating housing including a chamber (1612) and a latch (1654) protruding into the chamber, the position assurance component including a body and a protruding member, the body having an opening (1652) passing therethrough, the method comprising: (i) sliding a contact carrier through the opening in the body of the position assurance component and into the chamber of the insulating housing until the tab of the contact carrier engages the latch of the housing; and (ii) sliding the position assurance component into the chamber until the protruding member is adjacent to the latch so that disengagement of the latch from the tab is limited by the protruding member.

[0011] In another aspect, an electrical connector may include: (i) an insulating housing (1603) including a chamber (1612) and a latch (1654) adjacent to the chamber; (ii) a position assurance component (1650) including a body having an opening (1652) therethrough, a protruding member, and a slot separating the protruding member from the body; and (iii) a contact carrier (1606) having a tab (1611) extending through the opening of the position assurance component and disposed within the chamber of the insulating housing; wherein the latch (1654) of the housing engages the tab (1611) of the contact carrier (1606) to maintain the contact carrier (1606) in position within the chamber, and the position assurance component (1650) is positioned such that the latch is disposed within the slot such that movement of the latch is restricted.

[0012] On the other hand, a method of operating an electrical connector comprises: an insulating housing (1603), the insulating housing (1603) including a chamber (1612) and a latch (1654) adjacent to the chamber; a position assurance component (1650), the position assurance component (1650) including a body, a protruding member, and a slot separating the protruding member from the body, the body having an opening (1652) passing therethrough; the method comprising: (i) sliding a contact carrier into the chamber of the insulating housing until a tab of the contact carrier engages the latch of the housing; and (ii) sliding the position assurance component into the insulating housing until the latch of the insulating housing is disposed in the slot of the position assurance component. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The drawings are not limited to the dimensions shown. For clarity, not every component is labeled in every view.

[0014] In the picture:

[0015] Figure 1 is a perspective view of an illustrative interconnect system in accordance with some embodiments.

[0016] Figure 2 yes Figure 1 1 is an exploded perspective view of an exemplary board connector 100.

[0017] Figure 3A yes Figure 1 sectional view of an exemplary board connector 100.

[0018] Figure 3B yes Figure 3A Rear view of an exemplary board connector.

[0019] Figure 4A is a perspective view of an exemplary multi-port board connector.

[0020] Figure 4B yes Figure 4A A cross-sectional view of an exemplary multi-port board connector.

[0021] Figure 5 yes Figure 1 A perspective view of a cable connector 200 is shown.

[0022] Figure 6 yes Figure 5 An exploded perspective view of an exemplary cable connector.

[0023] Figure 7 yes Figure 5 A cross-sectional view of an exemplary cable connector.

[0024] Figure 8is a perspective exploded view of an exemplary unsealed multi-port cable connector terminating a cable assembly.

[0025] Figure 9 is a perspective view of an exemplary contact carrier position assurance member 1630 .

[0026] Figure 10 is assembled into a housing subassembly for an electrical connector Figure 8 A perspective view of a housing component of an illustrative unsealed multi-port cable connector with a contact carrier position assurance component inserted and engaged in an open position and without a contact carrier inserted into a subassembly.

[0027] Figure 11 yes Figure 9 A perspective view of an exemplary contact carrier position assurance component is shown with an enlarged view of a latch shown in the callout.

[0028] Figure 12 yes Figure 10 0015] A side view of an illustrative electrical connector subassembly with an enlarged view of the latch engaged to the housing to hold the contact carrier position assurance component in an open position within the housing.

[0029] Figure 13 is a cross-sectional view of an exemplary electrical connector subassembly with the contact carrier position assurance component latched in an open position.

[0030] Figure 14 yes Figure 8 A perspective view of an illustrative unsealed multi-port cable connector with a contact carrier inserted into a housing such that the contact carrier position assurance member is in an open position.

[0031] Figure 15 is in Figure 14 A cross-sectional view of an exemplary non-sealed multi-port cable connector in the illustrated state.

[0032] Figure 16 yes Figure 8 A perspective view of an illustrative unsealed multi-port cable connector with the contact carrier position assurance member slid into a closed position.

[0033] Figure 17A yes Figure 9 A perspective view of an exemplary contact carrier position assurance member and a contact carrier, wherein the carrier position assurance member is in an open position.

[0034] Figure 17B yes Figure 9 A perspective view of an exemplary contact carrier position assurance member and a contact carrier, wherein the contact carrier position assurance member is in a closed position.

[0035] Figure 17C is a top cross-sectional view of an exemplary unsealed multi-port cable connector with a contact carrier and a contact carrier position assurance member inserted into a housing and in a closed position.

[0036] Figure 18 yes Figure 8 A cross-sectional view of an illustrative multi-port cable connector with a contact carrier and a contact carrier position assurance member inserted into a housing, with the contact carrier position assurance member in a closed position.

[0037] Figure 19 yes Figure 8 A side cross-sectional view of an illustrative multi-port cable connector showing the contact carrier being retained within the housing by the walls of the contact carrier position assurance component in the closed position blocking tabs on the contact carrier, wherein an enlarged view of the tabs is shown with callouts.

[0038] Figure 20 yes Figure 8 1 is a side view of an illustrative unsealed multi-port cable connector showing a contact carrier position assurance component latched in a closed position within a housing.

[0039] Figure 21 is a perspective exploded view of an exemplary sealed multi-port cable connector.

[0040] Figure 22 is assembled into the connector subassembly Figure 21 A cut-away perspective view of a housing component of an exemplary sealed multi-port cable connector.

[0041] Figure 23 yes Figure 21 A perspective view of two illustrative contact carrier position assurance components of an illustrative sealed multi-port cable connector, wherein a contact carrier is inserted into one of the contact carrier position assurance components.

[0042] Figure 24A yes Figure 21 A cross-sectional view of an illustrative sealed multi-port cable connector in which a contact carrier is retained within a housing by a primary latch, with an enlarged view of the latch shown with callouts.

[0043] Figure 24B yes Figure 21 sectional view of an illustrative sealed multi-port cable connector showing the contact carrier position assurance member slid into a position blocking the primary latch.

[0044] Figure 24C yes Figure 211. Rear perspective view of an illustrative sealed multi-port cable connector with a cover holding a contact carrier position assurance member in a position blocking a primary latch.

[0045] Figure 25 yes Figure 21 A cross-sectional view of an illustrative sealed multi-port cable connector showing a seal and a cover blocking a contact carrier position assurance component. DETAILED DESCRIPTION

[0046] 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.

[0047] The inventors have recognized and appreciated various techniques that can be applied to components of a connector system 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.

[0048] For example, a connector configuration can be formed by an insulating outer housing that establishes at least a mating interface of the connector. The insulating outer housing can provide a latching feature. The set of components can include insulating outer housings 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.

[0049] The 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. A contact carrier position assurance component 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 dislodge the contact carriers from their intended positions. 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.

[0050] The contact carrier position assurance component may have a design that facilitates simple and reliable manufacture of the connector by engaging with the plurality of contact carriers when in the open position. Moving the position assurance component to the closed position may lock those plurality of contact carriers in place.

[0051] For example, the connector may include a position assurance component comprising an opening, a channel, and a surface adjacent to the channel. Each connector may also include a contact carrier having a tab. The position assurance component may be slidably mounted in the insulating housing and configured to slide between (i) an open position and (ii) a closed position, wherein the channel of the insulating housing, the channel of the position assurance component, and the tab on the contact carrier are aligned, and in the closed position, the surface of the position assurance component is aligned with the channel of the insulating housing.

[0052] The position assurance component may further have a wall defining its channel, wherein the surface comprises a side of the wall such that when the position assurance component is in the closed position, the surface interferes with withdrawing the tab of the contact carrier through the channel.

[0053] Alternatively or additionally, the electrical conductor may include an insulating housing including a cavity, a position assurance component including an opening and a surface, and a contact carrier having a tab and positioned within the cavity. The contact carrier may extend through the opening of the position assurance component, and the position assurance component may be positioned such that its surface interferes with the tab of the contact carrier to prevent the contact carrier from being withdrawn from the cavity of the insulating housing and the opening of the position assurance component.

[0054] The position assurance component may further include a protrusion, and the insulating housing may further include a first recess, such that the protrusion of the position assurance component is seated within the first recess of the insulating housing to maintain the position assurance component in a first position within the insulating housing. The insulating housing may further include a second recess, wherein the protrusion of the position assurance component is seated within the second recess of the insulating housing to maintain the position assurance component in a second position within the insulating housing. For example, the first position may correspond to an open position, and the second position may correspond to a closed position.

[0055] The use of the technology described herein can be facilitated by providing a housing subassembly for an electrical connector. For example, the subassembly can include an insulating housing in which a contact carrier position assurance component is retained in the housing. For example, the contact carrier position assurance component can be latched in an open position. Such a subassembly can include an insulating housing and a position assurance component, the insulating housing including a chamber and a channel, the position assurance component including an opening, a channel, and a surface adjacent to the channel, wherein the position assurance component is slidably mounted in the insulating housing to slide between (i) an open position and (ii) a closed position, in which the channel of the insulating housing and the channel of the position assurance component are aligned, in the closed position, the surface of the position assurance component is aligned with the channel of the insulating housing, and the position assurance component includes a latch configured to engage a complementary structure in the insulating housing when the position assurance component is in the open position.

[0056] Alternatively or additionally, the contact carrier can latch the housing, and the position assurance component can slide over one or more contact carriers into a closed position in which the latch is restricted from unlocking. For example, an electrical connector can include: (i) an insulating housing including a chamber and a latch adjacent to the chamber; (ii) a position assurance component including a body, a protruding member, and a notch separating the protruding member from the body, the body having an opening therethrough; and (iii) a contact carrier having a tab extending through the opening of the position assurance component, the contact carrier being disposed within the chamber of the insulating housing, wherein the housing latch engages the tab of the contact carrier to maintain the contact carrier in position within the chamber, and the position assurance component is positioned such that the latch is disposed within the notch, thereby restricting movement of the latch. Alternatively or additionally, sliding the position assurance component into the insulating housing can position the protruding member of the position assurance component to block movement of the insulating housing latch from unlocking the tab.

[0057] These techniques can be used individually or in combination. These techniques are described below in conjunction with an interconnect system that can be used, for example, to establish physical connections between components in an automobile.

[0058] Figure 1 1 is a perspective view of an exemplary interconnect system according to some embodiments. 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 in vehicles). In this example, the interconnect system includes a board connector 100 and a cable connector 200.

[0059] Figure 2 According to some embodiments Figure 1FIG2 is an exploded perspective view of an exemplary board connector 100 when not mated to a cable connector 200. The board connector 100 includes an opening 158 of the housing 150, which can be arranged to allow a mating contact to pass therethrough. The mating interface of the board connector 100 can be disposed within the opening 158.

[0060] The board connector 100 further includes a conductive housing 140. For example, the conductive housing 140 can be a die-cast component. In this example, the conductive housing has a mating portion 146 that extends into the opening 158 when the insulating housing 150 is attached to the conductive housing 140.

[0061] Conductive housing 140 may include a chamber into which a terminal assembly is inserted. In this example, the terminal assembly may be formed by an insulator 120 and one or more electrical conductors held by the insulator 120. As shown, board connector 100 includes electrical conductors that can be used as signal conductors. In this example, a pair of electrical conductors is shown so that the terminal assembly shown is configured to transmit differential signals. In addition to transmitting one or more signals through the connector, the electrical conductor may 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. Therefore, the electrical conductor may be used as a contact for the connector.

[0062] exist Figure 2 In the example of , the mating contact portions of the electrical conductors are shaped as pins, so that the board connector 100 is configured as a plug. In other embodiments, the mating contact portions of the electrical conductors in the plug connector can be shaped as blades or have other shapes. Alternatively or additionally, in some embodiments, the board connector can have electrical conductors that have mating contact portions that are shaped as sockets. Figure 2 In an example, the tail of the electrical conductor is formed into a post. For example, the post can be mounted to a printed circuit board using plated through hole or pin-in-solder paste soldering techniques.

[0063] Figure 2 A plurality of mating contacts are shown, including contacts 110A and 110B (also referred to herein as "terminals"). The mating contact portions of the terminals extend into openings 158. The tails of the contacts 110A and 110B extend from the mounting interface of the board connector 100 for mounting to a printed circuit board 160. The contacts 110A and 110B can be electrically connected to holes 162 and 163 on the board 160. In some examples, the board 160 can be a printed circuit board (PCB).

[0064] The opening 158 may be shaped and sized to receive a mating connector therein. The mating connector may include mating contacts configured to electrically connect to the contacts 110A and 110B when the interconnect system is in the mated configuration.

[0065] One or more mating contacts can be held within the insulator 120 to form a terminal assembly. The insulator can be shaped and sized to receive the mating contacts. For example, the contacts 110A and 110B can pass through openings in the insulator 120. The insulator 120 can be inserted into a cavity within the conductive housing 140. In this manner, the conductive housing partially surrounds the terminal assembly and the electrical conductors therein.

[0066] The conductive housing 140 may also include an attachment post 140 configured to electrically and mechanically connect the conductive housing 140 to the board 160. For example, the attachment post may extend into a hole 161, which may be a ground via. By grounding the conductive housing 140, the conductive housing 140 may serve as a shield for the terminal assembly and a pair of conductors in the terminal assembly.

[0067] The board connector 100 may include one or more additional shielding members, shown as shields 130. Shields 130 are also inserted into the cavity of the conductive housing 140 to further surround the terminal assembly. Shields 130 are electrically and mechanically coupled to the conductive housing 140 so that shields 130 can also be grounded. The combination of shields 130 and the spacers on the insulator 120 can also be used to position the terminal assembly within the cavity, and in this way, signal-to-ground separation can be established for the electrical conductors within the terminal assembly. This configuration can provide a desired and stable impedance.

[0068] Figure 3A yes Figure 1 and Figure 2 The exemplary board connector 100 is along Figure 2 3A-3A in FIG. As described herein, the board connector 100 includes an insulator 120. The insulator may include ribs 121. The ribs 121 may serve as spacers to position the terminal assembly relative to the shield 130. The size and arrangement of the spacers may be designed to establish a desired spacing between the shield 130 and the terminals 110A and 110B. The appropriate size and shape of the spacers may be determined based on the desired impedance. The shield 130 may contact one side of the ribs 121.

[0069] As described herein, the insulator 120 and the shield 130 can be engaged in a conductive housing 140. The conductive housing 140 can include retention features 141 for preventing movement of the insulator 120 and absorbing force. The retention features 141 can be ribs configured to contact the wall of the insulator 120. The conductive housing 140 can also include recesses 152. The housing 150 can include retention features 151 configured to engage corresponding recesses 152 of the conductive housing 140.

[0070] Figure 3B According to some embodiments Figure 3A 1. The conductive housing 140 may also include retention features 142 and 143 for retaining the shield 130.

[0071] Each of the contacts 110A and 110B may include one or more retention features configured to prevent the contact from moving within the insulator 120 of the connector 100. For example, the contact 110A may include a barb configured to provide retention within the insulator. For example, the insulator 120 may include a channel that receives each of the contacts 110A and 110B. The barbs penetrate the insulator at the sides of the channel to securely hold the contacts. The channel is narrower near the barb and wider away from the barb.

[0072] In some embodiments, the width of the barbs and / or channels can significantly affect the impedance along the contact 110A or 110B. Therefore, the contact can be provided with an impedance compensating portion adjacent to the retention feature. In this example, the impedance compensating portion is formed by the narrowed portion 111.

[0073] In the illustrated embodiment, the contacts 110A and 110B have the same shape. Therefore, the contacts 110A and 110B can have the same retention features and the same impedance compensation portion. It should also be understood that more than one retention feature can exist along the length of the contact 110A. Each retention feature and the impedance compensation portion adjacent to the retention feature can be shaped similarly. However, in some embodiments, the retention features along the length of the contact can have different sizes or different shapes.

[0074] Figure 4A is a perspective view of an exemplary multi-port board connector 400 according to some embodiments. For example, Figure 4A A 2×2 connector 400 is shown that includes four ports arranged in two rows of two ports each. A conductive housing is shown having ports 470A-D, each of which is shaped and sized to receive a mating component therein. Each of the ports can have the same configuration as the mating portion 146 of the board connector 100, so that the same mating components can mate with either connector. As with the board connector 100, the conductive housing 440 is configured for mounting to a board 460. Attached to the conductive housing 440 is an insulating housing 450 that provides the same function as the insulating housing 150 for the larger connector.

[0075] Figure 4B shows a method according to some embodiments of the present invention along Figure 4A A portion of the cross-sectional view of line 4B-4B. Figure 4BIn the example shown, the contacts in two of the ports are visible. Like connector 100, connector 400 has a pair of contacts in each port. In this example, the contacts in each port are held in a separate insulator, thereby forming a terminal assembly for each port. The insulator can have the same function as the connector 100 described above. For example, mating contact 410A is disposed in insulator 420A including ribs 421A. Mating contact 410B is disposed in insulator 420B including ribs 421B. Ribs 421A and 421B each position their corresponding terminal assembly relative to corresponding shields 430A and 430B. Each of the shields and insulators is engaged in a conductive housing 440, which is further disposed in an insulating housing 450.

[0076] Figure 5 is a perspective view of a cable connector 200 according to some embodiments. The cable connector 200 can have components similar to those described above for the board connector 100, including an outer insulating shell, an inner conductive shell serving as a shield, and a terminal assembly within a chamber within the shield. However, the outer insulating shell can have a mating interface and latching features that are complementary to the mating interface and latching features on the board connector 100, so that the cable connector 200 can mate with the board connector 100. Similarly, the inner conductive shell can have a mating portion configured to mate with the mating portion 146. In addition, the terminal assembly and other components can be configured for terminating cables rather than for mounting on a printed circuit board. For example, the contacts can be electrically coupled to one or more conductors of the cable.

[0077] Figure 6 FIG is an exploded perspective view of an exemplary cable connector 200 according to some embodiments. Figure 5 and Figure 6 As shown, the exemplary cable connector 200 is configured for terminating a cable 210. The cable connector 200 includes a mating end 520 and a cable terminating end 522 opposite the mating end. The cavity is open at the mating end 520. The connector terminates the cable at the cable terminating end 522, where the cable has been manipulated to facilitate termination.

[0078] The majority of the cable 210 may include one or more insulated conductors. In the example provided, the cable includes a pair of insulated conductors surrounded by a cable shield, which is then covered by an insulating jacket. For example, the cable shield may be a braided shield or a conductive foil. For termination, the jacket may be removed, exposing the cable shield. The insulated conductors may be separated, and at the distal end, the insulation may be removed. For cables in which the insulated conductors are twisted together in the majority of the cable, separating the insulated conductors may also involve untwisting the conductors. This manipulation of the cable enables the conductors of the insulated conductors to be attached to the terminals of the connector. The cable shield may also be attached to the connector shield.

[0079] The cable connector 200 also includes a ferrule 220 and an impedance adapter 230 that can be configured to surround the cable 210. According to some embodiments, the impedance adapter can be metal. The terminal 240 can be crimped to the conductor of the cable. The terminal can be part of a terminal assembly having an insulator, which is shown as a contact carrier housing 250. The conductive inner housing of the cable connector can be formed by a rear shield 260 and a front shield 270, which can be electrically coupled and mechanically connected. The front shield 270 can include a mating interface, and the rear shield 260 can be crimped to the cable and can be electrically coupled to the cable shield. These components can be at least partially enclosed in a cable connector housing 290.

[0080] Figure 6 The components 220, 230, 240, 250, 260 and 270 shown for terminating a cable provide contact carriers. In this example, the contact carriers are shielded. A contact carrier position assurance component (CCPA) 280 may be used to secure the position of the contact carrier within the housing.

[0081] Figure 7 According to some embodiments Figure 6FIG2 is a cross-sectional view of an exemplary cable connector. An impedance adapter 230 is located in a separation and / or untwisting area 231 of the cable termination. The area 231 where the cable has been manipulated provides space for the crimping process of crimping the contacts to the conductors of the cable. However, this manipulation of the cable changes the impedance of the conductors. Metal is positioned adjacent the cable to provide a compensating change in impedance in the opposite direction. The impedance adapter brings the metal closer to the cable core. In the embodiment shown, the impedance adapter will also contact a rear shield that connects the impedance adapter to ground, thereby establishing signal-to-ground spacing for the conductors of the cable, which in turn establishes the desired impedance to match the impedance of the bulk cable. As used herein, impedances do not have to be identical to be matched. Rather, the impedances can be close enough so as not to provide an impedance discontinuity that disrupts performance. For example, in some embodiments, the matched impedance can be within + / - 5% or within + / - 3 ohms.

[0082] To terminate the cable 210, the cable end can be prepared for termination and inserted through the ferrule 220 and the impedance adapter 230. The cable shield can be folded over the ferrule 220, and the conductor of the cable 210 can be crimped to the terminal 240. The terminal 240 can then be inserted into the contact carrier housing 250. The rear shield 260 can then be crimped around the ferrule 220. The front shield 270 can then be joined to the rear shield 260 and locked in place. These components can form a terminated cable assembly that is inserted into the housing 290. The housing 290 can include an opening 292 to receive the terminated cable assembly.

[0083] The terminated cable assembly can be latched to the housing 290, for example, by latching a beam in the housing to a tab extending from one of the connector shields. For example, the housing 290 can include a beam 294 including a cantilevered end 291 and a latch 293 extending into an opening 292 at the cantilevered end 291. The latch 293 can have a cam surface 295, and the tab of the terminated cable assembly can have a tapered front edge. When the terminated cable assembly is inserted into the housing 290, the tapered surface of the tab can engage the cam surface of the latch 293, thereby forcing the latch 293 upward until the rear edge of the tab passes over the cam surface. In this position, the spring force in the deflecting beam 294 will push the beam downward, thereby latching the tab in place.

[0084] Figure 7 A connector having one contact carrier held in an insulating housing is shown. Such a connector may be configured to mate with a single port board connector, such as Figure 1 The plug connector may be configured to mate with a multi-port connector by incorporating a plurality of contact carriers within an insulating housing, such as Figure 4AAs shown.

[0085] Figure 8 is a perspective exploded view of an exemplary non-sealed multi-port cable connector, which is configured as a plug and can be used with Figure 4A The board connector shown or other connectors having a similar mating interface may be mated. Figure 8 The exemplary non-sealed cable connector 1620 shown includes an insulating housing 1609 including four chambers 1622 arranged in a 2×2 matrix, each chamber receiving a contact carrier 806. Each contact carrier 806 may have a plurality of contact carriers 806 as described above. Figure 6 Describes the configuration.

[0086] The unsealed contact carrier connector 1620 may also include a contact carrier position assurance feature 1630. In this example, the contact carrier position assurance feature 1630 enables simple and reliable assembly of the cable connector with multiple contact carriers. For example, the contact carrier position assurance feature 1630 may be latched to the insulating housing 1609 in an open position, in which multiple contact carriers may be inserted into the housing 1609. If the contact carriers are properly seated in the insulating housing 1609, the contact carrier position assurance feature 1630 may be slid to a closed position by applying a force that overcomes the latch. When the contact carrier position assurance feature 1630 reaches the closed position, a latching feature on the contact carrier position assurance feature 1630 may snap into place, providing audible and / or tactile feedback to the user that the contact carriers are properly seated in the insulating housing 1609. Conversely, if one or more of the contact carriers are not properly positioned, the contact carrier position assurance feature 1630 may not slide or may require a significant force above a threshold that the user would notice. In this way, a user (who may be a person or an assembly machine) can quickly secure a plurality of contact carriers within a housing, or determine that one or more contact carriers are not properly seated.

[0087] Figure 9 is a perspective view of an exemplary contact carrier position assurance member 1630. In this example, the contact carrier position assurance member 1630 is configured to simultaneously secure four contact carriers. Figure 9 The contact carrier position assurance member 1630 may include four openings 1631 arranged in a 2×2 matrix, each opening receiving a contact carrier 806 when the contact carrier position assurance member 1630 is inserted into the insulating housing 1609 .

[0088] Figure 10 yes Figure 816. A perspective view of the housing subassembly of an exemplary non-sealed multi-port cable connector 1620 is shown. In this state, the contact carrier position assurance member 1630 is inserted into the insulating housing 1609. Either or both of the insulating housing 1609 and the contact carrier position assurance member 1630 may include one or more latching features and / or one or more complementary latching features such that the contact carrier position assurance member 1630 may be latched relative to the housing.

[0089] In some examples, the contact carrier position assurance member 1630 can include a latching feature, and the dielectric housing 1609 can have two complementary latching features such that the contact carrier position assurance member 1630 can be latched in two positions relative to the dielectric housing 1609 . Figure 10 The contact carrier position assurance member 1630 is shown latched in a first such position. In the illustrated state, the contact carrier position assurance member 1630 is in an open state such that a contact carrier can be inserted into the cavity 1622 through the opening 1631 .

[0090] One or more additional components may optionally be integrated into the connector housing subassembly. For example, a connector position assurance component 1610 may be attached to housing 1609.

[0091] Figure 11 yes Figure 9 A perspective view of an exemplary contact carrier position assurance component 1630 showing a latch 1632 configured to engage with a complementary latch feature of the insulating housing 1609 when the position assurance component 1630 is at one or more predetermined positions within the insulating housing 1609. Figure 9 The contact carrier position assurance component 1630 may include a body 1663. The latch 1632 of the contact carrier position assurance component 1630 may include a member 1665 separated from the body 1663 by a slit 1633. The latch 1632 of the contact carrier position assurance component 1630 may also include a protrusion 1635 on the member 1665. The member 1665 may be elongated in a direction between a first end and a second end, and the member 1665 may be attached to the body 1663 at the first and second ends. The member 1665 may include a central portion between the first and second ends, and the protrusion 1635 may extend from the central portion. The contact carrier position assurance component 1630 may be molded from plastic so that the member 1665 is integral with the body 1663.

[0092] Member 1665 can be compliant. When protrusion 1635 is pressed against the surface of housing 1609, the central portion of member 1665 can be pushed into notch 1663, so that protrusion 1635 does not interfere with the sliding movement of contact carrier position assurance member 1630 relative to the housing. However, when protrusion 1635 aligns with a rut in the surface of the housing, member 1665 can be ejected away from body 1663, thereby forcing protrusion 1635 into the rut. This action can provide tactile and / or audible feedback to the user, indicating that contact carrier position assurance member 1630 is in the position established by the relative positions of the protrusion and rut. Furthermore, the engagement of protrusion 1635 and rut can limit the movement of contact carrier position assurance member 1630 relative to housing 1609 until sufficient force is applied to contact carrier position assurance member 1630 to overcome the restriction by forcing member 1665 to deflect into notch 1633.

[0093] Figure 12 yes Figure 8 FIG1 is a side view of an exemplary unsealed multi-port cable connector showing the contact carrier position assurance member 1630 in an open position within the insulating housing 1609. A complementary latching feature of the insulating housing 1609 includes a first recess 1625 configured to engage a protrusion 1635 on a member 1665 of the contact carrier position assurance member 1630 to retain the contact carrier position assurance member 1630 in the open position within the insulating housing 1609.

[0094] like Figure 12 As shown, the dielectric housing 1609 may further include a second recess 1627 configured to engage a protrusion 1635 on a member 1665 of the contact carrier position assurance component 1630 to retain the contact carrier position assurance component 1630 in a closed position within the dielectric housing 1609 .

[0095] Figure 13 1 is a cross-sectional view of an exemplary housing subassembly. In the illustrated state, the contact carrier position assurance member 1630 is latched in the open position. Figure 13 As shown, the contact carrier position assurance component 1630 may include one or more openings 1631. In this example, the contact carrier position assurance component 1630 has four openings 1631 arranged in a 2×2 matrix. Figure 13 As shown, the insulating housing 1609 may include one or more chambers 1622. An opening 1631 of the contact carrier position assurance member 1630 may be aligned with each of the chambers 1622. In this example, the four chambers 1622 of the insulating housing 1609 are arranged in a 2×2 matrix. Alternatively, the four chambers 1622 of the insulating housing 1609 correspond to four corresponding openings 1631 of the contact carrier position assurance member 1630.

[0096] The contact carrier position assurance member 1630 and the housing 1609 can be collectively configured such that when the contact carrier position assurance member 1630 is in the open position, the contact carrier can be inserted into the chamber 1622 through the opening 1631, but when the contact carrier position assurance member 1630 is slid to the closed position, the contact carrier cannot be withdrawn. In the example shown, the contact carrier can have a protruding feature that can pass through a channel in the contact carrier position assurance member 1630 when the contact carrier position assurance member 1630 is in the open position, but is blocked from withdrawal from the opening when the contact carrier position assurance member 1630 is slid to the closed position.

[0097] like Figure 13 As shown, the contact carrier position assurance member has a channel 1626 and a wall 1634 defining the channel 1626. Optionally, the dielectric housing 1609 includes a channel 1628. When the contact carrier position assurance member 1630 is in the open position, the channel 1628 of the dielectric housing 1609 can be aligned with the channel 1626 of the contact carrier position assurance member 1630. In this state, the contact carrier 1606 and its tab 1611 can slide through the opening 1631 of the contact carrier position assurance member 1630 and into the cavity 1622 of the dielectric housing 1609, as explained in detail below.

[0098] Figure 14 yes Figure 8 A perspective view of an exemplary non-sealed multi-port cable connector with contact carrier 1606 and contact carrier position assurance member 1630 inserted into the connector. Figure 10 Inside the housing subassembly. Figure 14 , the contact carrier position assurance member 1630 is in the open position. In this example, it can be seen that the outer surface of the contact carrier position assurance member 1630 extends beyond the surface of the housing 1609.

[0099] Figure 15 yes Figure 14 A cross-sectional view of an exemplary non-sealed multi-port cable connector. Figure 15 The contact carrier position assurance member 1630 is shown inserted into the dielectric housing 1609 such that the opening 1631 of the contact carrier position assurance member 1630 is aligned with the cavity 1622 of the dielectric housing 1609 . Figure 15Also shown is contact carrier 1606 inserted into cavity 1622 of dielectric housing 1609 through opening 1631 of contact carrier position assurance member 1630. Tabs 1611 on contact carrier 1606, channels 1628 on dielectric housing 1609, and channels 1626 on contact carrier position assurance member 1630 are aligned, allowing tabs 1611 on contact carrier 1606 to pass through channels 1628 on dielectric housing 1609 and channels 1626 of contact carrier position assurance member 1630. In this position, contact carrier 1606 can be inserted into cavity 1622 of dielectric housing 1609 through opening 1631 of contact carrier position assurance member 1630. As shown, when the contact carrier is inserted far enough into the cavity to be in its designed position, the rear edge of tab 1611 extends beyond the forward-facing surface of wall 1634.

[0100] Figure 16 yes Figure 14 16. A perspective view of an exemplary non-sealed multi-port cable connector is shown, which shows the contact carrier 1606 inserted into the corresponding cavity 1622 of the insulating housing 1609 and the contact carrier position assurance member 1630 slid into the closed position within the insulating housing 1609. In this example, it can be seen that Figure 14 The outer surface of the contact carrier position assurance component 1630 is substantially flush with the surface of the housing 1609 .

[0101] Figure 17A yes Figure 9 FIG1 is a rear view of an exemplary contact carrier position assurance member 1630 and a contact carrier 1606 in an open position in an electrical connector 1620. Arrow 1700 indicates the sliding direction of the contact carrier position assurance member 1630 from the open position to the closed position. In this example, the sliding direction 1700 is orthogonal to the insertion direction of the contact carrier into the housing 1609. Figure 17B yes Figure 17B FIG. 1 is a rear view of an illustrative contact carrier position assurance member 1630 and contact carrier 1606 , wherein the contact carrier position assurance member 1630 is slid into a closed position in the electrical connector 1620 .

[0102] In this example, the opening 1631 is wider in the sliding direction than the portion of the contact carrier 1606 within the opening 1631. This additional width enables the contact carrier position assurance member 1630 to slide within the housing 1609 with the contact carrier inserted into the opening 1631.

[0103] exist Figure 17A In the state shown, the tab 1611 (see Figure 15) extends beyond the wall 1634 but is aligned with the channel 1626. The contact carrier position securing member 1630 is slid into Figure 17B In the closed position shown, the tab 1611 is aligned with the forward-facing surface of the wall 1634 such that the wall 1634 blocks withdrawal of the contact carrier from the cavity 1622 .

[0104] Figure 17C 16 is a top cross-sectional view of an exemplary unsealed multi-port cable connector, wherein the contact carrier 1606 and the contact carrier position assurance member 1630 are inserted into the insulating housing 1609 of the electrical connector 1620 . Figure 17A 、 Figure 17B and Figure 17C A method of operating an electrical connector is shown during which the contact carrier 1606 enters the insulating housing 1609 of the electrical connector 1620 through an opening of a contact carrier position assurance member 1630, wherein the contact carrier position assurance member 1630 is initially in an open position and subsequently in a closed position.

[0105] In an exemplary method, the contact carrier position assurance member 1630 is positioned in an open position at least partially within the insulating housing 1609, such that the cavity 1622 of the insulating housing 1609 is aligned with the corresponding opening 1631 of the contact carrier position assurance member 1630. In this open position, the channel 1628 of the insulating housing 1609 is also aligned with the channel 1626 of the contact carrier position assurance member 1630. The contact carrier 1606 is inserted into the cavity 1622 of the insulating housing 1609 through the opening 1631 of the contact carrier position assurance member 1630 by aligning the tab 1611 of the contact carrier 1606 with the channel 1628 of the insulating housing 1609 and the channel 1626 of the contact carrier position assurance member 1630. Next, the contact carrier position assurance member 1630 is slid relative to the insulating housing 1609, such that the channel 1628 of the insulating housing 1609 is blocked by the contact carrier position assurance member.

[0106] Alternatively, the contact carrier position assurance member 1630 can be pushed to slide relative to the insulating housing 1609 until the protrusion 1635 of the contact carrier position assurance member 1630 engages with the first recess 1625 of the insulating housing 1609, thereby securing and maintaining the contact carrier position assurance member 1630 in the open position. The housing and the contact carrier position assurance member 1630 in this state can form a housing subassembly. After the contact carrier 1606 is inserted into the cavity 1622 of the insulating housing 1609 through the opening 1631 of the contact carrier position assurance member 1630 (e.g., as described above, by aligning the tab 1611 of the contact carrier 1606 with the channel 1628 of the insulating housing 1609 and the channel 1626 of the contact carrier position assurance member 1630), the contact carrier position assurance member 1630 can be further slid relative to the insulating housing 1609 by further pushing the contact carrier position assurance member 1630 until the protrusion 1635 of the contact carrier position assurance member 1630 engages the second recess 1627 of the insulating housing 1609. In this second position, the contact carrier position assurance member can be in a closed position within the insulating housing 1609.

[0107] If the contact carrier is fully inserted into the insulating housing, tab 1611 will be in front of wall 1634, and the contact carrier position assurance component 1630 can slide relatively easily from the open position to the closed position. A first force above a first threshold may be required to overcome the retention of the latch of the contact carrier position assurance component 1630 within the first recess. However, if the contact carrier is not positioned in the designed position, this first force may be less than a second force required to move the contact carrier position assurance component 1630 to the closed position. If the contact carrier is not fully inserted, tab 1611 may interfere with wall 1634, thereby blocking the contact carrier position assurance component 1630 from easily sliding to the closed position. In some scenarios, the amount of force required to slide the contact carrier position assurance component 1630 may exceed the force that a person can easily generate, or may be so high that a user can recognize that one or more contact carriers are incorrectly positioned.

[0108] Figure 18 yes Figure 14 FIG10 is a front cross-sectional view of an exemplary multi-port cable connector 1620, wherein the contact carrier 1606 is in its designed position and the contact carrier position assurance member 1630 is secured in the closed position. In the closed position, the rear edge of the tab 1611 of the contact carrier 1606 faces the surface of the wall 1634 of the contact carrier position assurance member 1630, such that the surface interferes with withdrawing the tab 1611 of the contact carrier 1606 through the passageway of the insulating housing 1609.

[0109] Figure 19 yes Figure 16 16 is a cross-sectional view of an exemplary multi-port cable connector 1620 showing that the contact carrier 1606 is positioned within the insulating housing 1609 by the tabs 1611 on the contact carrier 1606 when the contact carrier position assurance member 1630 is in the closed position. Figure 19 It is also shown that the surface of the wall 1634 of the contact carrier position assurance member 1630 blocks withdrawal of the tab 1611 of the contact carrier 1606 through the passageway of the dielectric housing 1609 .

[0110] Figure 20 yes Figure 16 FIG1 is a side view of an exemplary unsealed multi-port cable connector 1620 showing the contact carrier position assurance member 1630 in a closed position within the insulating housing 1609. The protrusion 1635 on the member 1665 of the body 1663 of the contact carrier position assurance member 1630 is engaged with the second recess 1627 of the insulating housing 1609 to secure the contact carrier position assurance member 1640 in a final position within the insulating housing 1609.

[0111] In other embodiments, the contact carrier position assurance member can slide from an open position to a closed position in a direction parallel to the direction of insertion of the contact carrier into the connector housing. This configuration can enable one or more seals to be integrated into the connector. Furthermore, the sliding direction parallel to the insertion direction of the contact carrier can enable the contact carrier position assurance member to be inserted into the connector housing through the same opening in the connector housing as the contact carrier, thereby reducing the number of openings that must be sealed to provide a sealed connector.

[0112] Figure 21 16 is a perspective exploded view of an exemplary sealed multi-port cable connector 1600. In this example, the cable connector is assembled from one or more contact carriers 1606, as described above. The mating interface of the sealed connector can be the same as that of the unsealed cable connector, and can be, for example, Figure 16 shown.

[0113] Figure 21 The illustrated exemplary sealed cable connector 1600 includes a two-piece insulative housing comprising a main housing 1603 and a front housing 2103. This configuration facilitates mounting an annular seal 2110 around a mating interface within the main housing 1603. The annular seal 2110 can be positioned to engage with a mating connector and seal the interface between the cable connector and the mating connector.

[0114] The insulating housing in this example includes four chambers 1612 arranged in a 2×2 matrix, each chamber receiving a contact carrier 1606. The sealed contact carrier connector 1600 may also include one or more contact carrier position assurance components. In this example, two contact carrier position assurance components 1650A and 1650B may together form the contact carrier position assurance component 1650. Forming the contact carrier position assurance component 1650 as multiple pieces allows for the reinforcement of the walls or ribs between the individual components within the connector housing. Furthermore, forming each piece of the contact carrier position assurance component 1650 with multiple openings simplifies assembly and facilitates proper positioning of each piece within the connector housing. Thus, having one piece for each row or column of contact carriers in the connector provides enhanced manufacturability and robustness of the finished connector. In this example, the contact carrier position assurance component is formed in two pieces, one for each column in the 2×2 connector. This configuration can facilitate modularity in the connector system, as the same contact carrier position assurance component can be used to construct a 1×2 connector as the 2×2 connector. Similarly, the same components can be used for connectors of other sizes, such as a 4x4 connector.

[0115] exist Figure 21 In the example of FIG, when assembling the cable connector, the contact carrier position assurance member 1650 can be inserted into the housing 1603. Alternatively, the insulating housing 1603 can be preassembled into a housing subassembly, wherein the contact carrier position assurance member 1650 is inserted into the insulating housing 1609. In this configuration, the contact carrier position assurance member 1650 can be latched to the insulating housing 1603, for example, by using a latching feature and a complementary latching feature, as described above.

[0116] The exemplary sealed contact carrier connector 1600 may also include a cable seal 1607 having one or more openings 1609. The openings 1609 of the seal 1607 may be aligned with the cavity 1612 of the insulating housing 1603. The exemplary sealed contact carrier connector 1600 may also include a cover 1608. When the cover 1608 is installed, the cover 1608 may engage with the main housing 1603, for example, via a latch or other engagement feature. The cover 1608 may cover the cable seal 1607 and may retain the cable seal 1607 within the main housing 1603 and / or protect the cable seal 1607 from physical damage, etc. Optionally, the cover 1608 may be configured to press the seal 1607 against the contact carrier position assurance member 1650. In some embodiments, when the contact carrier is positioned in the designed position within the connector housing, the cover 1608 may be pressed against the housing with a force below a threshold. Conversely, if the contact carrier is not positioned in the designed position, the contact carrier position assurance component 1650 may not slide easily to its closed position and a greater force above the second threshold may be required to press the cover 1608 into place, thereby providing feedback to the installer (whether human or machine) that the component within the connector housing is not positioned in its designed position.

[0117] The exemplary sealed cable connector 1600 may also include a connector position assurance feature 1604 .

[0118] Figure 21 The exemplary contact carrier position assurance member 1650 has four openings 1652 arranged in a 2×2 matrix, each of which receives a contact carrier 1606 when the contact carrier position assurance member 1650 is inserted into the insulating housing 1603 .

[0119] Figure 22 yes Figure 21 FIG. 1 is a cross-sectional view of a portion of an exemplary unsealed multi-port contact carrier connector 1600 illustrating an insulative housing 1603 . The insulative housing may also include a latch 1654 adjacent each cavity 1612 .

[0120] Figure 23 It is shown by a dotted line Figure 21 16 is a perspective view of an exemplary sealed multi-port cable connector 1600, wherein the contact carrier 1606 is inserted into the insulating housing 1603. The contact carrier position assurance component 1650 may include a body having one or more openings therethrough, and a protruding member 2310 adjacent to each opening. Optionally, the contact carrier position assurance component 1650 may have a notch 2410 ( Figure 24B ). Figure 23The relative positions of the contact carrier position assurance member 1650 and the contact carrier 1606 are shown, wherein the contact carrier position assurance member 1650 is in an open position.

[0121] Figure 24A yes Figure 21 FIG1 is a cross-sectional view of an exemplary sealed multi-port cable connector 1600 showing the contact carrier 1606 positioned within the insulating housing 1603 by the primary latch 1654. In the illustrated state, the primary latch 1654 of the insulating housing 1603 engages the tab 1611 of the contact carrier 1606 to retain the contact carrier 1606 in position within the cavity 1612 of the insulating housing 1603. In the illustrated example, the latch 1654 includes a flexible beam having a hooked end that engages the rearward-facing edge of the tab 1611. When the latch 1654 is engaged with the tab 1611, the latch 1654 blocks movement of the tab 1611 in a direction that would withdraw the contact carrier from the housing.

[0122] exist Figure 24A In the state shown, the contact carrier position assurance member 1650 is in the open position and Figure 24A Optionally, the contact carrier position assurance member 1650 is slidably mounted with the insulating housing 1603 so that the contact carrier position assurance member 1650 can slide to a closed position. For example, installing the cover 11608 can apply a force to the contact carrier position assurance member 1650, forcing it to slide to the position shown.

[0123] Figure 24B yes Figure 21 FIG2 is a cross-sectional view of an exemplary sealed multi-port cable connector 1600 showing the contact carrier position assurance member 1650 in a closed position. In this position, the protrusion 2310 blocks the primary latch 1654. Optionally, the contact carrier position assurance member 1650 may include a notch 2410 such that the primary latch 1654 is disposed within the notch 2410 of the contact carrier position assurance member 1650 to limit movement of the primary latch 1654 when the contact carrier position assurance member 1650 is in the closed position. The primary latch 1654 is restrained in a position in which it engages the tab 1611. As shown, the protrusion 2310 blocks movement of the primary latch 1654 away from the tab 1611. Figure 24C It is installed with cover 1608 Figure 2116. A perspective view of an exemplary sealed multi-port cable connector 1600 is shown. The sealed multi-port cable connector 1600 is configured to mate with a mating connector in an insertion orientation, and the contact carrier position assurance member 1650 is configured to slide into the housing in the insertion orientation. In the assembled state, a cable connected to the contact carrier 1606 extends through the opening 1609 of the seal 1607 and the opening of the cover 1608.

[0124] Figure 25 yes Figure 24C 16. A cross-sectional view of an exemplary sealed multi-port cable connector 1600 is shown, which shows a seal 1607 and a cover 1608 blocking a contact carrier position assurance member 1650. Figure 21 system Figure 25 ) is produced by the method of constructing the connector. In an exemplary method, the cover 1608 and seal 1607 can be threaded onto the cable to be terminated by the contact carrier 1606. The contact carrier can then be attached.

[0125] The contact carrier 1606 can then be inserted into the opening of the contact carrier position assurance member 1650 and slid into the cavity 1612 of the dielectric housing 1603 until the tabs 1611 on the contact carrier 1606 engage the corresponding primary latches 1654 of the dielectric housing 1603. Next, the contact carrier position assurance member 1650 can be slid forward in the dielectric housing 1603 until a portion of the contact carrier position assurance member 1650 is adjacent to each latch 1654 on the dielectric housing, thereby blocking movement of the latch in a direction that would disengage the latch from the contact carrier. Optionally, the distal end of each of the latches can be disposed in a notch in the contact carrier position assurance member 1650.

[0126] The force that slides the contact carrier position assurance member 1650 into the closed position can be generated by pushing the cover 1608 toward the dielectric housing 1603. This pushing action can force the seal 1607 against the contact carrier position assurance member 1650. Optionally, when the magnitude of the force pushing the cover 1608 toward the dielectric housing 1603 exceeds a threshold but the cover 1608 does not engage the dielectric housing 1603, incorrect positioning of the contact carrier 1606 can be detected.

[0127] 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.

[0128] For example, the contact carrier position assurance member 1650 may include a latching feature to engage the connector housing in the open and / or closed positions.

[0129] As another example, the techniques described herein can be used in connectors having configurations other than those described above. For example, the techniques described herein can be used in, for example, board connectors or right-angle cable connectors. Furthermore, the features of the position assurance components described in conjunction with sealed connectors can be used in conjunction with unsealed connectors, instead of or in addition to the features described in conjunction with unsealed connectors. Similarly, the features of the position assurance components described in conjunction with unsealed connectors can be used in conjunction with sealed connectors, instead of or in addition to the features described in conjunction with sealed connectors.

[0130] 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.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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".

[0136] 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.

[0137] 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.

[0138] 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.

[0139] 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 (1620), comprising: an insulating housing (1609), the insulating housing comprising a chamber (1622) and a channel (1628); a position assurance member (1630) comprising an opening (1631) having a channel (1626) and a surface (1634) adjacent to the channel; and a contact carrier (1606) comprising a tab (1611); Wherein, the position ensuring component is slidably mounted in the insulating housing and is configured to slide between an open position and a closed position, wherein in the open position, the channel (1628) of the insulating housing (1609), the channel (1626) of the position ensuring component and the tab (1611) on the contact carrier (1606) are aligned, and in the closed position, the surface of the position ensuring component is aligned with the channel (1628) of the insulating housing (1609).

2. The electrical connector according to claim 1, wherein: The position assurance member has a wall (1634) defining the channel; The surface includes an end of the wall; and The position assurance member is in the closed position such that the surface interferes with withdrawal of the tab of the contact carrier through the passage.

3. The electrical connector according to claim 1, wherein: The position assurance component includes a latching feature, the latching feature including a slot (1633); and The insulating housing includes a complementary latching feature that is complementary to the latching feature of the position assurance component and is configured to engage the latching feature when the position assurance component is at a predetermined position within the insulating housing.

4. The electrical connector according to claim 3, wherein: The position ensuring component includes a main body (1663); The latch feature includes a member (1665); The slit (1633) separates the member from the body; and The latch feature includes a protrusion (1635) on the member.

5. The electrical connector according to claim 4, wherein: The member is elongated in a direction between the first end and the second end; and The member is attached to the body at the first end and the second end.

6. The electrical connector according to claim 4, wherein: The member includes a central portion between the first end and the second end; and The protrusion extends from the central portion.

7. The electrical connector according to claim 3, wherein: The complementary latching feature includes a recess (1625) configured to engage at least a portion of the latching feature of the position assurance component to retain the position assurance component in the predetermined position within the insulating housing.

8. The electrical connector according to claim 7, wherein: The dimple is a first dimple; The predetermined position is a first predetermined position; The insulating housing includes a second recess (1627); The second recess is configured to engage the latch feature when the position assurance component is in a second predetermined position within the insulative housing.

9. The electrical connector according to claim 1, wherein: The electrical connector comprises a plurality of contact carriers, wherein: The insulating housing includes a plurality of chambers; and The position ensuring member includes a plurality of openings.

10. The electrical connector according to claim 1, wherein: The electrical connector comprises four contact carriers, wherein: The insulating housing includes four chambers; and The position ensuring member includes four openings.

11. An electrical connector (1620), comprising: an insulating housing including a chamber; including position assurance components for openings and surfaces; as well as a contact carrier having a tab (1611) and positioned within the cavity; in: The contact carrier extends through the opening of the position assurance member; and The position assurance feature is positioned so that the surface interferes with the tab of the contact carrier to prevent the contact carrier from being withdrawn from the cavity of the insulating housing and the opening in the position assurance feature.

12. The electrical connector according to claim 11, wherein: The position ensuring member includes a protrusion (1635); and The insulating housing includes a first recess (1625), and the tab of the position assurance component is placed in the first recess (1625) of the insulating housing to maintain the position assurance component in a first position through the insulating housing.

13. The electrical connector according to claim 12, wherein: The insulating shell includes a second recess (1627), and the protrusion (1635) of the position assurance component is placed in the second recess of the insulating shell to maintain the position assurance component in the second position through the insulating shell.

14. The electrical connector according to claim 11, wherein: The electrical connector further comprises a plurality of contact carriers including the contact carrier, wherein: The insulating housing (1609) includes a plurality of chambers (1622) containing the chambers; The position ensuring member (1630) includes a plurality of openings (1631) including the opening.

15. The electrical connector according to claim 11, wherein: The electrical connector comprises four contact carriers (1609), wherein: The insulating housing includes four chambers (1622); and The position ensuring member includes four openings (1631).

16. The electrical connector according to claim 15, wherein: The four openings of the position ensuring member are arranged in a two-by-two matrix.

17. A housing subassembly for an electrical connector (1620), the subassembly comprising: an insulating housing (1609) comprising a chamber (1622) having a passage (1628); a position assurance member (1630) comprising an opening (1631) having a channel (1626) and a surface adjacent to the channel; as well as in, The position assurance member is slidably mounted in the insulating housing to slide between an open position and a closed position, wherein the channel (1628) of the insulating housing (1609) is aligned with the channel (1626) of the position assurance member in the open position and the surface of the position assurance member is aligned with the channel (1628) on the insulating housing (1609) in the closed position; The position assurance component (1630) includes a latch configured to engage a complementary structure in the insulating housing when the position assurance component is in the open position. The dependent claims emphasize the latching structure and the plurality of contact carriers.

18. The electrical connector subassembly according to claim 17, wherein: The position ensuring component includes a main body and a slit; The latch feature includes a member; The slit (1633) separates the member from the body; and The latch feature includes a protrusion on the member.

19. The electrical connector subassembly according to claim 18, wherein: The member is elongated in a direction between the first end and the second end; and The member is attached to the body at the first end and the second end.

20. The electrical connector subassembly according to claim 19, wherein: The member includes a central portion between the first end and the second end; and The protrusion extends from the central portion.

21. The electrical connector subassembly according to claim 20, wherein: The complementary latching feature includes a recess (1625) configured to engage at least a portion of the latching feature of the position assurance component to retain the position assurance component in the predetermined position within the insulating housing.

22. The electrical connector subassembly according to claim 21, wherein: The dimple is a first dimple; The predetermined position is a first predetermined position; The insulating housing includes a second recess (1627); The second recess is configured to engage the latch feature when the position assurance component is in a second predetermined position within the insulative housing.

23. The electrical connector subassembly according to claim 17, wherein: The electrical connector subassembly further includes four contact carriers (1609), wherein: The insulating housing includes four chambers (1622); and The position ensuring member includes four openings (1631).

24. The electrical connector subassembly according to claim 23, wherein: The four openings of the position ensuring member are arranged in a two-by-two matrix.

25. A method of operating an electrical connector, the electrical connector comprising an insulating housing (1609), a position assurance member (1630), and a contact carrier (1606), the insulating housing comprising a chamber (1622) and a channel (1628), the position assurance member comprising an opening (1631) having the channel (1626) and a surface (1634) adjacent to the channel, the contact carrier comprising a tab (1611), the method comprising: inserting the contact carrier into the cavity of the insulating housing through the opening of the position assurance component by aligning the tab of the contact carrier with the channel of the insulating housing and the channel of the position assurance component with the position assurance component disposed in a first position at least partially within the insulating housing such that the channel of the insulating housing is aligned with the channel of the position assurance component; and The position ensuring member is slid relative to the insulating housing so that the passage of the insulating housing is blocked by the position ensuring member.

26. The method for operating an electrical connector according to claim 25, wherein: The position assurance member further comprises a protrusion, and the insulating housing comprises a first recess (1625), the method further comprising: The position assurance member is pushed until the protrusion engages with the first recess of the insulating housing to secure the position assurance member in the open position within the insulating housing, whereby the position assurance member is held in the first position.

27. The method for operating an electrical connector according to claim 26, wherein: The insulating housing includes a second recess (1627) wherein: Sliding the position assurance member relative to the insulating housing includes pushing the position assurance member until the protrusion engages the second recess to secure the position assurance member in a final position within the insulating housing.

28. An electrical connector (1600-sealed type), comprising: an insulating housing (1603) comprising a chamber (1612) and a latch (1654) adjacent the chamber; a position assurance component (1650) including a body having an opening (1652) therethrough, a protruding member, and a notch separating the protruding member from the body; and a contact carrier (1606) having a tab (1611) extending through the opening of the position assurance member and disposed within the cavity of the insulating housing; wherein the latch (1654) of the housing engages the tab (1611) of the contact carrier (1606) to maintain the contact carrier (1606) in position within the chamber, and the position assurance member (1650) is positioned so that the latch is disposed within the slot so that movement of the latch is restricted.

29. The electrical connector (1600) according to claim 28, characterized in that The electrical connector further comprises: A seal (1607) having an opening (1609), wherein the opening (1609) of the seal (1607) is aligned with the cavity of the insulating housing.

30. The electrical connector according to claim 29, wherein: The insulating housing includes a cover (1608); The cover is configured to press the seal (1607) against the position assurance member (1650).

31. The electrical connector according to claim 29, wherein: The position ensuring member is slidably provided in the insulating housing.

32. The electrical connector according to claim 29, wherein: The electrical connector is configured to mate with a mating connector along an insertion direction; and The position assurance member is configured to slide within the insulating housing along the insertion direction.

33. The electrical connector according to claim 29, wherein: The insulating housing includes a cover (1608) for the seal (1607), the cover having an opening; The electrical connector further includes a cable connected to the contact carrier; and The cable extends through the opening of the seal and the opening of the cover.

34. The electrical connector according to claim 32, wherein: The electrical connector includes a plurality of contact carriers including the contact carrier; The insulating housing includes a plurality of chambers containing the chambers; The position ensuring member includes a plurality of openings including the opening; and The seal includes a plurality of openings including the opening.

35. The electrical connector according to claim 34, wherein: The plurality of contact carriers is four contact carriers; The plurality of chambers in the insulating housing is four chambers; The position ensuring member is a first position ensuring member, and the plurality of openings are two openings; The electrical connector includes a second position ensuring component, the second position ensuring component including two openings; and The plurality of openings of the seal is four openings.

36. A method of operating an electrical connector, the electrical connector comprising an insulating housing (1603) and a position assurance component (1650), the insulating housing (1603) comprising a cavity (1612) and a latch (1654) adjacent to the cavity, the position assurance component (1650) comprising a body, a protruding member, and a notch separating the protruding member from the body, the body having an opening (1652) therethrough, the method comprising: sliding the contact carrier into the cavity of the dielectric housing until the tab of the contact carrier engages the latch of the housing; as well as The position assurance component is slid into the insulating housing until the protruding member of the position assurance component is positioned to block movement of the latch of the insulating housing to unlock from the tab.

37. The method for operating an electrical connector according to claim 36, wherein: The electrical connector further includes a cover and a seal having an opening, and the method further includes: The cover is pushed toward the insulating housing to force the seal against the position assurance member.

38. The method for operating an electrical connector according to claim 36, wherein: The electrical connector further includes a cover and a seal having an opening, and the method further includes: The seal is forced against the position assurance member by pushing the cover toward the insulating housing.

39. The method for operating an electrical connector according to claim 38, wherein: Pushing the cover toward the insulating housing includes pushing the cover with a certain amount of force; and The method further includes detecting mis-positioning of the contact carrier when the magnitude of the force exceeds a threshold and the cover does not engage the dielectric housing.

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