Reinforced connector system

Abstract

An electrical interconnect system is described having an adapter mounted in an opening within a connector interface of a panel of an electronic chassis. The sealing member may be used to prevent foreign matter (such as liquid, gas, or dust particles) from entering the housing and into the mating region between the adapter and the mating plug connector. The sealing member may include a base and a sidewall configured to surround an outer boundary of the adapter. The sealing member may be configured to form a first sealing interface with the panel and a second sealing interface with the plug connector. The first and second sealing interfaces may be orthogonal to each other. The sealing member may be made of an elastomeric material.

Description

[0001] This application is a divisional application of invention patent application No. 202210872296.0, filed on October 8, 2018, entitled "Reinforced Connector System", which in turn is a divisional application of invention patent application No. 201811167433.0, filed on October 8, 2018, entitled "Reinforced Connector System". Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 568695, entitled “RUGGEDIZED PLUG CONNECTOR,” filed October 5, 2017, under Agent’s File No. A1156.70287US00, pursuant to 35 U.SC §119(e), the entire contents of which are incorporated herein by reference.

[0003] This application claims priority to U.S. Provisional Patent Application No. 62 / 597886 entitled “RUGGEDIZED CONNECTOR SYSTEM”, filed December 12, 2017, under Agent’s File No. A1156.70287US01, pursuant to 35 U.SC §119(e), the entire contents of which are incorporated herein by reference.

[0004] This application claims priority to U.S. Provisional Patent Application No. 62 / 629740, entitled “RUGGEDIZED CONNECTOR SYSTEM,” filed February 13, 2018, under Agent’s File No. A1156.70287US01, pursuant to 35 U.SC §119(e), the entire contents of which are incorporated herein by reference. Technical Field

[0005] This patent application generally relates to interconnection systems, such as those that include electrical connectors for interconnecting electronic components. Background Technology

[0006] Electrical connectors are used in many electronic systems. It is often easier and more cost-effective to manufacture a system as separate electronic components (such as printed circuit boards, or PCBs), which can then be joined together using electrical connectors. Connectors can be used to interconnect PCBs and to interconnect other types of devices (such as cables) to PCBs.

[0007] Some connectors are designed for use in harsh environments. For example, electrical components installed in outdoor housings, such as those housing cellular communication equipment, can receive power or control signals via connectors. Connectors can be installed in openings within the housing. To protect equipment inside the housing, connectors installed in openings should prevent dust and moisture from entering the housing. Summary of the Invention

[0008] Some embodiments relate to an adapter connector configured to mate with a plug connector such that, when mated, the adapter connector and the plug connector are attached to a panel. The adapter connector may include an insulating housing, a first plurality of mating contacts supported by the insulating housing, the first plurality of mating contacts configured to electrically contact a second plurality of mating contacts supported by the plug connector, and a resilient member having first and second sealing elements. The resilient member may be configured to form a first sealing interface with the panel and a second sealing interface with the plug connector, the first and second sealing interfaces being orthogonal to each other. The first sealing element may be configured to engage with the panel, and the second sealing element may be configured to engage with the plug connector.

[0009] In some embodiments, the resilient member includes a base and a sidewall configured to surround the outer boundary of the adapter connector.

[0010] In some embodiments, a first sealing element is disposed at the base, and a second sealing element is disposed at the sidewall.

[0011] In some embodiments, the first sealing element extends in a direction parallel to the mating direction of the adapter connector and the plug connector.

[0012] In some embodiments, the first sealing element includes a rib configured to engage with a corresponding groove formed in the panel.

[0013] In some embodiments, the second sealing element includes a rib configured to engage with a corresponding groove formed in the plug connector.

[0014] In some implementations, the adapter connector is attached to the panel by multiple screws.

[0015] In some implementations, the plurality of screws pass through corresponding openings formed in the elastic member.

[0016] In some embodiments, the insulating housing includes a body having a top surface and angled surfaces disposed at the edges of the top surface, and a first plurality of mating contacts extending through the top surface.

[0017] In some embodiments, the first sealing element is positioned to form a first sealing interface with the panel. In some embodiments, the second sealing element is positioned to form a second sealing interface with the plug connector. In some embodiments, the second sealing element has an upper edge. In some embodiments, the upper edge of the second sealing element is below the angled surface.

[0018] In some embodiments, the insulating housing includes a groove, and the resilient member includes a rib extending into the groove, and the groove and the rib each have an aspect ratio of at least 2:1.

[0019] Some embodiments relate to a resilient member configured to seal first and second electrical connectors attached to a panel. The resilient member may include a base having an opening formed therethrough, the base configured to form a first sealing interface with the panel, a sidewall connected to the base, the sidewall configured to form a second sealing interface with a second electrical connector, a first sealing element extending from the base, and a second sealing element extending from the sidewall. The first and second sealing interfaces are perpendicular to each other.

[0020] In some embodiments, the base, sidewalls, and first and second sealing elements are made of an elastic material.

[0021] In some implementations, the first sealing element and the sidewall extend in opposite directions.

[0022] In some embodiments, the opening is a first opening, and the resilient member further includes a second opening, wherein the first sealing element is disposed along at least a portion of the periphery of the second opening.

[0023] In some embodiments, the first sealing element includes a rib configured to engage with a corresponding groove formed in the panel.

[0024] In some embodiments, the second sealing element includes a rib configured to engage with a corresponding groove formed in the second electrical connector.

[0025] In some embodiments, the resilient member further includes a third sealing element extending from the base, wherein the first sealing element and the third sealing element form one or more recesses surrounding therebetween.

[0026] In some embodiments, the one or more recesses surround the opening in a plane defined by the base.

[0027] In some embodiments, the base is further configured to form a third sealing interface with the first connector, and the resilient member further includes a third sealing element extending from the base, the first and third sealing elements extending in opposite directions.

[0028] In some embodiments, the resilient member further includes a third sealing element extending from the base toward the opening.

[0029] Some embodiments relate to a method for mating a plug connector having a first plurality of mating contacts to an adapter connector having a second plurality of mating contacts. The method may include attaching the adapter connector to a resilient member, allowing the adapter connector to pass through an opening in a panel, and engaging the plug connector with the adapter connector. When the plug connector is engaged with the adapter connector, the first plurality of mating contacts electrically contact the second plurality of mating contacts, the plug connector contacts the panel, and the resilient member forms a first sealing interface with the panel and a second sealing interface with the plug connector.

[0030] In some embodiments, attaching the adapter connector to the resilient member includes allowing the adapter connector to pass through an opening in the resilient member.

[0031] In some embodiments, when the plug connector engages with the adapter connector, the first sealing element of the resilient member engages with the panel, and the second sealing element of the resilient member engages with the plug connector.

[0032] In some implementations, the first sealing interface and the second sealing interface are perpendicular to each other.

[0033] In some embodiments, the method further includes connecting a plug connector to a cable having multiple wires, such that a first plurality of mating contacts electrically contact the wires.

[0034] In some implementations, the method also includes attaching an adapter connector to a printed circuit board.

[0035] Some embodiments relate to a plug connector comprising a cable with a plurality of wires; a housing including a first opening, a second opening, and at least one third opening between the first and second openings configured to receive a portion of a mating connector; a plurality of terminals extending through the at least one third opening, the plurality of terminals including mating contact portions extending into the first opening and contact tails extending into the second opening, wherein the plurality of wires of the cable are electrically connected to the contact tails of the plurality of terminals within the second opening; and an insulating material within the second opening that encloses the contact tails of the plurality of terminals within the second opening and closes the passage between the at least one third opening and the second opening.

[0036] Some embodiments relate to a panel connector configured to attach to a board connector and mate with a plug connector, such that when mated, the panel connector and the plug connector are attached to a panel. The panel connector may include an insulating housing with a mating interface configured to mate with the plug connector; a mounting interface for mounting to the board connector, the mounting interface including a cavity configured to receive a portion of the board connector; one or more protrusions formed at the mounting interface and configured to slide into corresponding channels in one or more channels in the board connector; and a first plurality of mating contacts configured to electrically contact a second plurality of mating contacts supported by the plug connector at the mating interface.

[0037] Some embodiments relate to a panel configured to attach to a panel connector and receive a plug connector thereon, such that the plug connector makes electrical contact with the panel connector. The panel may include a planar base; an opening formed through the planar base and configured to receive the panel connector through an opening; and a raised portion formed on the planar base and surrounding the opening, the raised portion having a top surface that is perpendicularly offset from the top surface of the planar base.

[0038] Some embodiments relate to a panel connector configured to attach to a board connector and mate with a plug connector, such that when mated, the panel connector and the plug connector are attached to a panel. The panel connector may include at least one housing portion; an overmolded outer housing covering the at least one housing portion; and a first plurality of mating contacts supported by the at least one housing portion, the first plurality of mating contacts being configured to electrically contact a second plurality of mating contacts supported by the plug connector.

[0039] Some embodiments relate to a method for manufacturing a panel connector configured to attach to a board connector and mate with a plug connector, such that when mated, the panel connector and the plug connector are attached to a panel. The method may include manufacturing at least one housing portion using an insulating material; inserting a plurality of mating contacts into the at least one housing portion; and manufacturing an outer housing by overmolding the at least one housing portion using the plurality of mating contacts inserted into the at least one housing portion, such that corresponding ends of the plurality of mating contacts are exposed in the outer surface of the outer housing.

[0040] Some embodiments relate to an apparatus including an electrical connector having an opening; a plurality of mating contacts inserted through the opening of the electrical connector, each of the plurality of mating contacts having a mating contact portion, a contact tail portion, and an intermediate portion between the mating contact portion and the contact tail portion; a contact retainer at least partially disposed within the opening of the electrical connector and configured to support the plurality of mating contacts; and a contact cover at least partially disposed within the opening of the electrical connector, such that at least one of the plurality of mating contacts is disposed between the contact retainer and the contact cover; wherein the intermediate portion includes first and second side surfaces, and wherein the mating contacts are mounted such that they abut against... A first side of the contact retainer is a first distance from the end of the mating contact adjacent to the tail of the contact; and a contact cover is mounted such that a second side of the intermediate portion abutting the contact cover is a second distance from the end of the mating contact, the second distance being shorter than the first distance, wherein the contact cover includes one or more protrusions, and wherein the second side of the intermediate portion abuts the one or more protrusions at the second distance from the end of the mating contact, and wherein at least one of the one or more protrusions includes a first surface and a second surface opposite to the first surface, the first surface contacting the second side of the intermediate portion, and the second surface contacting the inner wall of the opening of the electrical connector.

[0041] Some embodiments relate to an adapter connector configured to mate with a plug connector such that, when mated, the adapter connector and the plug connector are attached to a panel. The adapter connector includes an insulating housing, a first plurality of mating contacts supported by the insulating housing, the first plurality of mating contacts being configured to electrically contact a second plurality of mating contacts supported by the plug connector, and an elastic member having first and second sealing elements. The elastic member is configured to form a first sealing interface with the panel and a second sealing interface with the plug connector, the first and second sealing interfaces being orthogonal to each other. The first sealing element is configured to engage with the panel, and the second sealing element is configured to engage with the plug connector. The insulating housing includes a body having a top surface and angled surfaces disposed at edges of the top surface, and the first plurality of mating contacts extending through the top surface.

[0042] Some embodiments relate to a plug connector comprising a cable with a plurality of wires; a housing comprising a first opening, a second opening, and at least one third opening between the first and second openings configured to receive a portion of a mating connector; a plurality of terminals extending through the at least one third opening, the plurality of terminals including mating contact portions extending into the first opening and contact tails extending into the second opening, wherein the plurality of wires of the cable are electrically connected to the contact tails of the plurality of terminals within the second opening; and an insulating material within the second opening, the insulating material encapsulating the contact tails of the plurality of terminals within the second opening and closing a channel between the at least one third opening and the second opening, wherein the housing comprises one or more ribs extending into the second opening and positioned to contact an overmolded material occupying at least a portion of the second opening.

[0043] Some embodiments relate to a panel connector configured to attach to a board connector and mate with a plug connector, such that when mated, the panel connector and the plug connector are attached to a panel. The panel connector may include an insulating housing with a mating interface configured to mate with the plug connector; a mounting interface for mounting to the board connector, the mounting interface including a cavity configured to receive a portion of the board connector; one or more protrusions formed at the mounting interface and configured to slide into corresponding channels in one or more channels in the board connector; and a first plurality of mating contacts supported by the insulating housing, the first plurality of mating contacts being configured to electrically contact a second plurality of mating contacts supported by the plug connector at the mating interface, wherein the first plurality of mating contacts are arranged symmetrically with respect to a first axis passing through the center of the interface between the panel connector and the board connector, and wherein the one or more protrusions are arranged asymmetrically with respect to the first axis.

[0044] Some embodiments relate to an electrical connector comprising a housing having an opening formed through the housing and a first rib extending into the opening; a plurality of mating contacts inserted through the opening of the housing; a contact retainer at least partially disposed within the opening of the housing and configured to support the plurality of mating contacts, the contact retainer including a second rib abutting against a first wall of the opening; and a contact cover at least partially disposed within the opening of the housing such that at least one of the plurality of mating contacts is disposed between the contact retainer and the contact cover, the contact cover including a third rib abutting against the first wall of the opening; wherein the second and third ribs are longitudinally aligned with each other and form a discontinuity between them, and wherein the first rib is disposed in the discontinuity. Attached Figure Description

[0045] The dimensions shown in the accompanying drawings are not limited to those depicted. For clarity, not every component can be labeled in every drawing. In the drawings: Figure 1It is an isometric view of an illustrative interconnection system according to some implementations.

[0046] Figure 2 This is an isometric view of a illustrative plug connector according to some embodiments.

[0047] Figure 3A This is an isometric view of a demonstrative panel connector according to some embodiments.

[0048] Figure 3B According to some implementation methods, when mounted on the panel of the housing Figure 3A Isometric view of the panel connector.

[0049] Figure 4A It is based on some implementation methods Figure 3B The 4-4 line obtained in Figure 1 A cross-sectional view of the interconnected system.

[0050] Figure 4B A more detailed description of some implementation methods Figure 4A A portion of the sectional view.

[0051] Figure 4C This is a cross-sectional view of another interconnection system according to some implementation methods.

[0052] Figure 4D A more detailed description of some implementation methods Figure 4C A portion of the sectional view.

[0053] Figure 4E This is a cross-sectional view of another interconnection system according to some implementation methods.

[0054] Figure 4F According to additional details of some implementation methods Figure 4E An enlarged sectional view of the section marked C.

[0055] Figure 5A This is an isometric view of a demonstrative seal according to some embodiments.

[0056] Figure 5B This is an isometric view of an alternative demonstrative seal according to some embodiments.

[0057] Figure 5C According to additional details of some implementation methods Figure 5B An enlarged isometric view of a portion of the seal marked D.

[0058] Figure 6 This is an exploded view of a cable assembly having multiple mating contacts and contact retainers according to some embodiments.

[0059] Figure 7A It is a cross-sectional view of a mating contact held by a contact holder according to some embodiments.

[0060] Figure 7B According to some embodiments, the plug connector housing along the edge before the overmolding operation. Figure 2 The sectional view of line 7-7 in the diagram.

[0061] Figure 7C Additional details are shown according to some implementation methods. Figure 7B Part of the plug connector housing marked F.

[0062] Figure 7D This is a cross-sectional view showing a contact cover with ribs positioned on protrusions according to some embodiments.

[0063] Figure 7E Demonstrating according to some implementation methods Figure 7C A cross-sectional view of the ribs when they abut against the inner wall of the plug connector.

[0064] Figure 8A According to some embodiments, the plug connector housing after the overmolding operation is along Figure 2 The sectional view of line 7-7 in the diagram.

[0065] Figure 8B This is an exploded view of a cable assembly according to some embodiments, the cable assembly having a plastic-coated molding for reliably securing the cable to a plug connector. Figure 8C This is an illustration based on some implementation methods. Figure 8B An isometric view of the cable assembly during assembly.

[0066] Figure 8D This is an isometric view of a plug connector according to some embodiments, the plug connector having multiple ribs in contact with the overmolded material.

[0067] Figure 9A This is an isometric view of an illustrative contact holder according to some embodiments.

[0068] Figure 9B According to some embodiments, when installed in the plug connector housing, along the contact retainer Figure 2 The sectional view of line 7-7 in the diagram.

[0069] Figure 10A It is based on some implementation methods Figure 9A An enlarged isometric view of a portion of the contact retainer, showing multiple ribs.

[0070] Figure 10B It is based on some implementation methods Figure 2An isometric view of the housing of the plug connector, showing the ribs.

[0071] Figure 11A-11B It is based on some implementation methods Figure 9B The sectional view of line 11-11 in the diagram.

[0072] Figure 12 This is an isometric view of a board connector according to some embodiments, the board connector having a channel for facilitating engagement with a panel connector.

[0073] Figure 13A It is based on some implementation methods as along Figure 12 The cross-section of line 13-13 in the middle was obtained. Figure 12 Bottom view of the board connector.

[0074] Figure 13B It is based on some implementation methods as along Figure 12 The cross-section of line 15-15 in the middle was obtained. Figure 12 Top view of the board connector.

[0075] Figure 14A This is a cutaway isometric view of an interconnection system according to some embodiments, the interconnection system having a plug connector that engages with a panel connector via a panel.

[0076] Figure 14B It is based on some implementation methods Figure 14A An enlarged isometric view of the section marked F.

[0077] Figures 15A-15E Examples of a sequence of methods for manufacturing panel connectors are shown, according to some implementation methods.

[0078] Figures 16A-16C Examples of sequences for assembling interconnect systems are shown according to some implementation methods.

[0079] Figure 17A This is an isometric view of an interconnection system according to some embodiments, the interconnection system having plug connectors and cable connectors.

[0080] Figure 17B This demonstrates according to some implementation methods. Figure 17A Isometric view of the cable connector.

[0081] Figure 18 It is an isometric view showing plug connectors and plug adapters according to some implementations. Detailed Implementation

[0082] The inventors have recognized and understood techniques for manufacturing robust, environmentally sealed connectors that can be economically manufactured and easily installed. Such connectors can be installed in panel openings within electronic housings installed in harsh environments. For example, the connector can be used to supply power to a fan inside an electronic housing housing housing an outdoor-mounted portion of a communication system. The connector prevents moisture, dust, and other environmental contaminants from contaminating the mating contacts and / or entering the housing.

[0083] The inventors have recognized and understood that sealing can be enhanced by appropriately selecting the shape and position of a seal inserted between two connectors mounted to a panel. In some embodiments, the seal can be arranged to provide a three-way seal. For example, a single, integral seal can provide a seal at the interface formed when three components (e.g., a plug connector, a panel connector, and a panel) are assembled together. The seal can be arranged to form a seal between the panel connector and the panel, and a seal between the panel connector and the plug connector. In this way, channels (through which foreign objects can pass) that could otherwise be formed through panel openings can be prevented. In some embodiments, the seal can include one or more ribs configured to mate with a corresponding recess formed in one of the connectors and one or more ribs configured to mate with a corresponding recess formed in the panel. The ribs can be sized and arranged to occupy gaps that could otherwise be formed between the connectors, thereby hermetically sealing the interior of the mating contacts of the connector. As a result, foreign objects (such as liquids, gases, and dust particles) can be prevented (or at least limited) from passing through these gaps, and the integrity of the electrical connection can be maintained.

[0084] The inventors further recognize and understand that the contact force between mating contacts in a mating configuration can be adjusted by regulating the degree to which the mating contact portions of the plug bend. In some cases, it may be desirable to adjust the contact force according to the environment in which the interconnection system is intended to be used. For example, environments that tend to have mechanical vibration (such as certain industrial environments) may require a large contact force (e.g., 1 N or greater) to prevent accidental disconnection of the mating contacts.

[0085] In some implementations, a contact cap positioned to contact the mating contact portion can be used to define the degree to which the mating contact portion is allowed to bend, such that the position of the end of the contact cap determines the position of the hinge axis of the mating contact portion (i.e., the position of the axis about which the mating contact portion can pivot). Reducing the distance between the end of the contact cap and the mating contact portion can increase the stiffness of the mating contact portion because it allows a shorter portion of the mating contact portion to bend. As a result, the force required to hold the mating contact increases. Conversely, increasing the distance between the end of the contact cap and the mating contact portion can reduce the contact force.

[0086] Therefore, the contact force can be set by appropriately sizing and positioning the contact cover relative to the mating contact portion.

[0087] The inventors further recognize and understand that, in certain circumstances, it may be desirable to overmold a plug connector to ensure that the cable to which it is connected can be reliably secured to the plug connector, and / or to insulate the conductors that may be exposed at the cable terminations. In this way, the component can be configured to withstand mechanical vibrations that may occur in the environment in which it is deployed. Overmolding, at least in some embodiments, can be performed by injecting a thermoplastic material heated to a fluid state into the opening through which the cable of the plug connector passes.

[0088] Once the cable has been assembled with the plug connector, injection can be performed. The fluid can then be allowed to solidify, thereby holding the cable and plug connector together. However, the inventors have recognized that injecting fluid into the plug connector, as described above, can cause some fluid to reach the mating contacts, which can create an undesirable insulating barrier around the mating contacts. The formation of this barrier can impair the connector's electrical contact with complementary connectors or alter the ability of the mating contact portion to bend, thus preventing the desired contact force from being achieved in practice. In some embodiments, fluid passage can be prevented by blocking the injection portion of the plug connector from the portion where the mating contacts are located.

[0089] In some implementations, blocking can be achieved by at least partially filling a channel, which may otherwise utilize ribs formed in the plug connector. In one embodiment, a combination of three ribs can be used to block the channel. Two such ribs can be longitudinally aligned with each other. A third rib can be aligned with the area where the first two ribs intersect and can fill any discontinuities that may arise between the first two ribs. Such discontinuities between the first two ribs may occur, for example, due to non-zero manufacturing tolerances. For example, in a connector where the contact cap can be installed in any of multiple locations, a gap may exist between the contact cap and other parts of the connector housing. This gap can be filled by the third rib to prevent fluid molding material from passing through the gap.

[0090] The inventors have recognized and understood that the lifespan of a seal can be significantly increased by preventing foreign objects (such as dust, moisture, or other particles) from reaching the area where the seal is located. Damage or wear to the seal can occur over time when foreign objects reach the area and contact it. To prevent damage caused by contact with foreign objects, in some embodiments, the panel portion of the seal that contacts the panel can be raised. The raised portion, which can be offset from the base of the panel, can form a block that prevents foreign objects from contacting the seal. In this way, foreign objects must climb the raised portion, significantly reducing the likelihood of establishing contact with the seal. To further protect the raised portion from foreign objects, in some embodiments, the sidewall of the plug connector housing can have a beveled end. The beveled end can be arranged to protect the seal from the passage of foreign objects without interfering with the raised portion. For example, the beveled end can extend outward relative to the plug connector housing.

[0091] In some implementations, one side of the panel connector can be configured to mate with a plug connector, and the other side of the panel connector can be configured to mate with a board connector connected to a board. In this way, the panel connector can allow interconnection between cables positioned on one side of an electronic housing formed by the panel and boards positioned on the inside of the housing.

[0092] The inventors have recognized and understood that the mating of panel connectors to board connectors can be simplified by using a guiding structure. In one embodiment, the guiding structure can be formed using protrusions in the panel connector and channels in the board connector. Therefore, mating can be performed by allowing the protrusions to slide into the corresponding channels, thereby guiding the panel connector into place. A relatively small guiding distance between board connectors and panel connectors can be achieved using the structure described herein. This connector system enables more compact electronic components.

[0093] The inventors further recognize and understand that the costs associated with manufacturing panel connectors of the type described herein can be reduced by designing the panel connector to include an inner housing for supporting mating contacts during overmolding and an outer housing for covering the inner housing. The inventors have recognized that by including an inner housing, the material required for overmolding, in addition to the outer housing, can be limited, thereby reducing manufacturing costs. Furthermore, the use of an inner housing allows for a reduction in the amount of material used in the overmolding process to form the outer housing. This reduction in material is desirable because it reduces the number and / or size of shrinkage cavities formed inside the outer housing as the molten plastic solidifies. In this respect, the inventors have recognized that the more material used in the walls of the outer housing, the greater the volume loss of the outer housing during its cooling process, and the greater the likelihood of shrinkage cavities forming. Shrinkage cavities in the outer housing are undesirable because they create weak points and / or pits that can trap moisture. Therefore, the use of an inner housing, in addition to the outer housing, results in a reduction in the material used for the outer housing.

[0094] As a further benefit, the use of an inner housing can limit (or even eliminate) the number of cuts in the outer housing, including avoiding cuts that are typically formed to hold the contacts in place during insert molding. In insert molding, plastic is typically injected at high speeds around the contacts. At high speeds, the plastic rushing toward the contacts can displace them from their desired positions due to pressure. To limit contact displacement, molds with protrusions are typically used, where the protrusions clamp and hold the contacts in place during plastic injection. These protrusions result in cuts forming in the outer housing, and the protrusions reach the contacts through these cuts during injection. Because precise machining of molds with protrusions is expensive, cuts in molded parts, regardless of their purpose, contribute to high costs, with a greater number of protrusions leading to even higher mold costs. To limit the costs associated with forming protrusions in the mold, the inventors have recognized that an inner housing can be used to hold the contacts in place during plastic injection. In this way, the number of mold protrusions can be reduced, and therefore the number of cuts can be reduced, or even eliminated altogether.

[0095] Figure 1An interconnect system 100 is illustrated according to some embodiments. The interconnect system 100 can be used to connect two electronic devices to each other. In some embodiments, the interconnect system 100 is used in ruggedized applications (e.g., in industrial applications). The interconnect system 100 can be mounted to a panel 102. In some embodiments, the panel 102 may include openings for allowing electrical signals to pass through the panel. The panel 102 may be a user-provided interface in some embodiments. For example, the panel 102 may be part of (or otherwise coupled to) a sidewall of a housing (e.g., a tank containing liquid). In this embodiment, the interconnect system 100 may be arranged to allow electrical communication between electronic devices (e.g., sensors) placed inside the tank and other electronic devices placed outside the tank. The panel 102 and the interconnect system 100 may be arranged to prevent foreign substances (such as liquids, gases, or dust particles) from passing from one side of the panel 102 to the other and / or to prevent foreign matter from depositing on the mating contacts.

[0096] exist Figure 1 In one embodiment, the interconnect system 100 is arranged to transmit signals between cables 106, including conductors 108, to a circuit board 111. The circuit board 111 may include one or more electronic devices mounted thereon. Of course, the interconnect system 100 is not limited to this arrangement. For example, other embodiments may not use cables and may utilize conductors that are not part of the cables to connect two printed circuit boards (or other types of devices) to each other. In alternative embodiments, the interconnect system 100 may be used to connect cables to other cables.

[0097] As shown, cable 106 passes through an opening formed in the housing of plug connector 104 and terminates in plug connector 104, such that the cable is electrically connected to contacts placed in plug connector 104. Plug connector 104 can be mounted to one side of panel 102. A board connector 110 can be positioned on the other side of panel 102. In some embodiments, board connector 110 can be mounted to panel 102 via panel connector 130 (also referred to as a “panel adapter” or “adapter connector”). While the board connector 110 shows that the printed circuit board 111 is substantially perpendicular to panel 102, other configurations are possible. For example, in other embodiments, board connector 110 can be arranged such that the printed circuit board 111 is parallel to panel 102. In other embodiments, board connector 110 can be arranged such that the printed circuit board 111 is neither parallel nor perpendicular to panel 102.

[0098] Figure 2 Demonstrates the situation when not installed on panel 102 according to some embodiments. Figure 1The example of the plug connector 104 is shown. The plug connector 104 includes an opening 145 that can be arranged to allow mating contacts to pass through it. Figure 2 Multiple mating contacts 105 (also referred to herein as “terminals”) are shown passing through opening 145. The mating contacts 105 can be electrically connected to the conductors 108 of cable 106. Figure 2 (Not visible in the image). The opening 145 can be shaped and sized to accommodate a mating element therein. The mating element may include a mating contact configured to be electrically connected to the mating contact 105 when the interconnect system 100 is in a mating configuration. In this way, the opening 145 can be used as a socket.

[0099] Examples of such mating components are in Figures 3A-3B The figure depicts a panel connector 130 and a mating contact 136. As shown, in this configuration, the panel connector 130 is configured to support the mating contact 136. In some embodiments, this support can be formed by overmolding the mating contact 136 using plastic. In some embodiments, the panel connector 130 includes a protrusion 134 extending away from the body of the panel connector. The protrusion 134 supports an end of the mating contact 136. The protrusion 134 can be shaped and sized to at least partially fit into an opening 145. Figure 2 As shown in the diagram, mating contact 136 makes electrical contact with mating contact 105. Mating contact 105 can be configured as a beam, and mating contacts of the panel connector can be configured as pads (although the reverse arrangement is also possible). While in this configuration, plug connector 104 includes a socket, and panel connector 130 forms mating elements (via protrusion 134), the reverse configuration is also possible.

[0100] In some embodiments, seal 132 serves to hermetically seal mating contacts 136 and 105 against the external environment. Seal 132 may be arranged to prevent foreign objects from passing through gaps that may otherwise be formed between plug connector 104 and panel connector 130 and / or gaps that may otherwise be formed between panel 102 and panel connector 130. In some embodiments, seal 132 may include a portion configured to surround the outer boundary of the panel connector, as will be further described below. Panel connector 130 may be mounted to panel 102 via attachment mechanism 141, which may be implemented using screws in at least some embodiments. In one embodiment, as... Figure 3B As shown, four screws are used. The screws can be spaced apart to provide uniform pressure on the panel. In at least some embodiments where the attachment mechanism is a screw, the panel connector 130 may include an opening 138 for allowing the respective screws to pass through. Similarly, the seal 132 may include an opening for allowing screws to pass through (e.g., Figure 5A (As shown).

[0101] In some embodiments, the top surface of the body of the panel connector 130 may include a sloped region arranged to allow dust, moisture, or other foreign matter to slide off to the sides of the panel connector. Figure 3A In one embodiment, for example, an angled surface 129 is formed at the edge of the top surface of the body of the panel connector 130. In this way, if dust, moisture, or other foreign matter inadvertently seeps into the area where the mating contacts are located, the angled surface can cause the foreign matter to slip off the panel connector. Alternatively or additionally, such as Figure 3A As shown, the upper edge of the seal 132 is below the top surface, preventing the seal 132 from trapping foreign objects. In the illustrated embodiment, the upper edge of the seal 132 is below the angled surface 129.

[0102] Figure 4A According to some embodiments, it is in a mating configuration (i.e., when mating contact 105 is connected to mating contact 136). Figure 1 A cross-sectional view of an exemplary interconnect system 100 according to an embodiment. As shown, in this configuration, a protrusion 134 is at least partially fitted within an opening 145. A plug connector 104 and a panel connector 130 can be connected to a panel 102. Figure 4B More detailed display Figure 4A Part of (labeled "A"). As described above, seal 132 can be used to prevent the passage of foreign objects. Seal 132 can be made of an elastic material such as a polymer or rubber. Seal 132 may include one or more sealing elements 142 for sealing the gap between plug connector 104 and panel connector 130. In some embodiments, sealing element 142 includes a rib that can be configured to mate with a recess formed in plug connector 104. Ribs and recesses can have any suitable shape and size. Alternatively or additionally, ribs can be formed on plug connector 104, and recesses can be formed in seal 132. The mate of ribs with corresponding recesses can ensure that the position of seal 132 relative to plug connector 104 is maintained over time.

[0103] In some embodiments, seal 132 may include one or more sealing elements 152 for sealing gaps between plug connector 104 and panel 102 and / or between panel connector 130 and panel 102. As described in conjunction with sealing element 142, sealing element 152 may include ribs that can be configured to mate with recesses formed in panel 102 (although the reverse arrangement is also possible). Ribs may extend along the z-axis, thereby forming a skirt. The engagement of ribs with corresponding recesses ensures that the position of seal 132 relative to panel 102 is maintained over time.

[0104] In some embodiments, the seal 132 may include a base and a sidewall that extends away from the base (along the z-axis) and is configured to surround the outer boundary 166 of the panel connector 130.

[0105] In some embodiments, the plug connector 104 may have a surface that forms a seal with the first surface of the seal 132 (thus forming a first sealing interface), and the panel 102 may have a surface that forms a seal with the second surface of the seal 132 (thus forming a second sealing interface). In some embodiments, the first and second sealing interfaces are orthogonal to each other. Figure 4A In the illustrated embodiment, the sealing interface between the plug connector 104 and the seal 132 is parallel to the z-axis, and the sealing interface between the panel 102 and the seal 132 is parallel to the y-axis. However, it should be understood that other arrangements are also possible.

[0106] It should be understood that seal 132 may include only sealing element 142, only sealing element 152, or both sealing elements 142 and 152. When seal 132 is used as described herein, it can prevent (or at least limit) the passage of foreign matter through the cavity formed between plug connector 104 and panel 102. In this way, the integrity of the electrical contacts can be maintained and / or the lifespan of the interconnect system can be extended.

[0107] Figure 4C This is a cross-sectional view of another interconnection system according to some embodiments. In this arrangement, in addition to the sealing elements for engaging with the plug connector 104 and the panel 102, the seal 133 also includes a sealing element for engaging with the panel connector 130. Figure 4D More detailed display Figure 4C Part of it (labeled "B"). As shown, seal 133 includes sealing elements 142 and 152 (such as...). Figures 4A-4B (As in the embodiment described above). Additionally, the seal 133 includes a sealing element 165 arranged to engage with the panel connector 130. In this embodiment, the panel connector includes a recess 167, and the sealing element 165 is a rib adapted to fit into the recess 167; however, the reverse arrangement is also possible. In this way, an additional barrier is formed to prevent the passage of foreign objects. Figure 4C-4D One embodiment is arranged such that the sealing interface formed between the seal 133 and the panel connector 130 is parallel to the sealing interface between the seal 133 and the panel 102. As further shown, sealing elements 165 and 152 extend from the base of the seal 133 in opposite directions (sealing element 165 extends away from the panel 102, and sealing element 152 extends toward the panel 102). However, not all embodiments are limited to making these sealing interfaces parallel to each other.

[0108] In some implementations, such as Figure 4E-4F As further shown, the seal 133 may include ribs extending toward an opening formed in the seal through which the panel connector 130 passes. These ribs, labeled 135, are as follows: Figure 4F As shown, the Figure 4F More detailed display Figure 4E Part C. Rib 135 can be sized and positioned to engage with a recess formed in the panel connector 130. Rib 135 can extend along the y-axis. The engagement of rib 135 with the recess of the panel connector can further prevent the passage of foreign objects.

[0109] Figure 5A The image depicts embodiments of a seal according to some implementations. The seal (also referred to as a “resilient member”) may be made of a resilient material (e.g., a polymer). In this configuration, the seal includes an opening 144 for allowing passage of a panel connector 130 and an opening 147 for allowing passage of an attachment mechanism 141. In some embodiments, the seal includes a base 153 and a sidewall 151. The sidewall may extend away from the base 153 (parallel to the z-axis) along the periphery (or at least a portion of the periphery) of the base 153. In a mating configuration, the inner surface of the sidewall may be arranged facing the panel connector 130, and the outer surface of the sidewall may be arranged facing the plug connector 104. In some embodiments, the sidewall 151 may be arranged to surround the outer boundary 166 of the panel connector 130. Figures 4A-4B (As shown).

[0110] In some embodiments, the sealing element 142 is formed around the sidewall 151. For example, in at least some embodiments where the sealing element 142 includes ribs, the ribs may extend away from the sidewall 151 (parallel to the y-axis or x-axis). In some embodiments, the sealing element 152 is formed on the base 153. For example, in at least some embodiments where the sealing element 152 includes ribs, the ribs may extend away from the base 153 (parallel to the z-axis), thereby forming a skirt. In some embodiments, such ribs may extend in the opposite direction to the direction in which the sidewall 151 extends. In some embodiments, the sealing element 152 is formed along the periphery of the corresponding opening 147. In some embodiments, the sealing element 152 is formed along the periphery of the opening 144 or at least a portion thereof. In some embodiments, although in Figure 5AWhile not visible, seal 132 may include one or more sealing elements 165 for sealing the surface between the seal and panel connector 130. In some embodiments, sealing element 165 may be a rib extending in the opposite direction to sealing element 152. The connector may have slots positioned to receive the ribs extending from seal 132. Each slot may be sized and positioned to tightly accommodate the corresponding rib. Ribs may be sized such that the distance the rib extends into the corresponding slot is a multiple of its width. The length-to-width ratio may be, for example, greater than 1:1, or in some embodiments, greater than 2:1 or greater than 3:1.

[0111] Figure 5B The demonstration shows that, according to some implementation methods, they can be combined Figure 4C-4F The arrangement may be used in conjunction with any other suitable arrangement of additional seals. In this case, the seal comprises multiple sets of sealing elements (e.g., ribs) for sealing the surface between the seal and panel 102. For example, such as Figure 5B As shown, sealing element 152 can be an internal sealing element that surrounds the outer sealing element 159. Figure 5C As further shown in the image, it displays in more detail. Figure 5B The portions marked D in the diagram, sealing elements 152 and 159, can be arranged such that one or more recesses 171 are formed between them. The recesses (one or more) can be arranged around the periphery of openings 144 and 147 in the xy plane.

[0112] In some embodiments, the recess(s) 171 can serve as a waterproof compartment. For example, if dust, moisture, or other foreign matter inadvertently seeps between the panel and the seal (which can happen in some cases if the seal and panel are not properly aligned), at least a portion of the moisture can be trapped in the recess(s), thereby reducing the likelihood of moisture penetrating the openings 147 and / or 144 and reaching the mating contacts. In this way, sealing elements 152 and 159 can provide a double barrier against the passage of moisture or other foreign matter. Of course, in some embodiments, more than two sealing elements can be provided, thus forming additional recesses. Figure 5C As shown, the pits can be separated by bridging element 173, where sealing element 152 meets sealing element 159, but in another embodiment, a single continuous pit can be formed. Figure 5B The next part showcases Rib 135 (combined with...) Figure 4F (Description), which extends into the opening 144 and can be configured to engage with a groove formed in the panel connector.

[0113] Figure 6This is an exploded view showing a cable assembly 101 for use in conjunction with an interconnect system 100 according to some embodiments. The cable assembly 101 includes a plug connector 104, which may include a contact retainer 140, a contact cover 143, and a mating contact 105. An end of a cable 106 can be inserted into the plug connector 104, and the cable conductor can terminate at the mating contact 105 and be positioned to make electrical contact with the mating contact. The contact retainer 140 and the contact cover 143 are collectively referred to as a "contact support".

[0114] Each mating contact 105 may include a mating contact portion 120 configured to contact mating contact 136, a contact tail portion 146 configured to contact wire 108, and an intermediate portion 121 disposed between the contact tail portions 146 and 120. In some embodiments, each contact tail portion includes a V-shaped receptacle for receiving the end of wire 108. The V-shaped receptacle may be shaped and sized to secure the end of the wire while providing an electrical contact. The mating contact 105 may be at least partially supported inside the opening 145 by a contact retainer 140. The contact cover 143 may include support features for setting the contact force associated with the mating contact portion 120.

[0115] According to one aspect of this application, the contact force associated with the mating contact portion of the mating contact 105 can be adjusted by regulating the compliance of the mating contact portion. Specifically, the stiffer the mating contact portion, the greater the force required to hold the protrusion 134 once it is inserted into the opening. The inventors have recognized that, in some cases, the contact force can be set based on the expected environment in which the interconnection system 100 will be utilized (e.g., by the manufacturer or user). For example, if the interconnection system is expected to experience mechanical vibration, it may be desirable to increase the contact force to reduce the likelihood of the mating contacts disengaging from each other. In some embodiments, the contact force provided by the connector can be determined by the degree to which the mating contact portion in the socket can bend when the mating element is inserted.

[0116] Figure 7A A cross-sectional view of a plug connector 104 according to some embodiments is shown. Figure 7A This illustrates how the bending capability of the mating contact portions can be adjusted to set a desired contact force. As shown, a pair of opposing mating contact portions 120 can form a socket for receiving a mating element therebetween. When the mating element is inserted, the mating contact portions 120 can bend outward as indicated by arrows A1 and A2. The lower the bending capability of the mating contact portions, the greater the insertion resistance of the mating element, and therefore the greater the holding contact force. Therefore, the contact force can be adjusted by regulating the bending capability of the mating contacts. This can be achieved, at least in some embodiments, by adjusting the hinge axis of the mating contacts.

[0117] The hinge axis of the mating contact 105 is in Figure 7A The number 199 is used to denote this. When the mating element is inserted into the opening 145, the mating element causes the mating contact portion 120 to bend outward. This bending is achieved by pivoting relative to the hinge axis 199. In some embodiments, the position of the hinge axis along the length of the mating contact can be determined by using a contact cap 143. In the illustrated embodiment, a portion of the mating contact 105 is disposed between the contact retainer 140 and the contact cap 143. In some embodiments, the contact cap 143 includes a protrusion 157 (also referred to as a "finger" or "finger portion") extending toward the mating contact portion 120 in the mating direction. The contact cap 143 is arranged such that its sidewall 154 contacts the mating contact 105.

[0118] In some embodiments, the intermediate portion 121 includes first and second side surfaces. The mating contact 105 can be mounted such that the first side surface of the intermediate portion 121 abutting the contact retainer 140 is a first distance D1 from the end 158 of the mating contact adjacent to the contact tail 146. The contact cover 143 can be mounted such that the second side surface of the intermediate portion 121 abutting the contact cover 143 is a second distance D2 from the end 158 of the mating contact adjacent to the contact tail. In some embodiments, the second distance D2 is shorter than the first distance D1, such as... Figure 7A As shown. However, it should be understood that in other embodiments, the second distance D2 may be greater than the first distance D1.

[0119] The position of the hinge axis 199 along the length of the mating contact is determined by the position of the end 155 of the protrusion 157. The closer the end 155 is to the mating contact portion 120, the less flexible the mating contact portion is, and the greater the contact holding force is. Therefore, the position of the end of the protrusion 157 can be adjusted to produce the desired contact force.

[0120] In some implementations, the mating contact associated with the mating contact portion 120 can be adjusted based on the length of the protrusion 153. For example, a protrusion arranged to extend further along the mating direction can result in a greater contact force. The length of the protrusion 153 can be set at the factory, for example, based on the application where a plug connector is intended to be used.

[0121] In some implementations, the contact force can be adjusted by the user. For example, the contact cover 143 can be allowed to slide in the mating direction (along the z-axis), allowing the position of the protruding end relative to the mating contact to be adjusted. In this way, the user can set the contact force as desired by sliding the contact cover, which can change the position of the hinge axis 199.

[0122] To facilitate the insertion of mating elements, in some embodiments, the mating contact portion 120 may include corresponding protrusions 125. In some embodiments, two opposing mating contact portions 120 are arranged such that their respective protrusions 125 face each other.

[0123] Figure 7B The diagram illustrates the contact retainer 140, contact cover 143, and mating contact 105 when positioned within the opening 145 of the plug connector 104. As shown, the contact cover 143 can be positioned within a cavity formed between a portion of the plug connector 104 and the contact retainer. When a mating element (e.g., protrusion 134) is inserted into the opening 145, the mating contact portion 120 can be bent outwards, thereby allowing further insertion of the mating element. Figure 7B As shown, opening 145 can be disposed between the first opening and the second opening. The first opening can be configured to receive part of a complementary connector (such as panel connector 130). The second opening can be configured to receive cable 106. The housing of plug connector 104 can be formed to include the first opening, the second opening, and opening 145.

[0124] exist Figures 7B-7C In the configuration shown, a gap can be formed between the protrusion 157 and the inner wall of the plug connector housing. More details are shown below. Figure 7B The part marked F Figure 7C This illustrates how gap 161 is formed between protrusion 157 and wall 169. In some cases, when the mating contact portion 120 bends after the plug connector mates with the complementary connector (e.g.) Figure 7A As shown by arrows A1 and A2), the distal portion of protrusion 157 can be pushed open by a mating contact, thereby closing gap 161. This movement of protrusion 157 may cause a deviation in the position of the hinge axis relative to axis 199. Figure 7A As a result, during the insertion of the complementary connector, the contact force of the mating contact 120 holding the complementary connector is reduced. In the presence of vibration, this reduction in contact force may lead to a poor electrical connection. However, the inventors have recognized that movement of the protrusion 157 after mating of the plug connector can be prevented (or at least limited) by reducing or eliminating the gap between the protrusion 157 and the wall 169.

[0125] Therefore, in some embodiments, the protrusion 157 may include ribs extending toward the wall 169, such as Figure 7D As shown. In this embodiment, the protrusion 157 includes a rib 159 that projects laterally along the x-axis direction. Figure 7EAs further shown, rib 159 can be sized to abut against wall 169 when the plug connector is assembled, but not all embodiments are limited in this respect. In this way, protrusion 157 can have very little space (or no space at all) to move after the mating contact bends, thereby maintaining the desired contact force.

[0126] In some embodiments, it may be necessary to overmold the plug connector 104 to ensure reliable cable attachment to the plug connector and / or to insulate the conductors that may be exposed at the cable termination. Overmolding can be performed, at least in some embodiments, by injecting fluid into the opening through which the cable passes in the plug connector. The fluid can then be allowed to solidify, thereby holding the cable and plug connector together. One exemplary configuration in which overmolding is performed is shown in… Figure 8A The diagram illustrates a description of some embodiments. Figure 1 A cross-sectional view of the plug connector (in the xz plane). In some embodiments, fluid 180 can be injected through an opening in the receiving cable 106 of the plug connector 104. The fluid 180 can form an insulating material upon curing. The overmolded portion prevents stress on the electrical connection between the cable conductors and mating contacts in the event of accidental cable pull-out.

[0127] Figure 8B This is an exploded view of a plug connector 104 according to another embodiment, showing how the fluid 180 behaves after solidification. In this non-limiting embodiment, the overmolded part 181 obtained by solidifying the fluid 180 extends within the connector housing of the plug and the external cable 106. In some embodiments, the overmolded part 181 may be formed via a low-pressure overmolding process. In some embodiments, such as Figures 8B-8C As further shown, the potting element 182 can be positioned inside the housing of the plug connector for shock absorption. The potting element 182 can be made of an elastic (e.g., silicone rubber) or a gel-like material (e.g., epoxy resin).

[0128] In some implementations, ribs may be formed in the area where the wires of the cable of the plug connector are inserted, such as... Figure 8C As shown in the figure, rib 183 can be formed in the sidewall of the plug connector within the overmolded area. Rib 183 helps to hold the overmolded part in place by increasing the friction between the overmolded part and the plug connector.

[0129] The inventors have recognized that injecting fluid into the plug connector as described above can cause some of the fluid to reach the mating contact portion of the mating contact 105, which can create an undesirable insulating barrier around the mating contact portion. The formation of such a barrier can impair the connector's ability to electrically contact complementary connectors. In some embodiments, fluid passage can be prevented by blocking the injection portion of the plug connector from the portion where the mating contact is housed. In some embodiments, the blockage can be achieved by utilizing ribs to at least partially fill channels that may otherwise be formed in the plug connector.

[0130] Figure 9A This demonstrates according to some implementation methods. Figure 1 An isometric view of a portion of the plug connector. Specifically, Figure 9A This diagram illustrates a contact holder 140, a contact cover 143, a mating contact portion 120, and the termination end of a cable conductor 108. In some embodiments, one or more ribs 160 may be formed on the outer surface of the contact holder 140, and one or more ribs 162 may be formed on the outer surface of the contact cover 143. Figure 9A As shown, ribs 160 and 162 can be longitudinally aligned with each other such that continuous ribs are formed around the outer periphery of the assembly (the assembly includes a contact retainer 140 and a contact cover 143). Rib 160 can project from the contact retainer in a direction perpendicular to the mating direction (e.g., along the x-axis or y-axis, depending on the location). Additionally or alternatively, rib 162 can project from the contact cover in a direction perpendicular to the mating direction (e.g., along the x-axis).

[0131] Figure 9B Based on some implementation methods Figure 1 This is a cross-sectional view taken in the xz plane of the plug connector. As shown, when the contact retainer 140 and contact cover 143 are placed in the housing of the plug connector, the presence of ribs 160 and 162 can prevent fluid from passing through. For example, rib 162 can be arranged to abut against wall 169. In this way, a channel that would otherwise exist between wall 169 and contact cover 143 is blocked. Similarly, rib 160 can abut against the wall of the plug connector housing ( Figure 9B (Not shown in the diagram). This wall may be perpendicular to wall 169. It should be understood that in some embodiments, ribs may be formed in the wall (e.g., wall 169) of the plug connector housing. These ribs may abut against the outer surface of the contact holder and / or contact cover.

[0132] The inventors further recognized that, in some cases, non-zero manufacturing tolerances can create discontinuities in the region where ribs 160 and 162 are joined. Exemplary discontinuities are found in... Figure 10AThe diagram illustrates corresponding portions of a contact holder 140 and a contact cover 143 according to some embodiments. In this case, a discontinuity 170 is formed between ribs 160 and 162, which can create a fluid passage.

[0133] To prevent the formation of these channels, in some embodiments, ribs may be formed in the wall 160 and the wall against which the rib 160 abuts. One embodiment of such a rib is... Figure 10B The image depicts, according to some embodiments, the removal of the contact retainer and contact cover. Figure 1 The internal portion of the plug connector. In this case, rib 172 is formed on wall 169 and positioned to align with discontinuity 170 so as to occupy the gap formed between ribs 160 and 162. In some embodiments, multiple ribs 172 may be used, and each of these ribs may be aligned with a corresponding discontinuity.

[0134] Figure 11A This is obtained in the xy plane according to some implementation methods. Figure 1 A cross-sectional view of the plug connector of an embodiment. The figure shows the contact retainer 140 and contact cover 143 when assembled in the plug connector 104. Figure 11B A portion of Figure 11 is shown in more detail (labeled "B"). As shown, rib 170 is aligned with the discontinuity present between ribs 160 and 162, so that the gap between these ribs is filled.

[0135] As mentioned above, plug connectors (such as Figure 11A (as shown) can be used with panel connectors (such as Figure 3A The panel connector 130 shown mates with the electronic housing. The panel connector can be mounted in the panel of the electronic housing, such as... Figure 3B As shown in the diagram. The panel connector can be used with other connectors inside the housing (such as...). Figure 3B The panel connector 110 shown mates with the board connector. The use of guide structures in at least some embodiments can facilitate the engagement of the panel connector with the board connector. These structures can be adapted to allow the panel connector to be guided into place by sliding protrusions into corresponding channels. Figure 12This is an isometric view of a board connector according to some embodiments, the board connector having one or more channels for receiving one or more guide structures from a panel connector. As shown, in this configuration, the panel connector 130 includes a plurality of protrusions 204 formed at a mounting interface through which the panel connector 130 can be mounted to the board connector 110. The board connector 110 may include channels 202 formed on the housing of the board connector. In one embodiment, the channel 202 includes a concave surface formed on the housing of the board connector. However, it should be understood that any suitable complementary guide structures on the panel connector and the board connector can be used, including, for example, fully circular or triangular protrusions and complementary channels.

[0136] Channels 202 and protrusions 204 can be arranged to facilitate mounting the panel connector to the board connector. For example, channels 202 and protrusions 204 can be sized and shaped such that protrusions 204 slide within corresponding channels, thereby guiding the board connector into insertion through openings formed inside the outer housing of the panel connector. It should be understood that the protrusions may extend from either the panel connector or the board connector. However, at least in some embodiments, it may be advantageous for the protrusions to extend from the panel connector because it reduces the guiding distance. Although the two channels and two protrusions are in Figure 12 The illustrated embodiment forms the desired shape, but any suitable number of channels and protrusions can be used in other embodiments. Furthermore, the guide protrusions and channels are shown as being integrally formed with the connector housing; this is due to the guide features being formed as part of the molded housing, and integrally formed guide components are not necessary. The guide features can, for example, be formed in any one or both separate modules coupled to the connector housing.

[0137] In some implementations, asymmetrical sockets can be used to ensure that the board connector and the panel connector mate in the correct orientation. In this way, if the board connector is inserted into the panel connector in the wrong orientation, mating is prevented. Figures 13A-13B Showing the following according to some implementation methods Figure 3B The diagram shows a bottom view and a top view of the oriented board connector 110. Specifically, Figure 13A From Figure 12 The bottom view is taken from the angle of line 13-13 in the middle. Figure 13B It is along Figure 12 Sectional view of line 15-15 in the middle. Figure 13A and 13B This shows two parallel planes obtained from different locations. The location of the board connector is shown. Figure 13B The plane is closer to plate 102.

[0138] As shown in the figure, board connector 110 includes receptacles, numbered 224 and 226. The receptacles are configured to receive the end of mating contact 136 (e.g., as shown in the figure). Figure 15E (As shown). Sockets 224 and 226 can be arranged symmetrically with respect to the line HH passing through the center of the panel connector to the mating interface of the board connector. As a result, even if the panel connector 130 is rotated 180 degrees relative to the board connector, the mating contact 136 will align with the corresponding socket. However, protrusion 204 and channel 202 can be arranged asymmetrically with respect to line HH. Figure 13B In this implementation, channel 202 is not centered on line HH. Instead, channel 202 and protrusion 204 are offset from line HH. As a result, if an attempt is made to mate the panel connector with the board connector in the wrong orientation, insertion of the mating contacts into the socket is prevented. Conversely, if the board connector is correctly inserted into the panel connector, mating is permitted.

[0139] The inventors have recognized that the aforementioned seals can be damaged or otherwise worn due to prolonged contact with foreign objects penetrating the interior of the interconnect system. Therefore, the inventors have developed a design to protect the seals from accidental damage. In some embodiments, the seals can be protected by raising the portion of the panel that contacts the panel connector relative to the plane of the panel, thereby forming a wall at the base of the panel. In this way, foreign objects that may otherwise penetrate and contact the seals can be blocked by the wall of the raised portion.

[0140] One embodiment of this arrangement is... Figures 14A-14B It is displayed in the middle. Figure 14A It is an isometric view of a partially cut-out interconnect system having a plug connector that engages with a panel connector mounted to a panel. Figure 14B It is based on some implementation methods Figure 14A An enlarged view of part E. As shown, in this embodiment, panel 102 includes a planar base 103 and a raised portion 220, the top surface of which is offset relative to the top surface of the planar base (along the z-axis). As further shown, the raised portion 220 can surround the opening through which the panel connector 130 is inserted. Even if a foreign object accidentally passes through the gap formed between the panel and the plug connector, the likelihood of the foreign object reaching the seal by climbing the raised portion 220 is greatly reduced compared to a panel with a completely flat surface.

[0141] The plug connector 104 may include an angled end 212 formed on a sidewall 210 of the plug connector housing. The angled end may be shaped to extend outward at an angle relative to the plug connector housing. The angled end may be arranged to protect the lift portion 220 and thus protect the seal from the passage of foreign objects. In some embodiments, when the plug connector is attached to a panel, the angled end 212 is separated from the top surface of the planar base 103 of the panel by a gap 214 (but in other embodiments, the angled end 214 may contact the top surface of the planar base 103 of the panel).

[0142] Figures 15A-15E Examples of sequences for manufacturing panel connectors according to some implementation methods are shown. This manufacturing sequence can result in lower cost and more robust connectors. Figure 15A In the process, a plurality of mating contacts 136 are provided. The mating contacts can be formed by stamping, electroplating, and any other suitable operation. In the illustrated embodiment, each contact has the same shape with a planar surface for mating with the beam of a cable connector, and an elongated end for accessing a socket of a board connector. In the illustrated embodiment, the contact has a shoulder 1536 at the interface between the planar surface and the shaft that joins the planar surface and the elongated end.

[0143] exist Figure 15B In this step, the mating contact 136 can be inserted into the first housing portion 230. In some embodiments, the first housing portion 230 is formed by overmolding the mating contact. In other embodiments, the first housing portion 230 is formed separately, and the mating contact is inserted through a channel formed in the first housing portion 230. In this method, the shoulder 1536 can engage a corresponding flange within the housing portion 230 to position the contact 136. In either case, the mating contact 136 can be positioned to match the arrangement of corresponding mating contacts in the plug connector.

[0144] The first housing portion 230 may include a protrusion 231 that may be shaped and sized to secure the housing 234 to the first housing portion.

[0145] exist Figure 15CIn this step, the second housing portion 232 can be mounted to the shaft portion of the mating contact 136. First and second housing portions, or any suitable number of housing portions, can be used, as molding multiple shorter housing portions is simpler and more precise than molding a single housing portion. Similar to the first housing portion 230, the second housing portion 232 can be formed by overmolding the mating contact, or it can be molded separately. It should be understood that, at least in some embodiments, the first and second housing portions are separate parts, but they can be positioned to contact each other when assembled with the mating contact 136. It should be further understood that the positioning order of the housing portions is not limited to the sequence shown, as the second housing portion can be positioned prior to the positioning of the first housing portion in some embodiments. In some embodiments, the second housing portion may include one or more protrusions shaped and sized to secure the second housing portion to the outer housing. The first and second housing portions may be offset relative to each other along the length of the mating contact 136.

[0146] Figure 15B-15C The steps ensure that the shoulder of the mating contact engages with the lug of the housing portion 230. Although Figure 15B-15C Two separate housing portions are shown, but in other embodiments, a single housing portion may be used.

[0147] like Figure 15D As shown (a perspective view of the resulting panel connector), an outer housing 234 can be formed for the panel connector. In some embodiments, the outer housing can be formed by... Figure 15C The structure is formed by high-pressure coating molding.

[0148] like Figure 15D As further shown, in order to allow mating contact 136 to be electrically connected to the corresponding mating contact (e.g., Figure 2 The mating contact 105), the end of the mating contact 136 (which is not limited to having a flat shape, such as...) Figures 15A-15D (As shown) can be exposed on the outer surface of the outer housing 234.

[0149] like Figure 15D As further shown, the outer housing can be molded around the protrusion 231, thereby securing the two parts together.

[0150] During this overmolding process, the mating contacts can be held in place by pressing them between the metal of the mold and the plastic housing 230. In some embodiments, for example... Figure 3AAs shown, the planar surface forming the mating contacts can be flush with the outer surface of the overmolded panel connector. Therefore, the surface of the mold used during overmolding to press the contacts and hold them in place can be largely flat. Such a mold can be relatively inexpensive—less expensive than a mold used to hold two rows of contacts in place without requiring a pre-formed housing 230.

[0151] As another advantage of preforming the first and second shell portions, the volume of material used in the overmolding can be reduced relative to the volume of overmolding material required to form the outer shell entirely via overmolding. This reduction in material quantity, due to the thickness of the outer shell walls, can reduce the formation of shrinkage cavities that might otherwise occur in the absence of the first and second shell portions.

[0152] The outer housing 234 can be molded in any desired shape, including features with guide protrusions, features for receiving seals, and a widened portion 236 configured for mounting to the panel 102. The widened portion 236 may have multiple threaded holes adapted for screw passage, which can be used to mount the panel connector to the panel.

[0153] exist Figure 15E In this step, the potting element 238 can be placed inside the outer housing 234. The potting element 238 can be made of an elastic (e.g., silicone rubber) or gel-like material (e.g., epoxy resin). The potting element 238 can at least partially surround the mating contact 136. According to some embodiments, the potting element 238 can form an environmental seal around the contact 136 and / or can be used as a shock-absorbing material, and can reduce vibration of the mating contact surface between the panel connector and the cable connector, for example, in the case of fans or other vibrating components within the electronic housing. Absorbing vibration can extend the life of the mating contact.

[0154] The connectors described herein support simple assembly operations for electronic housings. The assembly of rugged, environmentally sealed interconnect systems follows certain implementation methods. Figures 16A-16C It is displayed in the middle. Figure 16A Display panel 102, board connector 110 and circuit board 111. Figure 16A Only the portion of the display panel that can form a housing or support other structures for electronic components is shown. A printed circuit board, including board connector 110, can be mounted within the electronic housing. The printed circuit board can be positioned to align board connector 110 with an opening in the panel. This alignment can be achieved by attaching the printed circuit board to a guide rail or other suitable mounting hardware.

[0155] exist Figure 16BIn this step, panel connector 130 can be inserted, for example, by passing the panel connector through an opening in the panel 102. Alignment protrusions on the panel connector align the panel connector with the board connector. The panel connector can then be screwed or otherwise attached to the panel. Figure 16C In this step, the plug connector 104 can be assembled to the panel 102. The plug connector can be assembled such that its mating contacts are positioned to contact the mating contacts of the panel connector.

[0156] In some implementations, components can be configured for simple assembly, allowing the assembly process to be automated. For example, alignment features that ensure panel connectors are aligned with board connectors and whose asymmetry allows connectors to be assembled along only one orientation can enable the use of automated assembly tools. Similarly, the shape of the interface between the cable connector and the electronic housing can simplify the alignment of the cable connector and the panel connector, allowing those components to be assembled automatically in a similar manner.

[0157] Some embodiments described herein relate to plug connectors arranged to mate with panel connectors attached to a panel. For example, Figure 1 A plug connector 104 is shown that mates with a panel connector attached to a panel 102. Panel 102 may form part of an electronic housing (not shown for simplicity), such that panel connector 130 forms an electrical connection between plug connector 104 and the interior of the electronic housing. Mechanisms may be included to establish electrical connections from panel connector 130 to components inside the electronic housing. In the above embodiment, this mechanism is another mating interface on panel connector 130 that mates with board connector 110, which may be attached to a printed circuit board 111 inside the housing.

[0158] However, it should be understood that this application is not limited to these types of electrical interconnect systems, as alternative mechanisms for making electrical connections between panel connectors and components inside the electronic housing are also possible. Using such alternative arrangements, the external mating interface of the panel connector can be configured and manufactured using the techniques described above, including... Figures 15A-15D The molding process and the above combination Figure 3A-5C The sealing arrangement discussed in 14A-14B.

[0159] One possible configuration involves a panel connector configured to mate with a second cable connector. The second cable connector may support conductive terminals having ends arranged to form electrical contacts using mating contacts of the panel connector. Those mating contacts configured to mate with the second cable connector inside the housing may be configured to be in a position such as… Figure 3A and 3BThe external mating interface is shown. However, the specific configuration of the internal mating contacts does not need to match the configuration of the mating contacts at the external interface.

[0160] One embodiment of this arrangement is... Figure 17A The image depicts an interconnect system having a plug connector 104 and a second cable connector 304 according to some embodiments. In this embodiment, the plug connector 104 is electrically connected to a cable 306 via the cable connector 304 and a panel connector 302. The panel connector 302 has two interfaces: a first external interface to which the plug connector 104 is attached, and a second internal interface to which the cable connector 304 is attached. The conductor of the cable 306 is then guided to a component inside the housing. Although the panel (such as panel 102) is simplified for simplicity... Figure 17A Although not shown in the diagram, it can be seen that panel connector 302 is similar to... Figure 3A and 3B The panel connector has a lifting element that fits through a panel opening and an attachment feature that allows the connector to be attached to the panel, such as using screws or other fasteners.

[0161] like Figure 17B As further shown, it demonstrates when mated to the plug connector 104. Figure 17A The cable connector, panel connector 302, may have an external mating interface as shown above. It may present an end 308 with conductive terminals that are connected to the cable 306 via an internal interface of panel connector 302.

[0162] In some implementations, the same plug connector can be mated to a cable connector, such as Figure 1 As shown, and connected to the panel connector (at different times, of course), as Figure 17A As shown.

[0163] Furthermore, it should be understood that panel connectors with external interfaces as described herein are not limited to use in systems where cable assemblies (including plug connectors connected to the cables) mate with that interface. Any other component with a mating interface complementary to the mating interface of the panel connector can be used. For example, instead of a plug connector, a patch cord can be attached to the mating interface.

[0164] Figure 18 This is an isometric view showing a plug connector 104 juxtaposed with jumper 310 according to some embodiments. Jumper 310 may have a mating interface sized and shaped to resemble the mating surface of plug connector 104 for mating with the external interface of a panel connector, such as... Figure 3BOr as shown in 17B. However, jumper 310 is not attached to the cable as in cable connector 104. In the illustrated embodiment, mating contacts within jumper 310 that mate with the panel connector are attached to each other. Jumpers can be used to configure components inside an electronic housing by selectively forming connections between points inside the housing.

[0165] In one particular embodiment, the two terminals of the control input and ground can be connected to contacts of a panel connector. Cable connector 104 can be attached to the panel connector to direct the control input to an external controller, which generates a control signal indicating an on or off state. Alternatively, jumper 310 can be attached to the panel connector. This jumper can be internally connected between the control inputs, connecting the control input terminals together to create an always-on state. Alternatively, the jumper can be internally connected between the control input and ground to create an always-off state.

[0166] Although jumper 310 may internally contain connections between the terminals of the panel connector, it can be configured in other ways. For example, it may not be connected to some or all of the terminals of the panel connector, providing coverage for unused terminals in some systems. Alternatively or additionally, jumper 310 may contain electronic components, such as resistors, capacitors, or semiconductor chips, within its housing, which can generate or modify signals connected to the terminals of the panel connector.

[0167] The interconnect systems of the type described herein can be modified in any suitable manner. For example, in some embodiments, mating contacts may be placed in a panel connector instead of a plug connector. The contact force of these mating contacts can be adjusted using the techniques described herein. In some such embodiments, the plug connector may include a pad for contacting the mating contacts of the panel connector.

[0168] The techniques described herein can be used in connectors with configurations other than those described above. For example, the techniques described herein can be used in mezzanine connectors or backplane connectors. Such alternative connector configurations can be used with all or any suitable subset of the features described herein. Furthermore, it should be understood that all the structures, materials, and construction techniques described herein can be used together; however, in some embodiments, some or all of the structures, materials, or techniques may be omitted.

[0169] These changes, modifications, and improvements are intended to be part of this disclosure and are intended to fall within the spirit and scope of the invention. Furthermore, while advantages of the invention are pointed out, it should be understood that not every embodiment of the invention includes every described advantage. Some embodiments may not implement any features described herein and, in some cases, are advantageous. Therefore, the foregoing description and figures are merely illustrative.

[0170] Examples of arrangements that can be implemented according to some implementation methods include the following: A1. A plug connector, comprising: Cables, which consist of multiple conductors; The housing includes: The first opening is configured to receive part of a mating connector; The second opening; and At least one third opening between the first opening and the second opening; and A plurality of terminals extending through the at least one third opening, the plurality of terminals including mating contact portions extending into a first opening and contact tail portions extending into a second opening, wherein the plurality of wires of the cable are electrically connected to the contact tail portions of the plurality of terminals within the second opening; and The insulating material inside the second opening encloses the contact tails of the plurality of terminals within the second opening and seals the passage between the at least one third opening and the second opening.

[0171] A2. The plug connector of embodiment A1, wherein the housing includes: The housing includes a first opening, a second opening, and at least one third opening; and Insert the contact holder into the at least one third opening.

[0172] A3. The plug connector of embodiment A2, wherein: The plurality of terminals includes an intermediate portion that interconnects the corresponding mating contact portion with the corresponding contact tail portion; and The middle portion of the multiple terminals is attached to the contact bracket.

[0173] A4. The plug connector of embodiment A2 or A3, wherein: The contact support includes a contact retainer and a contact cover, the contact cover including at least one finger-like portion; The plurality of terminals includes an intermediate portion interconnecting corresponding mating contact portions with corresponding contact tail portions, the intermediate portion including first and second side surfaces, and wherein the terminals are mounted such that the first side surface abutting the contact retainer is spaced a first distance from the end of the terminal adjacent to the contact tail portion; and The contact cover is installed such that the second side of the middle portion abutting the contact cover is a second distance away from the end of the terminal, the second distance being shorter than the first distance.

[0174] A5. A plug connector according to any one of embodiments A2-A4, wherein: The at least one third opening extends along the first direction; and The contact support includes an outer surface, and at least one third opening is defined by an inner surface facing the outer surface; and At least one of the outer surface and the inner surface includes a plurality of parallel ribs extending transversely to the first direction, wherein the plurality of ribs are configured to close the channel between the at least one third opening and the second opening.

[0175] A6. A plug connector according to any one of embodiments A4-A5, wherein: The contact support includes a contact retainer and a contact cover, configured such that a channel between the contact retainer and the contact cover extends in a first direction; and The housing includes a second rib extending along a first direction and into a groove.

[0176] A7. A plug connector of any one of embodiments A1-A6, wherein the housing includes one or more ribs that extend into a second opening and contact an overlay molding material occupying at least a portion of the second opening.

[0177] B1. An apparatus comprising: An electrical connector having an opening; Multiple mating contacts are inserted through an opening in an electrical connector, each of the multiple mating contacts having a mating contact portion, a contact tail portion, and an intermediate portion between the mating contact portion and the contact tail portion; A contact retainer, which is at least partially disposed within an opening of the electrical connector and configured to support the plurality of mating contacts; and A contact cover, which is at least partially disposed within the opening of the electrical connector, such that at least one of the plurality of mating contacts is disposed between the contact retainer and the contact cover; The intermediate portion includes first and second side surfaces, and the mating contact is mounted such that the first side surface abutting the contact holder is a first distance away from the end of the mating contact adjacent to the tail portion of the contact; and The contact cover is installed such that the second side of the middle portion abutting the contact cover is a second distance away from the end of the mating contact, the second distance being shorter than the first distance.

[0178] B2. The device of embodiment B1, wherein the contact cover includes one or more protrusions, and wherein a second side of the middle portion abutting the one or more protrusions is a second distance from the end of the mating contact.

[0179] B3. The device of embodiment B2, wherein at least one of the one or more protrusions includes a first surface and a second surface opposite to the first surface, the first surface contacting a second side surface of the intermediate portion, and the second surface contacting the inner wall of the electrical connector opening.

[0180] B4. The device of any one of embodiments B1-B3, wherein the contact retainer and the contact cover are separate parts.

[0181] B5. The device of embodiment B1, wherein at least a portion of the middle section does not contact the contact cover.

[0182] B6. The device of any one of embodiments B1-B5, wherein the mating contact includes a raised surface adapted to make electrical contact with a pad formed in the mating connector.

[0183] B7. The device of embodiment B6, wherein the plurality of mating contacts includes at least a first mating contact and a second mating contact, and wherein the raised surface of the first mating contact faces the raised surface of the second mating contact.

[0184] B8. The device of any one of embodiments B1-B7, wherein the contact tail includes a V-shaped mechanism for receiving wires therein.

[0185] B9. The device of any one of embodiments B1-B8, wherein the electrical connector is configured to receive a cable therein.

[0186] B10. The apparatus of any one of embodiments B1-B9 further includes: Cables, which include multiple conductors; and Insulating materials; The opening is a first opening, and the electrical connector also includes a second opening configured to receive part of a mating connector and a third opening configured to receive a cable, with the first opening disposed between the second opening and the third opening; The plurality of mating contacts extend through a first opening, with a portion of the mating contact extending into a second opening and a tail portion extending into a third opening, wherein the plurality of wires of the cable are electrically connected to the tail portion of the contact within the third opening; and The insulating material is placed inside the third opening, encapsulating the contact tails of the multiple terminals inside the third opening and sealing the channel between the first and third openings.

[0187] B11. The device of any one of embodiments B1-B10, wherein the electrical connector is configured to mate with the adapter connector such that, when mated, the electrical connector and the adapter connector are attached to a panel, wherein the device further includes: An elastic member having first and second sealing elements, the elastic member being configured to form a first sealing interface with a panel and a second sealing interface with an electrical connector, the first and second sealing interfaces being orthogonal to each other. The first sealing element is configured to engage with the panel, and the second sealing element is configured to engage with the electrical connector.

[0188] C1. An adapter connector configured to mate with a plug connector such that, when mated, the adapter connector and the plug connector are attached to a panel, the adapter connector comprising: Insulating housing; A first plurality of mating contacts, supported by an insulating housing, are configured to electrically contact a second plurality of mating contacts supported by a plug connector; and An elastic member having first and second sealing elements, the elastic member being configured to form a first sealing interface with a panel and a second sealing interface with a plug connector, the first and second sealing interfaces being orthogonal to each other. The first sealing element is configured to engage with the panel, and the second sealing element is configured to engage with the plug connector.

[0189] C2. An adapter connector of embodiment C1, wherein the resilient member includes a base and a sidewall configured to surround the outer boundary of the adapter connector.

[0190] C3. The adapter connector of embodiment C2, wherein a first sealing element is disposed at the base and a second sealing element is disposed at the sidewall.

[0191] C4. An adapter connector of any one of embodiments C1-C3, wherein the first sealing element extends in a direction parallel to the mating direction of the adapter connector and the plug connector.

[0192] C5. An adapter connector of any one of embodiments C1-C4, wherein the first sealing element includes a rib configured to engage with a corresponding recess formed in the panel.

[0193] C6. An adapter connector of any one of embodiments C1-C5, wherein the second sealing element includes a rib configured to engage with a corresponding recess formed in the plug connector.

[0194] C7. An adapter connector of any one of embodiments C1-C6, wherein the adapter connector is attached to the panel by a plurality of screws.

[0195] C8. The adapter connector of embodiment C7, wherein the plurality of screws pass through corresponding openings formed in the elastic member.

[0196] C9. An adapter connector according to any one of embodiments C1-C8, wherein: The insulating housing includes a body having a top surface and an angled surface disposed at the edge of the top surface; and The first plurality of mating contacts extend through the top surface.

[0197] C10. The adapter connector of embodiment C9, wherein: The first sealing element is positioned to form a first sealing interface with the panel; The second sealing element is positioned to form a second sealing interface with the plug connector; The second sealing element has an upper edge; and The upper edge of the second sealing element is below the angled surface.

[0198] C11. An adapter connector for any one of embodiments C1-C10, wherein: The insulating housing includes a groove; and The elastic member includes a rib extending into the groove, and the groove and the rib each have an aspect ratio of at least 2:1.

[0199] D1. A resilient member configured to seal attachment to first and second electrical connectors on a panel, the resilient member comprising: The base has an opening formed therethrough, and the base is configured to form a first sealing interface with the panel; A sidewall connected to the base, the sidewall being configured to form a second sealed interface with the second electrical connector; A first sealing element, which extends from the base; and The second sealing element extends from the sidewall. The first sealing interface and the second sealing interface are perpendicular to each other.

[0200] D2. The elastic member of embodiment D1, wherein the base, sidewalls and first and second sealing elements are made of elastic material.

[0201] D3. An elastic member of any one of embodiments D1-D2, wherein the first sealing element and the sidewall extend in opposite directions.

[0202] D4. An elastic member of any one of embodiments D1-D3, wherein the opening is a first opening, and wherein the elastic member further includes a second opening, wherein the first sealing element is disposed along at least a portion of the periphery of the second opening.

[0203] D5. An elastic member of any one of embodiments D1-D3, wherein the first sealing element includes a rib configured to engage with a corresponding groove formed in the panel.

[0204] D6. An elastic member of any one of embodiments D1-D5, wherein the second sealing element includes a rib configured to engage with a corresponding groove formed in the second electrical connector.

[0205] D7. The elastic member of any one of embodiments D1-D6 further includes a third sealing element extending from the base, wherein the first sealing element and the third sealing element form one or more recesses surrounding therebetween.

[0206] D8. The elastic member of embodiment D7, wherein the one or more recesses surround the opening in a plane defined by the base.

[0207] D9. An elastic member of any one of embodiments D1-D8, wherein the base is further configured to form a third sealing interface with the first connector, and wherein the elastic member further includes a third sealing element extending from the base, the first and third sealing elements extending in opposite directions.

[0208] D10. The elastic member of any one of embodiments D1-D9 further includes a third sealing element extending from the base toward the opening.

[0209] E1. An electrical connector, comprising: A shell having an opening formed therethrough and a first rib extending into the opening; Multiple mating contacts are inserted through an opening in the housing; A contact retainer, at least partially disposed within an opening in the housing and configured to support the plurality of mating contacts, the contact retainer including a second rib abutting against a first wall of the opening; and A contact cover, which is at least partially disposed within an opening in the housing, such that at least one of the plurality of mating contacts is disposed between a contact retainer and a contact cover, the contact cover including a third rib abutting against a first wall of the opening; The second and third ribs are longitudinally aligned with each other and form a discontinuity between them, and the first rib is disposed in the discontinuity.

[0210] E2. An electrical connector of embodiment E1, wherein the housing is configured to receive a cable therein, the cable including at least one wire configured to be connected to at least one of the plurality of mating contacts.

[0211] E3. An electrical connector of embodiment E1 or E2, wherein the contact retainer and the contact cover are separate parts.

[0212] E4. An electrical connector of any one of embodiments E1-E3, wherein the plurality of mating contacts extend along a first direction and the third rib extends along a second direction perpendicular to the first direction.

[0213] E5. Electrical connector of embodiment E4, wherein the first rib extends along a first direction.

[0214] E6. An electrical connector according to any one of embodiments E1-E5, wherein: The plurality of mating contacts includes a mating contact portion, a contact tail portion, and an intermediate portion interconnecting the mating contact portion and the contact tail portion. The intermediate portion includes first and second side surfaces, and wherein a terminal is mounted such that the first side surface abutting against a contact retainer is a first distance away from the end of the mating contact adjacent to the contact tail portion; and The contact cover is installed such that the second side of the middle portion abutting the contact cover is a second distance away from the end of the mating contact, the second distance being shorter than the first distance.

[0215] E7. An electrical connector according to any one of embodiments E1-E6, wherein the electrical connector is configured to mate with an adapter connector such that, when mated, the electrical connector and the adapter connector are attached to a panel, wherein the electrical connector further includes: An elastic member having first and second sealing elements, the elastic member being configured to form a first sealing interface with the panel and a second sealing interface with the housing, the first and second sealing interfaces being orthogonal to each other. The first sealing element is configured to engage with the panel, and the second sealing element is configured to engage with the housing.

[0216] F1. A panel connector configured to attach to a board connector and mate with a plug connector, such that when mated, the panel connector and the plug connector are attached to a panel, the panel connector comprising: Insulating housing, comprising: The interface is configured to mate with a plug connector; The mounting interface is used for mounting to a board connector, and the mounting interface includes a cavity configured to receive part of the board connector; One or more protrusions formed at the mounting interface and configured to slide into corresponding one or more channels in the plate connector; and The first plurality of mating contacts, supported by an insulating housing, are configured to make electrical contact at the mating interface with the second plurality of mating contacts supported by the plug connector.

[0217] F2. A panel connector of embodiment F1, wherein a first plurality of mating contacts are arranged symmetrically with respect to a first axis passing through the center of the interface between the panel connector and the board connector, and wherein the one or more protrusions are arranged asymmetrically with respect to the first axis.

[0218] F3. A panel connector of any one of embodiments F1-F2, wherein the insulating housing includes first and second housing portions supporting a first plurality of mating contacts, and an outer housing covering the first and second housing portions.

[0219] F4. The panel connector of any one of embodiments F1-F3 further includes: An elastic member having first and second sealing elements, the elastic member being configured to form a first sealing interface with a panel and a second sealing interface with a plug connector, the first and second sealing interfaces being orthogonal to each other. The first sealing element is configured to engage with the panel, and the second sealing element is configured to engage with the plug connector.

[0220] F5. Panel connector of embodiment F4, wherein the resilient member includes a base and a sidewall configured to surround the outer boundary of the panel connector.

[0221] F6. A panel connector of any one of embodiments F1-F5, wherein the insulating housing includes a body having a top surface and an angled surface disposed at an edge of the top surface.

[0222] G1. A panel configured to be attached to a panel connector and to receive a plug connector thereon, such that the plug connector electrically contacts the panel connector, the panel comprising: Planar base; An opening formed through a planar base and configured to receive a panel connector therethrough; and The lifting portion is formed on the planar base and surrounds the opening, and has a top surface that is perpendicularly offset from the top surface of the planar base.

[0223] G2. The panel of embodiment G1 further includes a plug connector, wherein the plug connector comprises: An insulating housing having a plurality of sidewalls forming cavities configured to receive a raised portion of a panel therein, the plurality of sidewalls having corresponding inclined ends projecting outward relative to the insulating housing; and The first plurality of mating contacts, supported by an insulating housing, are configured to make electrical contact with the second plurality of mating contacts supported by the panel connector.

[0224] G3. Panel of embodiment G2, wherein the insulating housing is sized such that when the plug connector is received on the panel, the corresponding inclined end is adjacent to the top surface of the planar base.

[0225] G4. The panel of any one of embodiments G1-G3 further includes a plurality of grooves formed on the top surface of the lifting portion and configured to receive corresponding ribs of the seal, wherein the seal is configured to be disposed between the panel and the panel connector.

[0226] H1. A panel connector configured to attach to a board connector and mate with a plug connector, such that when mated, the panel connector and the plug connector are attached to a panel, the panel connector comprising: At least one housing portion; An overmolded outer shell covering at least one shell portion; and A first plurality of mating contacts, supported by the at least one housing portion, are configured to electrically connect to a second plurality of mating contacts supported by a plug connector.

[0227] H2. The panel connector of embodiment H1, wherein the at least one housing portion is a first housing portion, and further includes a second housing portion, wherein an overmolded outer housing covers the second housing portion, and wherein the first and second housing portions are manufactured separately.

[0228] H3. Panel connector of embodiment H2, wherein mating contacts extend along a first direction, and wherein first and second housing portions are offset relative to each other along the first direction.

[0229] H4. A panel connector of any one of embodiments H1-H3, wherein the at least one housing portion includes a protrusion configured to engage with an opening formed on an overmolded outer housing.

[0230] H5. A panel connector of any one of embodiments H1-H4, wherein the at least one housing portion includes a plurality of channels through which a first plurality of mating contacts pass.

[0231] H6. A panel connector of any one of embodiments H1-H5, wherein the first plurality of mating contacts have respective ends supported by an overmolded outer housing and exposed in the outer surface of the overmolded outer housing.

[0232] 11. A method for manufacturing a panel connector, the panel connector being configured to attach to a board connector and mate with a plug connector such that, when mated, the panel connector and the plug connector are attached to a panel, the method comprising: At least one shell portion is manufactured using insulating material; A plurality of mating contacts are inserted into at least one housing portion; and An outer housing is manufactured by overmolding at least one housing portion using a plurality of mating contacts inserted into at least one housing portion, such that the respective ends of the plurality of mating contacts are exposed in the outer surface of the outer housing.

[0233] I2. The method of embodiment I1, wherein manufacturing the at least one housing portion includes forming a plurality of channels through the at least one housing portion, and wherein inserting the plurality of mating contacts into the at least one housing portion includes: The multiple mating contacts are passed through the multiple channels.

[0234] I3. The method of any one of embodiments I1-I2, wherein the at least one housing portion is a first housing portion, and wherein the method further comprises: Manufacturing the second housing section; and Insert the multiple mating contacts into the second housing portion; Manufacturing the outer shell also includes molding the second shell portion.

[0235] I4. The method of any one of embodiments I1-I3, wherein the plurality of mating contacts extend along a first direction, and wherein the first and second housing portions are offset relative to each other along the first direction.

[0236] I5. The method of any one of Embodiments I1 to I4, wherein manufacturing the outer housing further includes forming a cavity such that the plurality of mating contacts are at least partially placed in the cavity.

[0237] I6. The method of Example I5 further includes filling at least a portion of the cavity with potting material.

[0238] Various aspects of the present invention can be used alone, in combination, or in various arrangements not specifically discussed in the embodiments described above, and are therefore not limited to their application to the details and arrangements of the components shown in the foregoing description or in the drawings. For example, aspects described in one embodiment can be combined with aspects described in other embodiments in any way.

[0239] The use of ordinal terms such as “first,” “second,” “third,” etc., in claims to modify the claim elements themselves does not imply that one claim element has priority, precedence, or order over another claim, or the chronological order of the actions of the method, but is merely used as a label to distinguish one claim element with a specific name from another element with the same name (but for the purpose of using ordinal terms), thus differentiating the claim elements.

[0240] All definitions used herein should be understood as control dictionary definitions, definitions in referenced and incorporated literature, and / or the general meaning of the defined terms.

[0241] Unless explicitly indicated to the contrary, the indefinite articles “a” and “an” used in this specification and claims shall be understood to mean “at least one”.

[0242] As used in this specification and claims, the phrase "at least one" in relation to a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the element list, but not necessarily including at least one of each and every element specifically listed in the element list, and does not exclude any combination of elements in the element list. This definition also allows for the optional presence of elements other than those specifically identified in the element list referred to by the phrase "at least one," whether related to or unrelated to those specifically identified elements.

[0243] The phrase “and / or” as used in this specification and claims should be understood to mean “one or two” of the elements so combined, i.e., elements that exist together in some cases and separately in others. Multiple elements listed using “and / or” should be interpreted in the same way, i.e., “one or more” of the elements so combined. Other elements may optionally exist in addition to those specifically identified by the “and / or” clause, whether related to or unrelated to those specifically identified. Therefore, as a non-limiting embodiment, when used in conjunction with open-ended language such as “comprising,” a reference to “A and / or B” may refer only to A in one embodiment (optionally including elements other than B); only to B in another embodiment (optionally including elements other than A); both A and B in yet another embodiment (optionally including other elements); and so on.

[0244] As used in this specification and claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” should be interpreted as inclusive, that is, including multiple elements or at least one element in the list of elements, but also including more than one element, and optionally including other unlisted items. Only terms that expressly indicate the opposite, such as “only one” or “exactly one”, or when used in a claim, “consisting of…”, will refer to exactly multiple elements or one element in the list of elements. In general, the term “or” as used herein should only be interpreted as the only alternative to indicating an exclusive clause, such as “any,” “one of,” “only one of,” or “exact one of” (i.e., “one or the other but not two”). When used in a claim, “consisting substantially of…” should have its ordinary meaning as used in the field of patent law.

[0245] Furthermore, the wording and terminology used herein are for descriptive purposes and should not be considered limiting. The use of “including,” “contains,” or “has,” “includes,” “involves,” and variations thereof in this document is intended to cover the items listed thereafter and their equivalents, as well as additional items.

Claims

1. A panel connector configured to attach to a board connector and mate with a plug connector, such that, when mated, the panel connector and the plug connector are attached to a panel, the panel connector comprising: At least one housing portion; An overmolded outer housing that encloses at least one housing portion; as well as A first plurality of mating contacts supported by at least one housing portion, the first plurality of mating contacts being configured to electrically contact a second plurality of mating contacts supported by a plug connector.

2. The panel connector according to claim 1, wherein, The at least one housing portion is a first housing portion, and also includes a second housing portion, wherein the overmolded outer housing encloses the second housing portion, and wherein the first housing portion and the second housing portion are manufactured separately.

3. The panel connector according to claim 1, wherein, The mating contact extends along a first direction, and wherein the first housing portion and the second housing portion are offset relative to each other along the first direction.

4. The panel connector according to claim 1, wherein, The at least one housing portion includes a protrusion configured to engage with an opening formed on an overmolded outer housing.

5. The panel connector according to claim 1, wherein, The at least one housing portion includes a plurality of channels, wherein a first plurality of mating contacts pass through the plurality of channels.

6. The panel connector according to claim 1, wherein, The first plurality of mating contacts have respective ends supported by an overmolded outer housing and exposed in the outer surface of the overmolded outer housing.

7. The panel connector according to claim 6, wherein, A plurality of mating contacts are stamped to form corresponding shoulders and shafts, wherein the exposed ends are defined in the shoulders, and wherein the shoulders engage with corresponding flanges formed in at least one housing portion.

8. The panel connector according to claim 1, wherein, The at least one housing portion is a first housing portion, and also includes a second housing portion, wherein the overmolded outer housing encloses the second housing portion, and wherein the first housing portion includes a first protrusion configured to engage with the overmolded outer housing, and wherein the second housing portion includes a second protrusion configured to engage with the overmolded outer housing.

9. The panel connector according to claim 1, wherein, The overmolded outer housing includes protrusions that extend from at least one housing portion and support corresponding ends of a plurality of mating contacts.

10. The panel connector of claim 1, further comprising a potting element which is encapsulated and surrounds the first plurality of mating contacts by an overmolded outer housing.

11. The panel connector according to claim 10, wherein, The potting element is made of silicone rubber or epoxy resin.

12. A method of manufacturing a panel connector, the panel connector being configured to attach to a board connector and mate with a plug connector such that, upon mating, the panel connector and the plug connector are attached to a panel, the method comprising: At least one shell portion is manufactured using insulating material; Insert multiple mating contacts into at least one housing portion; as well as An outer housing is manufactured by overmolding at least one housing portion using a plurality of mating contacts inserted into at least one housing portion, such that the respective ends of the plurality of mating contacts are exposed in the outer surface of the outer housing.

13. The method according to claim 12, wherein, Manufacturing at least one housing portion includes forming a plurality of channels through the at least one housing portion, and wherein inserting a plurality of mating contacts into the at least one housing portion includes: This allows multiple mating contacts to pass through the multiple channels.

14. The method of claim 12, wherein, The at least one housing portion is a first housing portion, and the method further includes: Manufacturing the second housing section; and Insert multiple mating contacts into the second housing portion; Manufacturing the outer shell also includes overmolding a second shell portion.

15. The method according to claim 14, wherein, Multiple mating contacts extend in a first direction, wherein first and second housing portions are offset from each other along the first direction.

16. The method according to claim 12, wherein, Manufacturing the outer housing also includes forming a cavity such that a plurality of mating contacts are at least partially placed within the cavity.

17. The method of claim 16, further comprising filling at least a portion of the cavity with a potting material.

18. The method according to claim 17, wherein, The potting element is made of silicone rubber or epoxy resin.

19. The method according to claim 12, wherein, Inserting a plurality of mating contacts into at least one housing portion includes mounting a widened portion of the plurality of mating contacts onto a flange of at least one housing portion.

20. The method according to claim 12, wherein, Overmolding at least one housing portion includes mounting the ends of a plurality of mating contacts on a protrusion formed in the outer housing.

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