Insulation displacement contact system
The IDC system with a carrier and insertion tool automates the alignment and secure connection of wires to electrical components, addressing the inefficiencies of manual connection methods and providing effective shielding and strain relief.
Patent Information
- Application Number
- DE112021006558
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2021-02-11
- Filing Date
- 2021-12-01
- Publication Date
- 2025-07-31
- Estimated Expiration
- 2041-12-01
AI Technical Summary
Existing electrical connectors for connecting wires to components, such as printed circuit boards, are cumbersome and prone to improper connections that can lead to short circuits, especially when connecting expensive components, necessitating a quick, efficient, and reliable means for accurately positioning wires of various dimensions.
An insulation displacement contact (IDC) system comprising a pair of electrical contacts and a strain relief cover, facilitated by a carrier and insertion tool, which allows for automated alignment and secure connection of a coaxial cable to an electrical component without manual manipulation, providing electromagnetic interference shielding and mechanical support.
Enables a quick, efficient, and reliable electrical connection with reduced electromagnetic interference and mechanical strain relief, ensuring proper alignment and secure attachment of wires to components without the need for plastic insulation.
Smart Images

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Abstract
Description
CROSS REFERENCE TO RELATED APPLICATIONSREGIONThe present application relates generally to the field of electrical connectors, and more particularly to electrical connectors configured to form an electrical connection between a plurality of electrical components.BACKGROUNDVarious types of connectors are used to form connections between a wire and an electronic or electrical component. These connectors are typically available as sockets, plugs and trough pinbars in a wide range of dimensions, latches and coating options. Typically, to mechanically and electrically connect a wire as a user to an electrical component, a user must properly position the wire relative to the electrical component to form the electrical connection. This process can be tedious, inefficient and cumbersome. The wire-to-component connection may unexpectedly fall apart or cause a short circuit due to improper placement during assembly, which may be hazardous or expensive, particularly when connecting the wire to an expensive component (e.g., a printed circuit board (PCB)). Therefore, a quick, efficient and reliable means for accurately positioning a plurality of wire dimensions in a variety of applications is needed.U.S. Pat. No. 9,882,293 B1 discloses an insulation displacement contact system for electrically contacting a coaxial cable with a printed circuit board. In this case, the insulation displacement contact system has a first insulation displacement contact functioning as a ground contact and a second insulation displacement contact functioning as a signal contact. Furthermore, a cover is provided which can be fastened by means of latching elements to an insulating body accommodating the insulation displacement contacts.Furthermore, U.S. Pat. No. 8,109,783 B2 discloses an insulation displacement contact system having a double insulation displacement contact fastened to a printed circuit board, with projections by means of which a cover can be fastened to the double insulation displacement contact.A comparable situation is present in U.S. Pat. No. 9,543,664 B2. In the insulation displacement contact system disclosed therein for contacting electrical conductors on a printed circuit board, each insulation displacement contact has a projection for fastening a cover.In the insulation displacement contact system from U.S. Pat. No. 7,309,252 B2, a cover has retaining gaps for insulation displacement contacts. Projections in the retaining gaps engage in recesses of the insulation displacement contacts for the purpose of fasteningFinally, EP 3 547 456 A1 discloses an insulation displacement contact system comprising dual insulation displacement contacts located on a printed circuit board and a cover having retaining gaps for engaging the cover with pairs of prongs of the insulation displacement contacts.SUMMARYThe apparatuses and methods of this disclosure each have several innovative aspects, no single one of which is solely responsible for the desirable properties disclosed herein.In accordance with some embodiments of the present disclosure, an insulation displacement contact system is disclosed. The IDC system includes a first IDC, a second IDC, and a cover having a first portion over the first IDC and a second portion over the second IDC. The cover further includes a retention gap between the first portion and the second portion to engage the cover with a first pair of prongs of the first insulation displacement contact, and the first portion of the cover includes a first protrusion and a second protrusion configured to engage the cover with a second pair of prongs of the first insulation displacement contact.In accordance with some embodiments of the present disclosure, a cover for an electrical contact is disclosed. The cover includes a first portion having a first top wall, a first side wall, and a second side wall, a second portion having a second top wall, a third side wall, and a fourth side wall, and a retention gap between the first portion and the second portion. The first portion is configured to be mounted over a first contact connected to an electrical component, the second portion is configured to be mounted over a second contact connected to the electrical component, the first sidewall includes a first protrusion opposite the retention gap such that the first protrusion is configured to engage a first tab of the first contact, and the second sidewall includes a second protrusion opposite the retention gap such that the second protrusion is configured to engage a second tab of the first contact. The retaining gap here comprises a first engagement surface between the first side wall and the third side wall and a second engagement surface between the second side wall and the fourth side wall, wherein the retaining gap extends from the first engagement surface to the second engagement surface.In accordance with some embodiments of the present disclosure, a method is disclosed. The method includes positioning a carrier having a first contact and a second contact engaged therein via an electrical component for mounting the first contact and the second contact on the electrical component, for mounting the first contact and the second contact on the electrical component, and for releasing the carrier from the first contact and the second contact upon mounting the first contact and the second contact on the electrical component. The method also includes engaging a cable between the first contact and the second contact upon releasing the carrier and securing a cover over the cable, the first contact, and the second contact by engaging a first protrusion of the cover with a first tine of the first contact, engaging a second protrusion of the cover with a second tine of the first contact, engaging a first engagement surface of the cover defined in a retention gap between a first portion and a second portion of the cover with a third tine of the first contact, and engaging a second engagement surface of the cover defined in the retention gap with a fourth tine of the first contact.BRIEF DESCRIPTION OF THE DRAWINGSFIGS. 1A and 1B are examples of a carrier having first and second insulation displacement contacts (IDC) secured therein to facilitate connection of the first and second IDCs to an electrical component in accordance with an illustrative embodiment. FIG. 2 is a top view of the carrier of FIGS. 1A and 1B, in accordance with an illustrative embodiment. FIG. 3 shows the carrier and the first and second IDCs positioned on the electrical component for electrical connection between the first and second IDCs and the electrical component, in accordance with an illustrative embodiment. FIG. 4 shows the first and second IDCs connected to the electrical component and the carrier detached from the first and second IDCs, in accordance with an illustrative embodiment. FIG. 5 illustrates a pouched belt having individualized carriers loaded into individual pouches for delivery, in accordance with an illustrative embodiment. FIG. 6 shows an example of a coaxial cable, in accordance with an illustrative embodiment. FIG. 7 shows an example of an insertion tool for attaching the coaxial cable of FIG. 6 therein for inserting the coaxial cable between the first and second IDCs, in accordance with an illustrative embodiment. FIG. 8 shows the insertion tool of FIG. 7 with the coaxial cable secured therein positioned over the first and second IDCs to transmit the coaxial cable from the insertion tool to the first and second IDCs, in accordance with an illustrative embodiment. FIG. 9 shows the first and second IDCs with the coaxial cable connected thereto and with the insertion tool removed, in accordance with an illustrative embodiment. FIG. 10 shows an example of a cover configured to be mounted over the first and second IDCs, in accordance with an illustrative embodiment.FIGS. 11A-11C show various views of the cover mounted over the first and second IDCs, in accordance with an illustrative embodiment. FIG. 12 is an exemplary flow diagram illustrating operations for mounting the first and second IDCs on the electrical component using the carrier, mounting the coaxial cable between the first and second IDCs using the insertion tool, and mounting the cover over the coaxial cable to electrically connect the coaxial cable to the electrical component, in accordance with an illustrative embodiment.DETAILED DESCRIPTIONReference will now be made to various embodiments, one or more examples of which are illustrated in the figures. The embodiments are provided to explain the invention and should not be construed as limiting the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to obtain yet another embodiment. It is intended that the present application cover these and other modifications and variations that are within the scope of the claims.An IDC system is presented herein that enables a quick connection of a coaxial cable to an electrical component such as a printed circuit board ("PCB"), a ground plane, a contactor, a bus bar, or other conductive surface. The IDC system closes off the coaxial cable without the need for plastic insulation and provides adequate shielding from electromagnetic interference (including radio frequency (RF)) and mechanical strain relief. The IDC system replaces the plastic insulation with air, thereby creating a more uniform electromagnetic environment. Thus, the IDC system enables an efficient and quick establishment of an electrical connection between a wire and an electrical component.Specifically, the IDC system includes a pair of electrical contacts and a strain relief cover mounted over the pair of electrical contacts. The strain relief cover protects the pair of electrical contacts and a coaxial cable installed between these electrical contacts from external elements such as dirt, dust, etc., and provides mechanical support for the electrical contacts and the cable. Further, in some embodiments, the strain relief cover may be configured such that at least a portion of the strain relief cover is electrically connected to a first electrical contact of the pair of electrical contacts. The strain relief cover also provides electromagnetic interference shielding for a second contact of the pair of electrical contacts opposite the first electrical contact. In some embodiments, the strain relief cover may be mounted over the second electrical contact such that an air gap exists between the cable over the second electrical contact and the strain relief cover. The air gap may serve as insulation for the cable, thereby avoiding the need for plastic insulation.In addition, the present disclosure provides a novel and simple mechanism for mounting the pair of electrical contacts on the electrical component, for mounting the cable between the pair of electrical contacts, and for mounting the strain relief cover over the pair of electrical contacts. Specifically, the present disclosure provides a carrier within which the pair of electrical contacts may be secured to properly axially position and align the pair of electrical contacts over the electrical component without having to manually manipulate (e.g., touch) the pair of electrical contacts. The carrier also ensures that the pair of electrical contacts remains in proper positioning without moving during assembly (e.g., soldering) of the pair of electrical contacts on the electrical component. The carrier also ensures a proper and uniform spacing between the pair of electrical contacts on the electrical component to reduce electromagnetic interference. Upon mounting the pair of electrical contacts on the electrical component, the carrier may be removed.Similarly, in some embodiments, the present disclosure provides a simple and convenient mechanism to install a coaxial cable between the pair of electrical contacts without having to manually manipulate (e.g., touch) the coaxial cable. The present disclosure provides an insertion tool having a cavity therein. The coaxial cable can be inserted into the cavity of the insertion tool. The cavity may be specifically configured to displace the coaxial cable from the insertion tool to the pair of electrical contacts when a downward force toward the electrical component is applied to the insertion tool. The insertion tool also enables uniform and proper vertical and axial positioning of the coaxial cable between the pair of electrical contacts. In assembling the coaxial cable between the pair of electrical contacts, the present disclosure provides a simple and convenient mechanism to install the strain relief cover over the coaxial cable without requiring any special tools or equipment. For example, in some embodiments, the strain relief cover may be configured with features (e.g., protrusions, engagement surfaces) that cooperate with features (e.g., tabs) on one of the pair of electrical contacts to latch or frictionally secure the strain relief cover over the pair of electrical contacts.FIGS. 1A and 1B show a portion of an IDC system in accordance with some embodiments of the present disclosure. The IDC system may include a carrier, an insertion tool, and a strain relief cover. Thus, FIGS. 1A and 1B show an example of a carrier system 100, while the insertion tool and strain relief cover are discussed further below. Specifically, FIG. 1A shows a top perspective view of the carrier system 100, while FIG. 1B shows a bottom view of the carrier system. The carrier system 100 includes a carrier 105 and electrical contacts 110. The carrier 105 may be configured to securely hold the electrical contacts 110 while the electrical contacts are being positioned on an electrical component (e.g., a printed circuit board) for assembly. When mounting the electrical contacts 110 on the electrical component, the carrier 105 may be removed.In some embodiments, the carrier 105 may be made of plastic. In other embodiments, the carrier 105 may be made of other non-conductive, non-metallic, and / or other suitable materials. In some embodiments, the carrier 105 may be disposable. The carrier 105 may include a base 115 having an upper surface 120 and a lower surface 125 (see FIG. 1B ). Although the base 115 is shown as having a rectangular shape, in other embodiments, the base may take other shapes and dimensions. The top surface 120 of the base 115 may include retention slots 130 to receive and secure the electrical contacts 110. FIG. 2, which shows the top surface 120 of the carrier 105, including the retention slots 130, in more detail, is discussed further below. The bottom surface 125 of the carrier 105 includes one or more legs extending therefrom and away from the top surface 120. In some embodiments, the bottom surface 125 may include three legs 135, 140, 145 extending therefrom. In other embodiments, more or less than three legs may also be provided. In some embodiments, the base 115 and the legs 135- 145 may be integrally formed. In other embodiments, the base 115 and the legs 135- 145 may be separate components that are joined together in operable association. In some embodiments, the height of the legs 135- 145 may be configured such that a bottom surface of each of the electrical contacts 110 lies in a single plane. Thus, depending on the height, width, and / or thickness of each of the electrical contacts 110, each of the legs 135- 145 may have a same (or similar) height or different heights to ensure that these electrical contacts rest on the same plane.Further, in some embodiments, each of the legs 135- 145 may also extend along a width direction 155 of the base 115. For example, as shown in FIGS. 1A and 1B, in some embodiments, each of the legs 135- 145 may have a tapered shape such that a wider portion of the legs extends along the width direction 155 adjacent the bottom surface 125 of the base 115 and gradually tapers downward toward the electrical contacts 110. In other embodiments, the shape of one or more of the legs 135- 145 may be different than the shape shown. In some embodiments, the width direction 155 may be the shorter edge of the base 115. In other embodiments, one or more of the legs 135- 145 may be disposed along a longitudinal direction 160 of the base 115. In some embodiments, the longitudinal direction 160 may be the longer edge of the base 115.Additionally, in some embodiments, each of the legs 135- 145 may be sized to extend across a substantial width (e.g., in the width direction 155) of the electrical contacts 110. Specifically, in some embodiments, the width of a bottom surface 150 of each of the legs 135- 145 may be sized in accordance with the width of the electrical contacts 110 that each of these legs is configured to support. Thus, in some embodiments, each of the legs 135- 145 may be sized differently. Further, in some embodiments, each of the legs 135- 145 may be spaced apart from each other along the longitudinal direction 160 of the base 115. In some embodiments, the distance between legs 135- 145 may be based on the configuration of electrical contacts 110. For example, in some embodiments, the electrical contacts 110 may include a ground contact 165 and a signal contact 170. In some embodiments, the ground contact 165 may be considered a first contact or insulation displacement contact and the signal contact 170 may be considered a second contact or insulation displacement contact. In some embodiments, each of the first contact and the second contact may be an insulation displacement contact configured to establish an electrical connection between a wire or cable (e.g., an insulated wire or cable) and an electrical component.In some embodiments, the ground contact 165 may include a pair of legs 175 and 180 that extend upwardly from a ground 185 of the ground contact toward the bottom surface 125 of the base 115. The shape and configuration of the legs 175 and 180 is better seen in Figure 4. The legs 175 and 180 may be spaced apart from each other. Thus, the distance between the legs 135 and 140 may be based on (e.g., less than) the distance between the legs 175 and 180. In some embodiments, the signal contact 170 may also include a leg 190 that extends upwardly from a bottom 195 of the signal contact toward the bottom surface 125 of the base. In some embodiments, the signal contact 170 may be spaced apart from the ground contact 165. In some embodiments, the distance between the ground contact 165 and the signal contact 170 may be determined by modeling and simulating to provide desirable high frequency (e.g., shielding) characteristics. Thus, in some embodiments, the distance between legs 140 and 145 may be configured to allow ground contact 165 and signal contact 170 to achieve the desired distance and thus the desired high frequency characteristics. Moreover, the distance between the legs 140 and 145 may ensure a constant distance between the ground contact 165 and the signal contact 170 on the electrical component each time.Thus, the carrier 105 may include the base 115 having the legs 135- 145 protruding therefrom. The base 115 and legs 135- 145 may be configured to engage the legs 175, 180, 190 of the ground contact 165 and the signal contact 170 for positioning on an electrical component for assembly. Figure 2 shows the engagement of the legs 175, 180, 190 to the base 115 in more detail. As discussed above, the top surface 120 of the base 115 includes the retention slots 130. The retention slots 130 are configured to secure the legs 175, 180, 190 of the ground contact 165 and the signal contact 170. Specifically, the retention slots 200 may be configured to engage the legs 175 of the ground contact 165, the retention slots 205 may be configured to engage the legs 180, and the retention slot 210 may be configured to engage the leg 190. Thus, each of the retention slots 200, 205, and 210 may be shaped and sized to receive and retain the legs 175, 180, and 190, respectively.As seen in FIG. 4, each of the legs 175, 180, and 190 includes a pair of prongs. For example, leg 175 may include prongs 215, 220, leg 180 may include prongs 225, 230, and leg 190 may include prongs 235, 240. In some embodiments, the tips of each of these prongs may be configured to engage the retaining slots 130. Thus, each of the retention slots 130 may be shaped and sized to securely receive the tips of the prongs 215-240 (but not too strong to prevent disengagement). Specifically, and as shown in FIG. 2, each of the retention slots 130 may include one or more retention ribs 245 that may be configured to secure a corresponding pair of the prongs 215- 240 within the retention slots 130. For example, in some embodiments, to retain or secure the prongs 215- 240 within the retention slots 130, these prongs may be inserted (e.g., frictionally secured) into the corresponding retention slots. During insertion, the shape and configuration of the retention ribs 245 may prevent the respective tine from being inadvertently pushed out of the retention slots 130. In other embodiments, one or more of the retention slots 130 may take other configurations to engage the prongs 215- 240. By engaging the prongs 215-240 with the retention slots 130, the carrier 105 can engage the ground contact 165 and the signal contact 170 to receive and position / align the ground contact and the signal contact on the electrical component to which these contacts must be mounted. Further, by appropriately spacing the legs 140 and 145, the carrier may achieve a uniform and desired spacing between the ground contact 165 and the signal contact 170. Upon engagement of the prongs 215-240 with the retaining slots 130, the legs 135 and 140 of the carrier 105 rest on the bottom 185 of the ground contact 165 and the leg 145 of the carrier rests on the bottom 195 of the signal contact 170.Turning now to FIG. 3, an example of mounting the ground contact 165 and the signal contact 170 on an electrical component 250 is shown, in accordance with some embodiments of the present disclosure. In some embodiments, the electrical component 250 may be a printed circuit board. In other embodiments, the electrical component 250 may be another type of electrical device on which the ground contact 165 and the signal contact 170 are to be mounted. To install the ground contact 165 and the signal contact 170 on the electrical component 250, the ground contact and the signal contact may be engaged with the carrier 105 by attaching (e.g., inserting) the prongs 215- 240 into one of the respective retention slots 130. Upon engaging the prongs 215- 240 of the ground contact 165 and the signal contact 170 with the carrier 105, the carrier may position the bottom 185 of the ground contact 165 for mounting (e.g., soldering) on the electrical component 250 such that the ground contact is mounted to a first contact pad 255. The carrier 105 may also position the bottom 195 of the signal contact 170 for mounting the signal contact to a second contact pad 260. When mounting (e.g. soldering) the bottom 185 of the ground contact 165 to the first contact pad 255 and the bottom 195 of the signal contact 170 to the second contact pad 260, the carrier 105 may be detached from the ground contact and the signal contact.In some embodiments, the carrier 105 can be detached from the ground contact 165 and the signal contact 170 by releasing the prongs 215- 240 from the respective retaining slots 130 in which those prongs were engaged. In some embodiments, disengagement of the prongs 215- 240 from the respective retention slots 130 may be accomplished by gently pulling the base 115 of the carrier 105 in a direction away from the electrical component 250. In some embodiments, tools such as tongs, levers, prongs, breaker bars, etc. may be used to remove the carrier 105 from the ground contact 165 and the signal contact 170. Upon removal of the carrier 105, the ground contact 165 and the signal contact 170 remain attached to the electrical component 250, as shown in FIG. 4, and are ready to receive a cable for providing an electrical connection between the cable and the electrical component 250. An example configuration of a cable is shown in FIG. 6 below.Referring now to FIG. 5, a portion of a pocket strap 265 is shown in accordance with some embodiments of the present disclosure. The pocket band 265 may be an embossed carrier band and may be made from a continuous strip of relatively thin plastic film. This plastic film strip can be passed through a machine that can heat the plastic film so that smaller areas can be sucked and / or blown into precise cavities in the processing line. The voids may be regularly spaced pockets 270A-270E in the continuous plastic film strip. Although the pocket band 265 is shown as having five pockets (e.g., pockets 270A- 270E), in other embodiments, the pocket band may be configured as a continuous strip having any number of pockets. Each of the pockets 270A- 270E may be specially designed and manufactured for the component for which it is intended to be worn to provide precise positioning and the ability to be picked up by a robot and placed on the electrical component 250. In some embodiments, each of the pockets 270A- 270E may be configured to support the carrier 105, which may be picked up (e.g., by a robot) and attached to the ground contact 165 and the signal contact 170 before being placed on the electrical component 250. In other embodiments, each of the pockets 270A- 270E may be configured to support the carrier system 100 (e.g., including the carrier 105 and the electrical contacts 110 secured therein).In some embodiments, an instance of the carrier 105 or the carrier system 100 may be placed in each of the pockets 270A- 270E. In some embodiments, upon placement of the carrier 105 or the carrier system 100 in the pockets 270A- 270E, a thin, transparent cover tape may be adhered to the pocket tape to prevent the components from coming out of the pockets. The pocket band 265 does not show this cover band. The filled bag tape (e.g., the bag tape 265 covered with the cover tape) may then be wound onto a reel for compact packaging for delivery. The cover tape may be peeled off to allow access to the components in the pockets 270A-270E. For example, in some embodiments, the top surface 120 of the base 115 of the carrier 105 located in one of the pockets 270A- 270E may be contacted by a vacuum head of a robot to grip the carrier in that pocket. In some embodiments, the pocketed tape package industry standards may dictate that a length of the pocketed tape be left empty at the beginning and end of the reel. For example, the pocket 270E is shown empty without a component therein. Thus, for delivery to the end user, the carrier 105 or carrier system 100 may be conveniently packaged in a segment of the continuous pouch tape (e.g., pouch tape 265).Turning now to FIG. 6, an example of a coaxial cable 275 is shown, in accordance with some embodiments of the present disclosure. In some embodiments, coaxial cable 275 may include an insulated outer jacket 280, a foil shield 285, a braided wire shield 290, a dielectric 295, and a signal conductor 300. An exposed portion 305 of coaxial cable 275 is shown with insulated outer jacket 280, foil shield 285, and braided wire shield 290 removed to expose dielectric 295 and signal conductor 300. The exposed portion 305 of the coaxial cable 275 may be received between the prongs 235 and 240 of the signal contact 170, while an unexposed portion 310 may be received between the prongs 215- 230 of the ground contact 165. In some embodiments, the length of the exposed portion 305 may be such that the exposed portion dielectric 295 does not form contact with the prongs 215- 230 of the ground contact 165. Thus, the length of the exposed portion 305 may correspond somewhat to the distance between the prongs 235 / 240 of the signal contact 170 and the prongs 225 / 230 of the ground contact 165. In other embodiments, coaxial cable 275 may have a varying configuration than that shown. Further, although coaxial cable 275 has been shown herein, in other embodiments, the present disclosure may be used with any type of cable or wire to be electrically connected to electrical component 250.Referring to FIG. 7, an example of an insertion tool 315 is shown in accordance with some embodiments of the present disclosure. The insertion tool 315 may be used to position the coaxial cable 275 axially over and into the ground contact 165 and the signal contact 170. Specifically, in some embodiments, the coaxial cable 275 may be engaged within the insertion tool 315, and the insertion tool with the coaxial cable engaged therein may be positioned over the prongs 215- 240 to insert the coaxial cable through the prongs. In positioning / inserting the coaxial cable 275 within the prongs 215-240, the ground contact 165 provides two contact points (each pair of prongs providing a contact point) between the coaxial cable and the electrical component 250, while the signal contact 170 provides a single contact point between the coaxial cable and the electrical component. In some embodiments, upon insertion of the coaxial cable 275 into the prongs 215- 240, the ground contact 165 connects the shield portion(s) (e.g., one or more of the insulated outer jacket 280, the foil shield 285, the braided wire shield 290, the dielectric 295) of the coaxial cable 275 to the electrical component 250, while the signal contact 170 connects the signal conductor 300 of the coaxial cable to the electrical component.In some embodiments, the insertion tool 315 may be made of plastic or metal. In other embodiments, the insertion tool 315 may be made of other non-conductive materials, other conductive materials, or other suitable materials. The insertion tool 315 may include an upper portion 320 and a lower portion 325. The upper portion 320 may be used to grip the insertion tool during positioning of the coaxial cable 275 therein and, upon engaging the coaxial cable with the insertion tool, to position the coaxial cable via the ground contact 165 and the signal contact 170. Although the upper portion 320 is shown as having a rectangular configuration, in other embodiments, the upper portion may take other shapes and dimensions. The lower portion 325 may be configured to receive the coaxial cable 275 therein and transmit the coaxial cable from the insertion tool to the ground contact 165 and the signal contact 170.In some embodiments, the bottom portion 325 may include a cavity 330 having a curved inner wall 335A. The inner wall 335A may define one or more surfaces (e.g., ribbed surfaces) 335B that may allow the coaxial cable to be displaced from the insertion tool 315 to the ground contact 165 and the signal contact 170 when a downward force is applied to the insertion tool. The cavity 330 and the inner wall 335A may define a first opening 340 on a first side wall 345 of the insertion tool and a second opening 350 (see FIG. 8 ) on a second side wall 355 (see FIG. 8 ) of the insertion tool. In some embodiments, the cavity 330, the inner wall 335A, the first opening 340, and the second opening 350 may each be semicircular or substantially semicircular to receive the coaxial cylindrical cable therein. Further, in some embodiments, a width 360 of the first opening 340 may be greater than a width 365 (see FIG. 8 ) of the second opening 350. The width 360 of the first opening 340 may be configured to accommodate the unexposed portion 310 of the coaxial cable 275, while the width 365 of the second opening 350 may be configured to accommodate the exposed portion 305 of the coaxial cable. Further, the cavity 330 may be sized to secure the coaxial cable 275 within the insertion tool 315 for engagement with the ground contact 165 and the signal contact 170 without unintentional disengagement from the insertion tool.To position the coaxial cable 275 within the cavity 330, in some embodiments, the end of the coaxial cable at the exposed portion 305 may be slid into the cavity through either the first opening 340 or the open end of the cavity such that the end of the exposed portion abuts adjacent the second opening 350. In some embodiments, the second opening 350 may be sized such that the end of the exposed portion 305 cannot come out of the second opening 350 when the coaxial cable is inserted into the cavity 330. Thus, in some embodiments, the second aperture 350 may serve as a stopping point for the coaxial cable (e.g., if the coaxial cable cannot be slid further into the cavity with adequate force, the coaxial cable may be considered positioned within the cavity). Upon insertion of the coaxial cable 275 into the insertion tool 315, the insertion tool may be positioned over the ground contact 165 and the signal contact 170 to insert the coaxial cable between the prongs 215- 240 thereof, as shown in FIG. 8.Specifically, and as shown in FIG. 8, in some embodiments, the insertion tool 315 may be positioned over the ground contact 165 and the signal contact 170 such that the second opening 350 of the insertion tool is adjacent to the signal contact and the first opening 340 is adjacent to the ground contact. Because the exposed portion 305 of the coaxial cable 275 is secured closer to the second opening 350 within the cavity 330 of the insertion tool and because the exposed portion is configured to be inserted between the prongs 235 and 240 of the signal contact 170, by positioning the insertion tool such that the second opening is closer to the signal contact, the exposed portion of the coaxial cable can be inserted between the prongs of the signal contact. Similarly, since the unexposed portion 310 of the coaxial cable 275 is secured closer to the first opening 340 of the insertion tool 315 and since the unexposed portion is configured to be inserted between the prongs 215-230 of the ground contact, by positioning the insertion tool such that the first opening is closer to the ground contact, the unexposed portion can be inserted between the prongs of the ground contact. Further, the insertion tool 315 may include a plurality of slots, such as slots 368A, 368B, and 368C, which may be configured to receive the prongs 215- 240 and allow the insertion tool with the coaxial cable 275 inserted therein to be pressed downward toward the electrical component 250 without being obstructed by those prongs. In some embodiments, each of the slots 368A- 368C may extend in the width direction 360 from a first wall 369A of the insertion tool to a second wall 369B that is opposite the first wall. The thickness and positioning of each of the slots 368A- 368C may correspond to the thickness and positioning of the prongs 215- 240 configured to receive each of these slots.As described above, in order to displace the coaxial cable 275 from the insertion tool 315 onto the ground contact 165 and the signal contact 170, the insertion tool may be positioned over these contacts and gently pressed down toward the electrical component 250. The downward force of the insertion tool 315 toward the electrical component 250 may cause the surfaces 335B of the insertion tool to abut one or more surfaces of the ground contact 165 and the signal contact 170 and restrict movement of the insertion tool toward the electrical component, resulting in the coaxial cable 275 being released from the cavity 330 of the insertion tool and inserted between the prongs 215- 240 of the ground contact and the signal contact. As the coaxial cable 275 is displaced from the insertion tool 315 to the ground contact 165 and the signal contact 170, the insertion tool may be removed (e.g., pulled away). The coaxial cable 275 inserted between the ground contact 165 and the signal contact 170 with the insertion tool 315 removed is shown in FIG. 9.In some embodiments, the insertion tool 315, and in particular the dimension of the cavity 330, may be sized based on the distance between the prongs 235 / 240 of the signal contact 170 and the prongs 225 / 230 of the ground contact 165. Specifically, the insertion tool 315, and more specifically the dimension of the cavity 330, may be sized such that when the insertion tool is positioned over the ground contact 165 and the signal contact 170, the exposed portion 305 of the coaxial cable 275 does not contact the ground contact prongs 225 / 230. By dimensioning and configuring the cavity 330 of the insertion tool 315, the insertion tool allows proper positioning and alignment of the coaxial cable 275 over the ground contact 165 and the signal contact 170 without having to manipulate (e.g., contact) the coaxial cable. Thus, the insertion tool 315 enables proper vertical and axial positioning of the coaxial cable 275 with respect to the ground contact 165 and the signal contact 170.The prongs 215-240 are shaped and sized to receive and retain the coaxial cable 275. In some embodiments, each pair of prongs 215- 240 may be biased towards each other. The distance between the respective pairs of biased prongs may be based on the diameter or circumference of the coaxial cable for which these pairs of prongs are configured to be received. For example, the exposed portion 305 of the coaxial cable 275 has a smaller diameter (e.g., due to the insulation of some layers of the coaxial cable) than the unexposed portion 310 of the coaxial cable. Thus, to accommodate the smaller diameter of the exposed portion 305, as can be seen more clearly in FIG. 4, the prongs 235 / 240 of the signal contact 170 have a smaller spacing therebetween than the prongs 215-230 that receive the unexposed portion 310. Further, in some embodiments, each of the prongs 215- 240 may have a sharper edge 370 that intersects the surface of the coaxial cable 275 when the coaxial cable is inserted through these prongs by the insertion tool 315. In some embodiments, the edge 370 may have a particular configuration (e.g., slope and angle) to enable the desired depth of the cut with minimal pressure. The edge 370 of each of the prongs 215-240 may lead to a curved surface 375 configured to insert the coaxial cable 275 and accommodate the curvature of the coaxial cable. Each pair of corresponding prongs 215- 240 may form a substantially U-shaped configuration. The shape and configuration of the prongs 215-240 is more clearly seen in Figure 4. When the coaxial cable 275 is inserted between the prongs 215-240, the edge 370 of the signal contact 170 may cut through the dielectric 295 such that when the coaxial cable rests on the curved surface 375, the curved surface of the prongs forming contact with the signal conductor 300. Similarly, the edge 370 of the ground contact 165 may cut through one or more desired layers of the coaxial cable when the coaxial cable is inserted between the prongs 215- 240 such that the curved surface of the prongs 215- 230 contacts the corresponding surface (e.g., the foil shield 285 and the braided wire shield 290) when the coaxial cable rests on the curved surface 375.As described above, upon insertion of the coaxial cable 275 into the ground contact 165 and the signal contact 170, the ground contact 165 provides two contact points (one contact point with each pair of prongs 215 / 220, 225 / 230) with the coaxial cable to increase mechanical stability and provide a better electrical connection between the coaxial cable and the electrical component 250. In some embodiments, a separate shield (e.g., in a low frequency application) or mechanical strain relief may not be required or desired (e.g., when the assembly of the electrical contacts 110 and the coaxial cable 275 is to be molded in a resin). In such cases, a cover may not be necessary. In other embodiments, a cover may be provided over the ground contact and the signal contact to provide mechanical stability and strain relief as well as a separate shield. An example configuration of such a cover 380 is shown in FIG. 10, in accordance with some embodiments of the present disclosure. The mounting of the cover 380 over the ground contact 165 and the signal contact 170 is shown in FIGS. 11A-11C.Referring to FIGS. 10-11C, the cover 380 includes a first portion 385 and a second portion 390. During assembly, the first portion 385 may cover the ground contact 165 and the second portion 390 may cover the signal contact 170. In some embodiments, the first portion 385 and the second portion 390 may be separated by a retention gap 395. The retention gap 395 may be configured to house the prongs 225 and 230 of the ground contact 165, as shown in FIGS. 11A-11C. In some embodiments, the cover 380 may be made of a metal or other conductive material.Further, both the first portion 385 and the second portion 390 may have a somewhat C-shaped configuration. For example, the first portion 385 may include a first top wall 400, a first side wall 405, and a second side wall 410. The top wall 400, the first side wall 405, and the second side wall 410 may be configured to provide mechanical stability for the ground contact 165 during assembly of the cover 380. In some embodiments, the top wall 400 of the first portion 385 may be bent or kinked inwardly toward the tine 215- 230 to obtain a substantially concave top surface. Further, in some embodiments, the first sidewall 405 and the second sidewall 410 may be biased towards each other to provide a snug fit over the ground contact 165. The curved surface of the top wall 400 may be configured to contact the coaxial cable 275, and more specifically the unexposed portion 310 of the coaxial cable, during assembly over the ground contact 165. By making contact with the coaxial cable 275, the first portion 385 compresses the coaxial cable 275, and more specifically the unexposed portion 310, to provide support for the coaxial cable over the ground contact and maintain the electrical connection between the unexposed portion and the electrical component 250.Further, in some embodiments, each of the first sidewall 405 and the second sidewall 410 may include a protrusion 415, 420, respectively, extending therefrom and away (e.g., opposite) from the retention gap 395. The protrusion 415 may be configured to engage a tab 425 of the tine 215 of the ground contact 165. The protrusion 420 may be configured to engage a tab 430 of the tine 220 of the ground contact 165. As can be seen more clearly in Figure 4, the prongs 215 and 220, respectively, have the tabs 425 and 430, respectively, extending outwardly therefrom. The tabs 425 and 430 may be configured to engage the cover 380. Specifically, when the cover 380 is positioned over the ground contact 165 and the signal contact 170, a bottom surface of the tab 425 abuts the protrusion 415 and a bottom surface of the tab 430 abuts the protrusion 420. By resting on the tabs 425 and 430, the protrusions 415 and 420 form contact with portions of the prongs 215 and 220 and form an electrical connection between at least the first portion 385 of the cover 380 and the ground contact 165.Similar to tabs 425 and 430, prongs 225 and 230, respectively, also include tabs 435 and 440, respectively. The tab 435 is configured to rest on a first engagement surface 445A formed in the retention gap 395 in the area where the first portion 385 is connected to the second portion 390. The tab 440 is configured to rest on a second engagement surface 445B formed in the retention gap 395 in the area where the first portion 385 is connected to the second portion 390. Also similar to the protrusions 415 and 420, the contact between the surface 445 and the tabs 435 and 440 forms an electrical connection between the ground contact 165 and at least the first portion 385 of the cover 380.Thus, the cover 380 includes the first portion 385 over the ground contact 165 (e.g., the first insulation displacement contact) and the second portion 390 over the signal contact 170 (e.g., the second insulation displacement contact). The cover 380 further includes the retention gap 395 between the first portion 385 and the second portion 390 to engage the cover with a first pair of prongs (e.g., the prongs 225, 230) of the first insulation displacement contact (e.g., the ground contact 165). The first portion 385 of the cover 380 includes the first protrusion 415 and the second protrusion 420 configured to engage the cover with a second pair of prongs (e.g., the prongs 215, 220) of the first insulation displacement contact (e.g., the ground contact 165). The first engagement surface 445A, the second engagement surface 445B, the first protrusion 415, and the second protrusion 420 electrically connect the first portion 385 of the cover 380 to the first insulation displacement contact (e.g., the ground contact 165).As shown in FIGS. 11A-11C, the cover 380 may be positioned over the ground contact 165 and the signal contact 170 and pressed downward toward the electrical component 250 until the first engagement surface 445A contacts the tab 435 (e.g., the tab 435 overlies the first engagement surface), the second engagement surface 445B contacts the tab 440 (e.g., the tab 440 overlies the second engagement surface), the tab 425 contacts the protrusion 415 (e.g., the tab 425 overlies the protrusion 415), and the tab 430 contacts the protrusion 420 (e.g., the tab 430 overlies the protrusion 420). Thus, by engaging the first engagement surface 445A and the second engagement surface 445B of the cover 380 with the tabs 435 and 440, respectively, and by engaging the protrusions 415 and 420 with the tabs 425 and 430, respectively, the cover 380 generates a voltage against the tabs 425-440 and locks onto the ground contact, thereby ensuring a good electrical connection between the ground contact and at least the first portion 385 of the cover. The inward biasing or tapering of the first sidewall 405 and the second sidewall 410 of the first portion 385 promotes the compression of the coaxial cable 275 and maintains the electrical connection between the ground contact 165 and the first portion of the cover, thereby maintaining the electrical connection between the coaxial cable and the electrical component 250. During assembly, the top wall 400, the first side wall 405, and the second side wall 410 of the first portion 385 are clamped between the prongs 215 / 220 and the prongs 225 / 230. Further, in the assembly, in some embodiments, there is a small clearance between the cover 380 and the electrical component 250. In other words, in some embodiments, the cover 380 does not contact the electrical component 250.In addition to the first portion 385, the cover 380 includes the second portion 390. The second portion 390 is provided to cover the signal contact 170. The second portion 390 is also provided to provide electromagnetic interference (e.g., RF) shielding to the signal contact 170 from the ground contact 165 and to prevent extraneous electromagnetic signals from getting to the signal contact or extraneous signals from getting out of the signal contact. The air gap between the second portion 390 and the exposed portion 305 of the coaxial cable 275 may serve as a dielectric. The second portion 390 includes a second top wall 450, a third side wall 455, and a fourth side wall 460. In some embodiments, because the top wall 450 is not intended to contact the coaxial cable 275, the top wall 450 may not be bent or kinked as the top wall 400 of the first portion 385. In some embodiments, top wall 450 may have a flat (e.g., non-curved) surface or a slightly convex surface (e.g., curved away from electrical component 250). Further, in some embodiments, the third sidewall 455 and the fourth sidewall 460 may not be biased towards each other. Rather, in some embodiments, the third sidewall 455 and the fourth sidewall 460 may be substantially parallel to each other.Further, as discussed above, the retention gap 395 may be formed between the first portion 385 and the second portion 390 of the cover 380. In some embodiments, the retention gap 395 may extend from the first engagement surface 445A to the second engagement surface 445B. In some embodiments, the first engagement surface 445A may be formed between the first sidewall 405 of the first portion 385 and the third sidewall 455 of the second portion 390. Similarly, in some embodiments, the second engagement surface 445B may be formed between the second sidewall 410 of the first portion 385 and the fourth sidewall 460 of the second portion 390. In some embodiments, the retention gap 395 may also extend across a width of the top wall 400 all the way from the first side wall 405 to the second side wall 410. In some embodiments, the retention gap 395 may also extend across a width of the top wall 450 all the way from the third side wall 455 to the fourth side wall 460.Turning now to FIG. 12, an example flow diagram is shown illustrating a process 465 for mounting in accordance with some embodiments of the present disclosure. Assembly starts at operation 470 with the electrical component 250 to which a first contact (e.g., the ground contact 165) and a second contact (e.g., the signal contact 170) need to be installed. The first contact (e.g., ground contact 165) and the second contact (e.g., signal contact 170) are secured in the retention slots 130 of the carrier 105, as discussed above in FIGS. 1A and 1B. At operation 475, the carrier 105 engaged by the first contact (e.g., the ground contact 165) and the second contact (e.g., the signal contact 170) is positioned over the electrical component 250 to mount the first contact and the second contact on the electrical component. In some embodiments, the carrier 105 to which the first contact (e.g., the ground contact 165) and the second contact (e.g., the signal contact 170) are attached may be received by the pocket strap 265. At operation 480, the first contact (e.g., ground contact 165) and the second contact (e.g., signal contact 170) are mounted (e.g., soldered) to the electrical component 250. At operation 485, the carrier 105 may be detached from the first contact (e.g., the ground contact 165) and the second contact (e.g., the signal contact 170) upon mounting the first contact and the second contact to the electrical component.Upon removal of the carrier 105, the first contact (e.g., the ground contact 165) and the second contact (e.g., the signal contact 170) are ready to receive the coaxial cable 275. Thus, at operation 490, the coaxial cable 275 is inserted or secured within the cavity 330 of the insertion tool 315, as discussed above in FIG. 7. The insertion tool 315 with the coaxial cable secured therein is positioned over the first contact (e.g., ground contact 165) and the second contact (e.g., signal contact 170), as discussed above in FIG. 8. In positioning the insertion tool 315 over the first contact (e.g., the ground contact 165) and the second contact (e.g., the signal contact 170), the insertion tool may be gently pressed downward (e.g., a downward force may be applied) toward the electrical component 250 until the coaxial cable 275 disengages from the insertion tool and is inserted between the ground contact and signal contact prongs 215- 240. Thus, at operation 490, upon releasing the carrier 105, the cable 275 is engaged between the first contact (e.g., the ground contact 165) and the second contact (e.g., the signal contact 170). Upon engagement of the coaxial cable 275 with the first contact (e.g., the ground contact 165) and the second contact (e.g., the signal contact 170), the insertion tool 315 is removed.If the cover 380 is desired over the first contact (e.g., the ground contact 165) and the second contact (e.g., the signal contact 170), at operation 495, the cover is secured over the coaxial cable 275, the first contact (e.g., the ground contact 165), and the second contact (e.g., the signal contact 170), as discussed above in FIGS. 10-11C. Specifically, the cover 380 is placed over the coaxial cable 275, the first contact (e.g., the ground contact 165), and the second contact (e.g., the signal contact 170) by engaging a first protrusion (e.g., the protrusion 415) of the cover with a first tine (e.g., the tine 215) of the first contact, engaging a second protrusion (e.g., the protrusion 420) of the cover with a second tine (e.g., the tine 220) of the first contact, engaging a first engagement surface (e.g., the first engagement surface 445A) of the cover defined in the retention gap 395 between the first portion 385 and the second portion 390 of the cover, a third tine (e.g., tine 225) of the first contact, and engaging a second engagement surface (e.g., second engagement surface 445B) of the cover defined in the retention gap with a fourth tine (e.g., tine 230) of the first contact. Process 465 ends with operation 500.Thus, the present disclosure provides a simple and convenient mechanism for accurately positioning and connecting a first IDC and a second IDC to an electrical component using a carrier. The present disclosure also provides a simple and convenient mechanism for positioning and engaging a coaxial cable with the first IDC and the second IDC. A strain relief cover may be used to provide mechanism stability and RF shielding.As regards the use of substantially all terms in the plural and / or singular, persons skilled in the art may transfer from the plural to the singular and / or from the singular to the plural as appropriate to the context and / or the application. The various permutations of singular / plural may be expressly listed herein for purposes of clarity.It will be understood by those skilled in the art that the terms used herein, and particularly in the appended claims (e.g., in the sections of the appended claims), are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including, but not limited to", the term "having" should be interpreted as "having at least", the term "including" should be interpreted as "including, but not limited to", etc.). It will be further understood by those skilled in the art that when a specific number of an introduced claim enumeration is provided, such an intent is expressly recited in the claim and that when such enumeration is absent, no such intent is present. For example, as an aid to understanding, the following appended claims may include the use of the introductory phrases "at least one" and "one or more" to introduce claim enumerations. However, the use of such terms should not be construed to indicate that the introduction of a claim enumeration by the indefinite articles "a", "an" or "an" limits any particular claim incorporating such an introduced claim enumeration to inventions incorporating only such enumeration, even if the same claim incorporates the introductory terms "one or more" or "at least one" and indefinite articles such as "a", "an" or "an" (e.g., "a", "an" and / or "an" should typically be interpreted to mean "at least one" or "one or more"); the same applies to the use of certain articles used to introduce a claim enumeration. In addition, even if a specific number of an introduced claim enumeration is expressly mentioned, those skilled in the art will recognize that such enumeration should generally be interpreted to mean at least the mentioned number (e.g., the mere enumeration of "two enumerations" without other destination words will generally mean at least two enumerations or two or more enumerations). Moreover, in cases where a convention analogous to "at least one of A, B, and C, etc." is used, such a construction is generally intended in the sense that one of ordinary skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include, but are not limited to, systems having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In cases where a convention analogous to "at least one of A, B or C, etc." is used, such a construction is generally intended in the sense that one skilled in the art would understand the convention (e.g., "a system having at least one of A, B or C" would include, but are not limited to, systems having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B and C together, etc.). It will be further understood by those skilled in the art that virtually any disjunctive word and / or phrase containing two or more alternative terms, whether in the specification, claims, or drawings, is to be understood as including one of the terms, one of the two terms, or both terms.
Claims
An insulation displacement contact system, the insulation displacement contact system comprising: a first insulation displacement contact; a second insulation displacement contact; and a cover (380) comprising a first portion (385) over the first insulation displacement contact and a second portion (390) over the second insulation displacement contact, the cover (380) further comprising a retention gap (395) between the first portion (385) and the second portion (390) to engage the cover (380) with a first pair of prongs (225, 230) of the first insulation displacement contact; and wherein the first portion (385) of the cover (380) comprises a first protrusion (415) and a second protrusion (420) configured to engage the cover (380) with a second pair of prongs (215, 220) of the first insulation displacement contact.The insulation displacement contact system of claim 1, wherein the first portion (385) of the cover (380) further comprises a first top wall (400), a first side wall (405), and a second side wall (410), wherein the first top wall (400) comprises a curved surface, and wherein the first side wall (405) and the second side wall (410) are biased toward each other.The insulation displacement contact system of claim 2, wherein the second portion (390) of the cover (380) comprises a second top wall (450), a third side wall (455) and a fourth side wall (460), wherein the second top wall (450) comprises a non-curved surface, and wherein the third side wall (455) and the fourth side wall (460) are substantially parallel to each other.The insulation displacement contact system of claim 3, wherein the retention gap (395) comprises a first engagement surface (445a) between the first sidewall (405) and the third sidewall (455) and a second engagement surface (445b) between the second sidewall (410) and the fourth sidewall (460).The insulation displacement contact system of claim 4, wherein the retention gap (395) extends from the first engagement surface (445a) to the second engagement surface (445b).The insulation displacement contact system of claim 4 or 5, wherein a first tine (225) of the first pair of tines (225, 230) comprises a first tab (435) and a second tine (230) of the first pair of tines (225, 230) comprises a second tab (440), and wherein the first tab (435) is configured to rest over the first engagement surface (445a) and the second tab (440) is configured to rest on the second engagement surface (445b) to secure the cover (380) to the first insulation displacement contact and the second insulation displacement contact.The insulation displacement contact system of any one of claims 4 to 6, wherein the first engagement surface (445a), the second engagement surface (445b), the first protrusion (415), and the second protrusion (420) electrically connect the first portion of the cover (380) to the first insulation displacement contact.The insulation displacement contact system of any one of claims 1 to 7, wherein a first tine (215) of the second pair of tines (215, 220) comprises a first tab (425) configured to rest over the first protrusion (415) of the cover (380), and a second tine (220) of the second pair of tines (215, 220) comprises a second tab (430) configured to rest over the second protrusion (420) of the cover (380).The insulation displacement system of any one of claims 1 to 8, wherein the first insulation displacement contact is a ground contact (165), and wherein the second insulation displacement contact is a signal contact (170).A cover (380) for electrical contacts, the cover (380) comprising: a first portion (385) having a first top wall (400), a first side wall (405), and a second side wall (410); a second portion (390) having a second top wall (450), a third side wall (455), and a fourth side wall (460); and a retention gap (395) between the first portion (385) and the second portion (390), wherein the first portion (385) is configured to be mounted over a first contact connected to an electrical component (250); wherein the second portion (390) is configured to be mounted over a second contact connected to the electrical component (250); wherein the first side wall (405) has a first protrusion (415) opposite the retention gap (395), and wherein the first protrusion (415) is configured to engage a first tab (425) of the first contact; wherein the second side wall (410) has a second protrusion (420) opposite the retention gap (395), and wherein the second protrusion (420) is configured to engage a second tab (430) of the first contact; and wherein the retention gap (395) comprises a first engagement surface (445a) between the first side wall (405) and the third side wall (455) and a second engagement surface (445b) between the second side wall (410) and the fourth side wall (460), wherein the retention gap (395) extends from the first engagement surface (445a) to the second engagement surface (445b).The cover (380) of claim 10, wherein the first top wall (400) has a curved surface and the first side wall (405) and the second side wall (410) are biased towards each other to compress a portion of a cable (275) mounted between the first contact upon mounting of the first portion (385) over the first contact.The cover (380) of claim 10 or 11, wherein the first engagement surface (445a) is configured to rest under a third tab (435) of the first contact and the second engagement surface (445b) is configured to rest under a fourth tab (440) of the first contact to secure the cover (380) over the first contact and the second contact.The cover (380) of any of claims 10 to 12, wherein the first engagement surface (445a), the second engagement surface (445b), the first protrusion (415), and the second protrusion (420) are configured to electrically connect the first portion (385) to the first contact upon mounting the cover (380) over the first contact.The cover (380) of any of claims 10 to 13, wherein the second top wall (450) comprises a non-curved or curved surface away from the electrical component (250) configured to maintain a gap between the second top wall (450) and a portion of a cable (275) that engages between the second contact upon mounting of the second portion (390) over the second contact, and wherein the third side wall (455) and the fourth side wall (460) are substantially parallel to each other.A method comprising: positioning a carrier (105) having a first contact and a second contact engaged therein over an electrical component (250) for mounting the first contact and the second contact on the electrical component (250); mounting the first contact and the second contact on the electrical component (250); releasing the carrier (105) from the first contact and the second contact upon mounting the first contact and the second contact on the electrical component (250); engaging a cable (275) between the first contact and the second contact upon releasing the carrier (105); and securing a cover (380) over the cable (275), the first contact, and the second contact by engaging a first protrusion (415) of the cover (380) with a first tine (215) of the first contact, engaging a second protrusion (420) of the cover (380) with a second tine (220) of the first contact, engaging a first engagement surface (445a) of the cover (380) defined in a retention gap (395) between a first portion (385) and a second portion (390) of the cover (380) with a third tine (225) of the first contact, and engaging a second engagement surface (445b) of the cover (380) defined in the retention gap (395) with a fourth tine (230) of the first contact.The method of claim 15, wherein a printed circuit board is used as the electrical component (250).The method of claim 15 or 16, further comprising securing the first contact and the second contact in retaining slots of the carrier (105) to engage the first contact and the second contact with the carrier (105).The method of any of claims 15 to 17, wherein engaging the cable (275) between the first contact and the second contact comprises: securing the cable (275) in a cavity (330) of an insertion tool (315); positioning the insertion tool (315) with the cable (275) secured therein over the first contact and the second contact; and applying a downward force to the insertion tool (315) toward the electrical component (250), wherein the downward force displaces the cable (275) from the cavity (330) of the insertion tool (315) to the first contact and the second contact.Method according to one of Claims 15 to 18, wherein a ground contact (165) is used as the first contact and a signal contact (170) is used as the second contact.
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