Highly reliable hybrid electrical connector

Abstract

To provide a highly reliable hybrid electrical connector.SOLUTION: A connector 1 includes power and signal modules disposed in a space at least partially enclosed by a housing 10, and having first ends facing a housing rear and second ends extending out of a housing bottom. Power and signal cables 31, 32 are attached to the first ends of the power and signal modules, respectively, and extend out of the housing rear through a rear cap 200. The rear cap has a cavity, and a first sealing member inside the cavity forms a seal around the power and signal cables. A cover is disposed at a top of the housing, and a second sealing member exists around the cover and between the cover and the housing. A third sealing member 43 is disposed between a hoop disposed around a sheath of the power cable and the power module.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of Chinese Patent Application No. 202321787033.6, filed on July 7, 2023. This application also claims priority to and the benefit of Chinese Patent Application No. 202310835578.8, filed on July 7, 2023. The entire contents of these applications are incorporated by reference herein in their entireties.

[0002] Technical Field This patent application relates generally to interconnection systems, such as those that include electrical connectors, used to interconnect electronic assemblies. [Background technology]

[0003] background

[0003] Electrical connectors are used in many electronic systems. Generally, it is easier and more cost-effective to fabricate a system as separate electronic assemblies that can be coupled using electrical connectors. Electrical connectors can be used to interconnect electronic assemblies so that they can operate in concert as parts of a system. The connectors can be mounted, for example, on printed circuit boards in two assemblies that are connected by mating connectors. In other systems, it can be infeasible to couple two printed circuit boards by directly mating connectors on the printed circuit boards. For example, when the system is assembled, the printed circuit boards may be too far apart for a direct connection between the connectors mounted on the printed circuit boards.

[0004]

[0004] In some systems, connections between electronic assemblies may be made through cables. The cables may be terminated with connectors that mate with connectors mounted on the printed circuit boards. Thus, connections between electronic assemblies may be made by plugging a connector that is part of a cable assembly into a board connector mounted on the printed circuit board. In other system architectures, a connector terminating a cable may be mated with another connector terminating another cable.

[0005]

[0005] One example of a system in which assemblies are connected through cables is a modern automobile. For example, an automobile vehicle includes electronic control units (ECUs) for controlling various vehicle systems, such as an engine control unit, a transmission control unit (TCU), a security system, an emission control system, a lighting control unit, an advanced driver assistance system (ADAS), an entertainment system, a navigation system, and cameras. These electronic control units may be manufactured as separate assemblies. To simplify the manufacture of the automobile, assemblies may be connected through cables terminated with connectors that allow for connection to mating connectors that terminate other cables or are mounted on printed circuit boards within the assembly.

[0006]

[0006] Automobiles present a harsh environment for electrical connectors. Automobiles can vibrate, which can cause connectors to become dislodged and stop functioning completely. Even if the vibration does not completely prevent the operation of the connector, it can create electrical noise, which can disrupt the operation of electronic devices coupled through an interconnect that includes the connector. Noise can result, for example, from relative motion of components within the connector, which can change the electrical characteristics of the connector. The change in electrical characteristics causes a change in the signal passing through the interconnect, which in turn is a form of noise that disrupts the processing of the underlying signal.

[0007]

[0007] In an automotive environment, electrical noise may also result from automotive components that generate electromagnetic radiation. The radiation may couple to the conductive structures of connectors, producing noise on any signals passing through those conductive structures. In an automobile, any of a number of components may generate electromagnetic radiation, such as spark plugs, alternators, or power switches. The noise may be particularly disruptive to high-speed signals, such as those used to communicate data over the automotive network. Summary of the Invention [Problem to be solved by the invention]

[0008] overview

[0008] Aspects of the present disclosure relate to a high-reliability hybrid electrical connector that provides high signal integrity in harsh environments, such as those presented by automobiles, and that can be economically assembled to supply reliable power. [Means for solving the problem]

[0009]

[0009] Some embodiments relate to an electrical connector. The electrical connector may include a housing at least partially enclosing a space, the housing including an opening at an upper portion connected to the space and a cap disposed at a rear portion of the housing, the cap including a cavity having first and second channels connected to the space, a first cable extending through the first channel of the cap into the space of the housing, a second cable extending through the second channel of the cap into the space of the housing, and a sealing material disposed within the cavity of the cap, whereby portions of the first and second cables extending through the first and second channels are fixedly disposed within the sealing material.

[0010]

[0010] Optionally, the electrical connector may include a first module disposed within the space and including a first end connected to the first cable and a second end extending from the bottom of the housing out of the housing and configured for attachment to a circuit board, and a second module disposed within the space and including a first end connected to the second cable and a second end extending from the bottom of the housing out of the housing and configured for attachment to a circuit board.

[0011]

[0011] Optionally, the first module is a power module configured to supply power and the second module is a signal module configured to transmit an Ethernet signal.

[0012]

[0012] Optionally, the cap includes a bottom having a groove and a protrusion that protrudes into the cavity and engages the sealing material.

[0013]

[0013] Optionally, the electrical connector may include a cover disposed on the top of the housing and substantially covering the opening in the top of the housing, and the sealing material includes a first portion disposed around the cover to fill a groove between the cover and the housing.

[0014]

[0014] Optionally, the cover is separated from the cap by a first portion of the housing space, the sealing material includes a second portion disposed within the first portion of the housing space, and portions of the first and second cables extending into the first portion of the space pass through and are retained by the second portion of the sealing material.

[0015]

[0015] Optionally, the housing includes a rib, a first portion of the housing space is between a rear of the housing and the rib, the housing space includes a second portion between the rib and a front of the housing, and the electrical connector includes one or more modules disposed in the second portion of the space, each of the one or more modules being a terminal subassembly.

[0016]

[0016] Optionally, the first cable includes a sheath and a plurality of wires within the sheath, each of the plurality of wires including an end extending outside the sheath, the first module is connected to the first cable at the end extending outside the sheath, the housing includes a chamber through which the ends of the plurality of wires extend to the first module, and the sealing material includes a third portion disposed within the chamber of the housing, whereby the ends of the plurality of wires of the first cable are fixedly disposed within the third portion.

[0017]

[0017] Optionally, the sealing material includes a curable adhesive.

[0018]

[0018] Optionally, the electrical connector may include a hoop disposed adjacent the chamber of the housing and attached to the sheath of the first cable.

[0019]

[0019] Some embodiments relate to an electrical connector. The electrical connector may include a housing including an opening at a rear and a plurality of mounting portions extending outward from a front and / or side, a first module disposed within the housing, the first module including a plurality of first ends extending toward the rear of the housing and a plurality of second ends extending outward from a bottom of the housing, and a second module disposed within the housing, the second module including a plurality of first ends extending toward the rear of the housing and a plurality of second ends extending outward from the bottom of the housing.

[0020]

[0020] Optionally, each of the multiple mounting portions of the housing includes a hole extending therethrough.

[0021]

[0021] Optionally, the plurality of mounting portions of the housing include a first pair of mounting portions extending outwardly from a front of the housing, and a second pair of mounting portions extending outwardly from opposing sides of the housing, respectively.

[0022]

[0022] Optionally, the electrical connector may include a first cable attached to the multiple first ends of the first module and extending from the rear of the housing to outside the housing, and a second cable attached to the multiple first ends of the second module and extending from the rear of the housing to outside the housing, the second cable including a pair of signal wires.

[0023]

[0023] Optionally, the rear of the housing includes a cap having a cavity through which the first and second cables extend, and the electrical connector includes a sealing member disposed within the cavity of the cap and surrounding portions of the first and second cables extending therein.

[0024]

[0024] Optionally, the electrical connector may include a cover disposed on top of the housing and a second sealing member disposed between the housing and the cover.

[0025]

[0025] Optionally, the first cable includes two or more wires, a hoop disposed around a sheath of the first cable, and a third sealing member disposed between the first module and the hoop.

[0026]

[0026] Some embodiments relate to a method of making an electrical connector. The method may include providing a subassembly including a first module and a second module, a rear cap of a housing, and first and second cables extending through the rear cap of the housing and into the housing, where the rear cap of the housing includes a cavity, providing adhesive in the cavity of the rear cap and around portions of the first and second cables extending through the cavity of the rear cap of the housing to form a seal between the housing and the first and second cables, positioning the first and second modules in the housing, and attaching the rear cap to the housing.

[0027]

[0027] Optionally, the method may include providing an adhesive within an interior chamber of the housing and around a portion of the wire of the first cable to form a seal between the housing and the first cable. Optionally, the method may include disposing a cover on top of the housing and providing adhesive around the cover and in the gap between the cover and the housing to form a seal between the housing and the cover.

[0028]

[0028] Some embodiments relate to an electrical connector. The electrical connector may include a housing including a plurality of walls surrounding a space, a first wall of the plurality of walls including a cavity formed therein, a first channel extending from the cavity through a rear portion of the first wall to an exterior of the housing, and a second channel extending from the cavity through a front portion of the first wall to the space, a module at least partially disposed within the space, a cable extending from an exterior of the housing through the first channel, the cavity, and the second channel of the first wall into the space, the cable connected at an end thereof to the module, and a first bonding agent filled within the cavity, the first bonding agent disposed around a portion of the cable disposed within the cavity to secure the cable to the first wall.

[0029]

[0029] Optionally, the housing includes at least a body, the space being disposed within the body, the body including a rear end and a rear opening connecting the space at the rear end, and a rear cap attached to the rear end of the body to close the rear opening, the first wall of the housing being formed by the rear cap.

[0030]

[0030] Optionally, the forward portion of the first wall includes a front surface facing toward the space and a slot extending from the front surface through the forward portion into the cavity, and a rear end portion of the body is inserted into the slot and the first adhesive engages with the rear end portion.

[0031]

[0031] Optionally, a portion of the rear end of the body includes a first surface exposed within the cavity and a protrusion extending from the first surface into the cavity, and a first adhesive is disposed on the first surface and engages the protrusion.

[0032]

[0032] Optionally, the protrusion is configured as a barb.

[0033]

[0033] Optionally, a portion of the rear end of the body includes a first surface exposed within the cavity and a recess recessed from the first surface into the portion, and a first bonding agent is disposed on the first surface and filled into the recess.

[0034]

[0034] Optionally, the portion of the cable disposed within the cavity extends in a first direction, and the first wall includes an opening extending from the exterior of the housing through a side portion of the first wall into the cavity in a second direction perpendicular to the first direction, allowing the first bonding agent to be filled into the cavity through the opening.

[0035]

[0035] Optionally, the rearward and forward portions of the first wall oppose one another and are spaced apart in the first direction by a cavity, and the face portion connects the rearward and forward portions.

[0036]

[0036] Optionally, the forward portion of the first wall includes a front surface facing toward the space and a slot extending from the front surface through the forward portion into the cavity, a rear end portion of the body is inserted into the slot and includes a first surface exposed in the cavity on a side of the portion of the cable facing away from the opening, and a first adhesive is disposed on and engages the first surface.

[0037]

[0037] Optionally, the first wall further includes a bottom portion, the bottom portion and the face portion facing each other and spaced apart in the second direction by the cavity, the bottom portion including an upper surface facing toward the dispensing chamber and a groove recessed from the upper surface into the bottom portion and connecting to the slot, a portion of the rear end of the body being inserted into the groove through the slot, and the first surface being flush with the upper surface.

[0038]

[0038] Optionally, the rear end portion of the body further includes a protrusion protruding from the first surface into the cavity, the first adhesive being disposed on the first surface and engaging the protrusion.

[0039]

[0039] Optionally, the rear end portion of the body further includes a recess recessed into the portion from the first surface, and the first bonding agent is disposed on the first surface and filled into the recess.

[0040]

[0040] Optionally, the first channel and the second channel are aligned with each other in a first direction, and a cross-section of the cavity perpendicular to the first direction is larger than a cross-section of the first channel perpendicular to the first direction and larger than a cross-section of the second channel perpendicular to the first direction.

[0041]

[0041] Optionally, the body further includes a front end opposite the rear end, a first surface between the rear end and the front end, an upper opening at the first surface connecting the space with an exterior of the housing, and an edge portion defining the upper opening, the housing further includes an upper cover including a top surface, a bottom surface opposite the top surface, a side surface extending between the top surface and the bottom surface, and a flange extending outward beyond the side surface, the flange including a top surface and a bottom surface opposite the top surface, the top surface being lower than the top surface, the upper cover is disposed within the upper opening of the body to close the upper opening, the bottom surface and the bottom surface facing toward the space, the edge portion of the body forms a groove together with the side surface and top surface of the upper cover, and the electrical connector further includes a second bonding agent filled in the groove to provide a seal.

[0042]

[0042] Optionally, the body further includes a flange protruding into the upper opening, a bottom surface of the flange of the upper cover being supported on the flange.

[0043]

[0043] Optionally, the body includes a bottom wall facing the upper opening and a rib protruding from the bottom wall into the space, the rib dividing the space into a first space between the rear end and the rib and a second space between the rib and the front end, the module is disposed in the second space, the cable extends from outside the housing through the first wall and the first space into the second space, the top cover is disposed over the second space to separate the second space from the outside of the housing, the top cover engages with the rib and together with the rib separates the second space from the first space, and the electrical connector further comprises a third bonding agent filled in the first space to provide a seal.

[0044]

[0044] Optionally, the groove extends into and communicates with the first space to allow the second bonding agent and the third bonding agent to be applied together.

[0045]

[0045] Optionally, the top cover further includes a rear flange extending downwardly from the bottom surface or flange toward the rib, the rear flange engaging the rib and a passage formed at the engaged portion of the rear flange and the rib, and the cable extending through the passage into the second space.

[0046]

[0046] Optionally, the cable includes a first cable including a wire and a sheath surrounding the wire, a portion of the sheath at an end of the first cable is removed to allow the wire to extend beyond the end of the sheath, the end of the sheath is disposed in the space, and the electrical connector is disposed in the space around the end of the sheath and further includes a fourth bonding agent forming a seal at the end of the sheath.

[0047]

[0047] Optionally, the housing includes a chamber formed around an end of the sheath within the space, and the fourth bonding agent is filled within the chamber.

[0048]

[0048] Optionally, the electrical connector further comprises a hoop mounted on a sheath of the first cable to secure the first cable within the space.

[0049]

[0049] Optionally, the hoop includes an annular body mounted on the sheath and a tab protruding outwardly from the annular body, and the housing includes a receiving area formed within the accommodating cavity, and the tab is received within the receiving area to secure the first cable within the accommodating cavity.

[0050]

[0050] Optionally, the first cable is a power cable configured to transmit power.

[0051]

[0051] Some embodiments relate to an electrical connector. The electrical connector may include a housing including a body, the body including a plurality of walls surrounding a space, an opening in a first side of the body that communicates the space with the outside of the housing, and an edge portion that defines the opening, and a top cover, the housing including a top surface, a bottom surface opposite the top surface, a side extending between the top surface and the bottom surface, and a flange extending outward beyond the side surface, the flange including the top surface and the bottom surface opposite the top surface, the top surface being lower than the top surface, a module at least partially disposed in the space, and a cable extending from the outside of the housing through a first wall of the plurality of walls into the space and connected at its end to the module. The top cover is disposed in the opening of the body to close the opening, the bottom surface and the bottom surface facing toward the space, and the edge portion of the body forming a groove together with the side surface and the top surface of the top cover. The electrical connector further includes a first bonding agent filled in the groove to form a seal.

[0052]

[0052] Optionally, the body further includes a flange protruding into the opening, a bottom surface of the flange of the top cover being supported on the flange.

[0053]

[0053] Optionally, the plurality of walls further includes a second wall opposite the first wall and a bottom wall extending between the first wall and the second wall, the bottom wall opposite the opening, the body further includes a rib extending from the bottom wall into the space, the rib dividing the space into a first space between the first wall and the rib and a second space between the rib and the second wall, the module is disposed in the second space, the cable extends from outside the housing through the first wall and the first space into the second space, the top cover is disposed over the second space to separate the second space from the outside of the housing, the top cover engages with the rib and, together with the rib, separates the second space from the first space, and the electrical connector further comprises a second bonding agent filled in the first space to provide a seal.

[0054]

[0054] Optionally, the groove extends into and communicates with the first space to allow the first bonding agent and the second bonding agent to be applied together.

[0055]

[0055] Optionally, the top cover further includes a rear flange extending downwardly from the bottom surface or flange toward the rib, the rear flange engaging the rib and a passage formed at the engaged portion of the rear flange and the rib, and the cable extending through the passage into the second space.

[0056]

[0056] Optionally, the cable includes a first cable including a wire and a sheath surrounding the wire, a portion of the sheath at an end of the first cable is removed to allow the wire to extend beyond the end of the sheath, the end of the sheath is disposed in the space, and the electrical connector is disposed in the space around the end of the sheath and further includes a third bonding agent forming a seal at the end of the sheath.

[0057]

[0057] Optionally, the electrical connector further comprises a hoop mounted over a sheath of the first cable to secure the first cable within the space.

[0058]

[0058] Optionally, the first cable is a power cable configured to transmit power.

[0059]

[0059] Optionally, the first wall includes a cavity formed in the first wall, a first channel extending from the cavity through a rear portion of the first wall to an exterior of the housing, and a second channel extending from the cavity through a front portion of the first wall to the space, a cable extending from an exterior of the housing through the first channel, the cavity, and the second channel in the first wall into the space, and a fourth bonding agent is filled in the cavity and disposed around a portion of the cable disposed in the cavity to secure the cable to the first wall.

[0060]

[0060] Some embodiments relate to an electrical connector. The electrical connector may include a housing including a plurality of walls surrounding a space, a module at least partially disposed within the space, a cable extending from an exterior of the housing through a first of the walls into the space and connected at an end thereof to the module, the cable including a wire and a sheath surrounding the wire, a portion of the sheath at an end of the cable being removed to allow the wire to extend beyond an end of the sheath, the end of the sheath being disposed within the space, and a first bonding agent disposed within the space around the end of the sheath and forming a seal at the end of the sheath.

[0061]

[0061] Optionally, the housing includes a chamber formed around an end of the sheath within the space, and the first bonding agent is filled within the chamber.

[0062]

[0062] Optionally, the cable is a power cable configured to transmit power.

[0063]

[0063] Optionally, the electrical connector further comprises a hoop mounted over the sheath of the cable to secure the cable within the space.

[0064]

[0064] Optionally, the hoop includes an annular body mounted on the sheath and a tab protruding outwardly from the annular body, and the housing includes a receiving area formed within the accommodating cavity, and the tab is received within the receiving area to secure the cable within the accommodating cavity.

[0065]

[0065] Optionally, the cable includes a power cable configured to transmit power and a signal cable configured to transmit a signal, and the module includes a power module configured to transmit power and a signal module configured to transmit a signal, and the power cable is connected to the power module and the signal cable is connected to the signal module.

[0066]

[0066] Optionally, the signal cable is configured to transmit Ethernet electrical signals.

[0067]

[0067] Optionally, the portions of the power cable and the signal cable that extend outside the housing are surrounded by the same jacket.

[0068]

[0068] Optionally, the module includes a conductive terminal including a first end and a second end opposite the first end, the first end configured to be connected to a cable and the second end configured to be mounted to a circuit board.

[0069]

[0069] Optionally, the housing further includes an outwardly protruding mounting portion and a hole formed within the mounting portion.

[0070]

[0070] Some embodiments relate to a method for making an electrical connector. The method may include providing a housing including a plurality of walls surrounding a space, a first wall of the plurality of walls including a cavity formed therein, a first channel extending from the cavity through a rear portion of the first wall to an exterior of the housing, and a second channel extending from the cavity through a front portion of the first wall to the space, disposing a module at least partially within the space, extending a cable from an exterior of the housing through the first channel of the first wall, the cavity, and the second channel into the space and connecting the cable at an end thereof to the module, filling a first bonding agent into the cavity and disposing the first bonding agent around a portion of the cable disposed within the cavity to secure the cable to the first wall.

[0071]

[0071] Optionally, the housing includes at least a body and a rear cap, the space is disposed within the body, the body includes a rear end and a rear opening connecting to the space at the rear end, the rear cap configured to form a first wall of the housing, and the method further includes attaching the rear cap to the rear end of the body to close the rear opening.

[0072]

[0072] Optionally, the forward portion of the first wall includes a front surface facing toward the space and a slot extending from the front surface through the forward portion into the cavity, and the method further includes inserting a rear end portion of the body into the slot and engaging the first adhesive with the rear end portion.

[0073]

[0073] Optionally, the rear end portion of the body includes a first surface exposed within the cavity and a protrusion protruding from the first surface into the cavity, and engaging the first bonding agent with the rear end portion includes disposing the first bonding agent on the first surface and engaging the protrusion.

[0074]

[0074] Optionally, the rear end portion of the body includes a first surface exposed within the cavity and a recess recessed into the portion from the first surface, and engaging the first bonding agent with the rear end portion includes disposing the first bonding agent on the first surface and filling the first bonding agent into the recess.

[0075]

[0075] Optionally, the portion of the cable disposed within the cavity extends in a first direction, the first wall includes an opening extending from the exterior of the housing through a face portion of the first wall into the cavity in a second direction perpendicular to the first direction, allowing a first bonding agent to be filled into the cavity through the opening, and filling the first bonding agent into the cavity includes filling the first bonding agent into the cavity through the opening.

[0076]

[0076] Optionally, the rear and front portions of the first wall face each other and are spaced apart in a first direction by a cavity, the face portion connecting the rear and front portions, and the front portion of the first wall including a front surface facing toward the space and a slot extending from the front surface through the front portion into the cavity, the method further including inserting a portion of the rear end of the body into the slot such that a first surface of the portion is exposed in the cavity on a side of the portion of the cable facing away from the opening, and disposing a first adhesive on and engaging the first surface.

[0077]

[0077] Optionally, the first wall further includes a bottom portion, the bottom portion and the face portion opposing each other and spaced apart in the second direction by the cavity, the bottom portion including an upper surface facing the distribution chamber and a groove recessed from the upper surface into the bottom portion and connecting to the slot, and inserting the rear end portion of the body into the slot includes inserting the rear end portion of the body through the slot and into the groove, and the first surface is flush with the upper surface.

[0078]

[0078] Optionally, the rear end portion of the body further includes a protrusion protruding from the first surface into the cavity, and disposing the first bonding agent on the first surface and engaging the first surface includes disposing the first bonding agent on the first surface and engaging the protrusion.

[0079]

[0079] Optionally, the rear end portion of the body further includes a recess recessed into the portion from the first surface, and disposing the first bonding agent on the first surface and engaging the first surface includes disposing the first bonding agent on the first surface and filling the first bonding agent into the recess.

[0080]

[0080] Optionally, the body further includes a front end opposite the rear end, a first side between the rear end and the front end, an upper opening at the first side connecting the space with an exterior of the housing, and an edge portion defining the upper opening, and the housing further includes an upper cover including a top surface, a bottom surface opposite the top surface, a side surface extending between the top surface and the bottom surface, and a flange extending outwardly beyond the side surface, the flange including a top surface and a bottom surface opposite the top surface, the top surface being lower than the top surface, and the method further includes disposing the top cover within the upper opening of the body to close the upper opening, the bottom surface and the bottom surface facing toward the space and the edge portion of the body forming a groove with the side surface and top surface of the top cover, and filling a second bonding agent into the groove to provide a seal.

[0081]

[0081] Optionally, the body further includes a flange protruding into the upper opening, and disposing the top cover within the upper opening includes disposing a bottom surface of the flange of the top cover on the flange.

[0082]

[0082] Optionally, the body includes a bottom wall facing the upper opening and a rib protruding from the bottom wall into the space, the rib dividing the space into a first space between the rear end and the rib and a second space between the rib and the front end, the module is disposed in the second space, the cable extends from outside the housing through the first wall and the first space into the second space, the top cover is disposed over the second space to separate the second space from the outside of the housing, the top cover engages with the rib and, together with the rib, separates the second space from the first space, and the method further includes filling a third bonding agent into the first space to provide a seal.

[0083]

[0083] Optionally, the groove extends into and communicates with the first space, allowing the second adhesive and the third adhesive to be applied together, and the method further includes applying the second adhesive and the third adhesive together.

[0084]

[0084] Optionally, the cable includes a first cable including a wire and a sheath surrounding the wire, and the method further includes removing a portion of the sheath at an end of the first cable to allow the wire to extend beyond an end of the sheath, the end of the sheath being disposed in the space, and disposing a fourth bonding agent in the space around the end of the sheath to form a seal at the end of the sheath.

[0085]

[0085] Optionally, before the fourth bonding agent is applied, a hoop is placed over the sheath of the first cable, and the first cable is secured within the space by the hoop.

[0086]

[0086] Optionally, the first cable is a power cable configured to transmit power.

[0087]

[0087] Some embodiments relate to a method for making an electrical connector. The method may include providing a housing including a body, the body including a plurality of walls surrounding a space, an opening in a first side of the body communicating the space with an exterior of the housing, and an edge portion defining the opening, and a top cover including a top surface, a bottom surface opposite the top surface, a side extending between the top surface and the bottom surface, and a flange extending outward beyond the side surface, the flange including the top surface and the bottom surface opposite the top surface, the top cover being lower than the top surface; disposing a module at least partially in the space; extending a cable from the exterior of the housing through a first wall of the plurality of walls into the space and connecting the cable at an end thereof to the module; disposing the top cover in the opening of the body to close the opening, the bottom surface and the bottom surface facing toward the space, and an edge portion of the body forming a groove with the side surface and the top surface of the top cover; and filling a first bonding agent in the groove to form a seal.

[0088]

[0088] Optionally, the body further includes a flange protruding into the opening, and disposing the top cover within the opening includes disposing a bottom surface of the flange of the top cover on the flange.

[0089]

[0089] Optionally, the plurality of walls further includes a second wall opposite the first wall and a bottom wall extending between the first wall and the second wall, the bottom wall opposite the opening, the body further includes a rib extending from the bottom wall into the space, the rib dividing the space into a first space between the first wall and the rib and a second space between the rib and the second wall, the module is disposed in the second space, the cable extends from outside the housing through the first wall and the first space into the second space, the top cover is disposed over the second space to separate the second space from the outside of the housing, the top cover engages with the rib and, together with the rib, separates the second space from the first space, and the method further includes filling a second bonding agent into the first space to provide a seal.

[0090]

[0090] Optionally, the groove extends into and communicates with the first space, enabling the first adhesive and the second adhesive to be applied together, and the method further includes applying the first adhesive and the second adhesive together.

[0091]

[0091] Optionally, the cable includes a first cable including a wire and a sheath surrounding the wire, and the method further includes removing a portion of the sheath at an end of the first cable to allow the wire to extend beyond an end of the sheath, the end of the sheath being disposed in the space, and disposing a third bonding agent in the space around the end of the sheath to form a seal at the end of the sheath.

[0092]

[0092] Optionally, before applying the third bonding agent, a hoop is placed over the sheath of the first cable, and the first cable is secured within the space by the hoop.

[0093]

[0093] Optionally, the first cable is a power cable configured to transmit power.

[0094]

[0094] Optionally, the first wall includes a cavity formed in the first wall, a first channel extending from the cavity through a rear portion of the first wall to an exterior of the housing, and a second channel extending from the cavity through a front portion of the first wall to the space, and extending the cable from outside the housing through the first wall and into the space includes extending the cable from outside the housing through the first channel, the cavity, and the second channel in the first wall and into the space, and the method further includes filling a fourth bonding agent into the cavity and disposing the fourth bonding agent around a portion of the cable positioned in the cavity to secure the cable to the first wall.

[0095]

[0095] Some embodiments relate to a method for making an electrical connector. The method may include providing a housing including a plurality of walls surrounding a space; disposing a module at least partially within the space; extending a cable from an exterior of the housing through a first wall of the plurality of walls into the space and connecting the cable at an end thereof to the module, the cable including a wire and a sheath surrounding the wire, a portion of the sheath at the end of the cable being removed to allow the wire to extend beyond an end of the sheath, the end of the sheath being disposed within the space; and disposing a first bonding agent in the space around the end of the sheath to form a seal at the end of the sheath.

[0096]

[0096] Optionally, before applying the first bonding agent, a hoop is placed over the sheath of the cable, and the cable is secured within the space by the hoop.

[0097]

[0097] Optionally, the cable is a power cable configured to transmit power.

[0098]

[0098] These techniques may be used alone or in any suitable combination. The above summary is provided by way of example and is not intended to be limiting.

[0099] BRIEF DESCRIPTION OF THE DRAWINGS

[0099] The accompanying drawings are not intended to be drawn to scale. In the drawings, identical or nearly identical components shown in various figures may be represented by similar reference numerals. For purposes of clarity, not all components may be labeled in every drawing. [Brief description of the drawings]

[0100] [Figure 1]

[0100] FIG. 1 is a top perspective view of a hybrid electrical connector according to some embodiments. [Diagram 2]

[0101] FIG. 2 is a bottom perspective view of the electrical connector of FIG. [Diagram 3]

[0102] FIG. 3 is an exploded view of the electrical connector of FIG. [Figure 4]

[0103] 4 is a perspective view of the electrical connector of FIG. 1 with the top cover of the housing, the first adhesive, the second adhesive, the third adhesive, the fourth adhesive, and the hoop hidden. [Diagram 5]

[0104] FIG. 5 is a partial exploded view of the electrical connector of FIG. [Figure 6]

[0105] FIG. 6 is a perspective view of the electrical connector of FIG. 4 with the cable hidden. [Figure 7]

[0106] 7 is a perspective view of the electrical connector of FIG. 1 with the top cover of the housing, the second bonding agent, and the third bonding agent hidden. [Figure 8]

[0107] FIG. 8 is an enlarged view of area A enclosed by the dashed line in FIG. [Figure 9]

[0108] FIG. 9 is an enlarged view of area B enclosed by the dashed line in FIG. [Figure 10]

[0109] 10 is a perspective view of a hoop of the electrical connector of FIG. [Figure 11]

[0110] 11 is a perspective view of a cable of the electrical connector of FIG. 1. FIG. [Figure 12]

[0111] 12 is a perspective view of the electrical connector of FIG. 1 with the second bonding agent and the third bonding agent hidden. [Figure 13]

[0112] 13 is a partial cross-sectional view of the electrical connector taken along line II in FIG. [Figure 14]

[0113] 14 is a perspective view of the rear cap of the electrical connector of FIG. 1. FIG. [Figure 15]

[0114] 15 is a top perspective view of the upper cover of the electrical connector of FIG. 1. FIG. [Figure 16]

[0115] 16 is a bottom perspective view of the top cover of the electrical connector shown in FIG. 15. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0101]

[0116] List of reference numbers:

[0117] XX Longitudinal

[0118] YY Horizontal

[0119] ZZ Vertical direction

[0120] 1 Electrical Connector

[0121] 10. Housing

[0122] 11 Space

[0123] 11a First Space

[0124] 11b The Second Space

[0125] 12 Mounting part

[0126] 13 holes

[0127] 20 Modules

[0128] 21 Power Module

[0129] 21a Power module body

[0130] 21b second end of the power terminal of the power module

[0131] 22 Signal Module

[0132] 22a Signal module body

[0133] 22b second end of the signal terminal of the signal module

[0134] 30 Cable

[0135] 31 Power Cable

[0136] 31a Power cable ends

[0137] 33 Power Cable Wires

[0138] 33a Power cable wire conductor

[0139] 33b Power cable wire insulation

[0140] 34 Power cable sheath

[0141] 34a End of power cable sheath

[0142] 32 Signal cable

[0143] 32a Signal Cable End

[0144] 35 Signal Cable Wires

[0145] 35a signal cable wire conductor

[0146] 35b Signal cable wire insulation

[0147] 36 Signal cable sheath

[0148] 36a End of sheath of signal cable

[0149] 41 First Bonding Agent

[0150] 42 Second Bonding Agent

[0151] 43 Third Bonding Agent

[0152] 44 The Fourth Bonding Agent

[0153] 50 Jacket

[0154] 60 grooves

[0155] 70 Passage

[0156] 100 Body

[0157] 101 Rear end

[0158] 101a Rear end portion

[0159] 101b: first surface of rear end portion 101a

[0160] 101c Protrusion

[0161] 101d Recess

[0162] 102 Front end

[0163] 103 First side wall

[0164] 103a: Edge portion of first side wall

[0165] 104 Second Side Wall

[0166] 104a: Edge portion of second side wall

[0167] 105 Third Sidewall

[0168] 105a: Edge portion of third side wall

[0169] 106 Bottom wall

[0170] 107 Rear opening

[0171] 108 Top opening

[0172] 109 Latch

[0173] 120 Flange

[0174] 130 Ribs

[0175] 140 Chamber

[0176] 150 Reception Area

[0177] 200 Rear Cap

[0178] 200a hollow

[0179] 200b opening

[0180] 201 Rear part

[0181] 202 Front part

[0182] 202a Front of the front part

[0183] 203 area

[0184] 204 Bottom part

[0185] 204a Upper surface of bottom part

[0186] 204b Groove in bottom part

[0187] 210 First Channel

[0188] 220 Second Channel

[0189] 300 Top cover

[0190] 301 Top surface

[0191] 302 Bottom

[0192] 303 Side

[0193] 304 flange

[0194] 304a top side

[0195] 304b Bottom

[0196] 304c side

[0197] 305 Rear flange

[0198] 400 hoops

[0199] 401 Annular body

[0200] 402 tab.

[0102] Detailed Description

[0201] The inventors have recognized and appreciated techniques for making hybrid connectors that can be economically constructed to provide high signal integrity and deliver reliable power in harsh environments such as those presented by automobiles. The connectors can be configured to provide power and signal interconnects for applications such as automotive LiDAR. The connectors can comply with relevant standards such as USCAR-2 and TC9.

[0103]

[0202] In some embodiments, the electrical connector can include a housing at least partially enclosing a volume and a power and signal module disposed within the volume of the housing, In some embodiments, each of the power and signal modules can have a first end facing a rear of the housing and a second end extending outwardly from a bottom of the housing.

[0104]

[0203] In some embodiments, power and signal cables may be attached to first ends of the power and signal modules, respectively, and may extend out of the rear of the housing through the cap. The cap may have a cavity with a first sealing member disposed therein and around the portions of the power and signal cables that extend into the cap cavity. The first sealing member may be formed by filling the cavity with a first adhesive to seal the rear of the housing and inhibit movement of the portions of the power and signal cables that extend into the cap cavity. The adhesive may be flexibly molded to conform to the shape of the cavity, thus ensuring a reliable seal despite variations in the shape of the parts to be sealed, which may result, for example, from manufacturing tolerances.

[0105]

[0204] In some embodiments, a cover may be disposed on top of the housing. A second sealing member may be disposed around the cover and between the cover and the housing. The second sealing member may be formed by filling a second adhesive around the cover and into any gaps between the cover and the housing. A space may exist between the cover and the rear cap of the housing. The second sealing member may have a portion disposed within the space. The second sealing member may surround and be bonded to portions of the first and second cables passing through the space between the cover and the rear cap of the housing. Such a second sealing member may seal any gaps between the cover and the housing and also inhibit movement of portions of the power and signal cables extending through the space between the cover and the rear cap of the housing. The adhesive may flexibly mold to the shape of these gaps and spaces, thus resulting in a robust connector that is resistant to environmental conditions despite manufacturing tolerances.

[0106]

[0205] In some embodiments, a third sealing member may be disposed between the hoop disposed around the power cable sheath and the power module. A portion of the power cable sheath may be removed to attach the power cable wires to the power module. The third sealing member may seal any gaps between the power cable sheath and the power cable and act as an insulating layer around the exposed wires to inhibit movement of the exposed wires.

[0107]

[0206] In some embodiments, the housing can include portions that protrude outwardly and are configured to secure the connector onto another component. Each portion can have a hole through which a screw can extend to hold the portion to the other component.

[0108]

[0207] 1-16 illustrate an electrical connector 1 according to some embodiments of the present application. The electrical connector 1 may be a hybrid connector for providing both power and signal interconnections. In some examples, the electrical connector 1 may be a connector used to provide both power and Ethernet signal interconnections, for example, to an automotive LIDAR. The electrical connector 1 may conform to standards such as USCAR-2 and TC9. It is understood that the electrical connector 1 may be used in any suitable application.

[0109]

[0208] For ease of understanding and simplicity of explanation, a longitudinal direction XX, a lateral direction YY, and a vertical direction ZZ may be defined. The longitudinal direction XX, the lateral direction YY, and the vertical direction ZZ may be perpendicular to each other. The longitudinal direction XX may refer to the length direction of the electrical connector 1, the lateral direction YY may refer to the width direction of the electrical connector 1, and the vertical direction ZZ may refer to the height direction of the electrical connector 1. It should be understood that aspects of the present application are not intended to be limited by these directions.

[0110]

[0209] FIG. 1 is a top perspective view showing the electrical connector 1, FIG. 2 is a bottom perspective view showing the electrical connector 1, and FIG.

[0111]

[0210] 1-3, the electrical connector 1 includes a housing 10, a module 20 disposed at least partially within the housing 10, and a cable 30 extending from the exterior of the housing 10 into the housing 10 and connected to the module 20. It should be understood that only a portion of the cable 30 is shown in the figures.

[0112]

[0211] In some embodiments, cable 30 may include a power cable 31 configured to transmit power and a signal cable 32 configured to transmit signals. Signal cable 32 may be configured to transmit Ethernet electrical signals. Module 20 may include a power module 21 configured to transmit power and a signal module 22 configured to transmit signals. Power cable 31 is connected to power module 21 and signal cable 32 is connected to signal module 22.

[0113]

[0212] In some embodiments, the housing 10 may include a body 100, as well as a rear cap 200 and a top cover 300 that are attached to the body 100. In some embodiments, the housing 10 may also include a hoop 400 that is attached within the body 100 for securing cables (hoop 400 is shown securing power cable 31).

[0114]

[0213] 1 and 3, the electrical connector 1 may include a first bonding agent (or adhesive) 41, a second bonding agent (or adhesive) 42, a third bonding agent (or adhesive) 43, and a fourth bonding agent (or adhesive) 44. The bonding agents (or adhesives) may also be referred to as "bonding agent members (or adhesive members)."

[0115]

[0214] FIG. 4 is a perspective view of the electrical connector 1 of FIG. 1 with the top cover 300 of the housing 10, the first adhesive 41, the second adhesive 42, the third adhesive 43, the fourth adhesive 44, and the hoop 400 of the electrical connector 1 hidden. FIG. 5 is a partially exploded view of the electrical connector 1 of FIG. 4 with the cable 30 and the rear cap 200 not yet attached to the body 100 and the module 20 attached to the body 100. FIG. 6 is a perspective view similar to FIG. 4 with the cable 30 of the electrical connector 1 hidden. FIG. 8 is an enlarged view of the area A surrounded by the dashed line in FIG. 4. FIG. 11 is a perspective view of the cable 30. FIG. 13 is a partial cross-sectional view taken along the line II in FIG. 1.

[0116]

[0215] Fig. 7 is another perspective view of the electrical connector 1 of Fig. 1, in which the top cover 300 of the housing 10, the second bonding agent 42, and the third bonding agent 43 of the electrical connector 1 are hidden. Fig. 9 is an enlarged view of the area B surrounded by the dashed line in Fig. 7. Fig. 12 is yet another perspective view of the electrical connector 1 of Fig. 1, in which the second bonding agent 42 and the third bonding agent 43 of the electrical connector 1 are hidden.

[0117]

[0216] As shown in Figs. 3 to 7 and 12, the housing 10 includes a plurality of walls surrounding the space 11. As shown in the illustrated example, the main body 100 of the housing 10 includes a rear end 101 and a front end 102 that are opposite to each other in the longitudinal direction XX, a first side wall 103 at the front end 102, and a second side wall 104, a third side wall 105, and a bottom wall 106 that extend between the rear end 101 and the front end 102. The second side wall 104 and the third side wall 105 face each other in the lateral direction YY. The bottom wall 106 extends in the lateral direction YY between the second side wall 104 and the third side wall 105. The first side wall 103 connects the second side wall 104, the third side wall 105, and the bottom wall 106. The first side wall 103, the second side wall 104, the third side wall 105, and the bottom wall 106 of the body 100 may form four of the walls of the housing 10. Further, the rear cap 200 may form one of the walls of the housing 10, and the top cover 300 may form another of the walls of the housing 10. The first side wall 103, the second side wall 104, the third side wall 105, and the bottom wall 106 of the body 100, the rear cap 200, and the top cover 300 surround a space 11.

[0118]

[0217] In some embodiments, the body 100 may include an outwardly protruding mounting portion 12 and an aperture 13 formed within the mounting portion 12. With this configuration, the electrical connector 1 may be securely fastened to, for example, a panel using fasteners such as screws or pins.

[0119]

[0218] The body 100, rear cap 200, and top cover 300 may be formed from any suitable material. For example, the body 100, rear cap 200, and top cover 300 may be formed from an insulating material. Examples of insulating materials suitable for forming the body 100, rear cap 200, and top cover 300 include, but are not limited to, plastic, nylon, liquid crystal polymer (LCP), polyphenylene sulfide (PPS), high temperature nylon or polyphenylene oxide (PPO), or polypropylene (PP).

[0120]

[0219] 3-7 and 12, the space 11 is disposed within the body 100. The body 100 includes a rear opening 107 (FIG. 5) that connects to the space 11 at the rear end 101 and allows the cable 30 to extend through the rear opening 107 into the space 11.

[0121]

[0220] The rear cap 200 is attached to the rear end 101 of the body 100 to close the rear opening 107. As described above, one of the walls of the housing 10 is formed by the rear cap 200. FIG. 14 is a perspective view of the rear cap 200. As shown in FIG. 14, the rear cap 200 (or referred to as the "first wall" of the housing 10) includes a cavity 200a formed therein, a first channel 210 extending from the cavity 200a through a rear portion 201 of the rear cap 200 to the outside of the housing 10, and a second channel 220 extending from the cavity 200a through a front portion 202 of the rear cap 200 to the space 11.

[0122]

[0221] 1-5, 7, and 11-12, cable 30 includes a power cable 31 configured to transmit power, and a signal cable 32 configured to transmit a signal. The portions of power cable 31 and signal cable 32 that extend outside of housing 10 may be surrounded by the same jacket 50. It should be understood that the portions of power cable 31 and signal cable 32 that extend outside of housing 10 may each be surrounded by a separate jacket, or may not have a jacket.

[0123]

[0222] The power cable 31 includes wires 33 and a sheath 34 surrounding the wires 33. Although the power cable 31 is shown having four wires 33, it should be understood that the application is not intended to be so limited and the power cable 31 may include any suitable number of wires. A portion of the sheath 34 at the end 31a of the power cable 31 is removed to allow the wires 33 to extend beyond the end 34a of the sheath 34. The wires 33 may include a conductor 33a and an insulation 33b surrounding the conductor. A portion of the insulation 33b corresponding to the connection between the conductor 33a and the power module 21 is removed. This allows the power cable 31 to be ready for connection to the power module 21.

[0124]

[0223] Similar to the power cable 31, the signal cable 32 includes a wire 35 and a sheath 36 surrounding the wire 35. Although the signal cable 32 is shown having two wires 35, the application is not intended to be so limited, and the signal cable 32 may include any suitable number of wires. A portion of the sheath 36 at the end 32a of the signal cable 32 is removed to allow the wire 35 to extend beyond the end 36a of the sheath 36. The wire 35 may include a conductor 35a and an insulation 35b surrounding the conductor. A portion of the insulation 35b corresponding to the connection between the conductor 35a and the signal module 22 is removed. This allows the signal cable 32 to be ready for connection to the signal module 22. In some embodiments, the signal cable 32 may include a shielding casing disposed at the end 36a of the sheath 36.

[0125]

[0224] The rear cap 200 is shown in Fig. 14 to include two first channels 210 corresponding to the power cable 31 and the signal cable 32 of the cable 30, respectively, thereby allowing the power cable 31 and the signal cable 32 to extend from the outside of the housing 10 into the cavity 200a through the corresponding first channels 210, respectively. Furthermore, the rear cap 200 is also shown in Fig. 14 to include two second channels 220 corresponding to the power cable 31 and the signal cable 32 of the cable 30, respectively, thereby allowing the power cable 31 and the signal cable 32 to extend from the cavity 200a into the space 11 through the corresponding second channels 220, respectively. It should be understood that the present application is not intended to be limited thereto, and the number of the first channels 210 and the second channels 220 may be one or more than two.

[0126]

[0225] As shown in FIGS. 2-9, the module 20 includes a power module 21 configured to transmit power, and a signal module 22 configured to transmit a signal.

[0127]

[0226] The power module 21 may include a body 21a and a power terminal held by the body 21a. The power terminal may be formed of a conductive material. The power terminal may include a first end, a second end 21b opposite the first end, and an intermediate portion extending between the first end and the second end. The first end of the power terminal is configured to be connected to a conductor 33a of a corresponding wire 33 of the power cable 31. The second end 21b of the power terminal may be configured to be mounted on a circuit board, such as a motherboard of an automotive LIDAR. As shown in FIG. 2 and FIG. 4 to FIG. 7, when the power module 21 is mounted on the housing 10, the body 21a is disposed in the space 11, and the second end 21b extends to the outside of the body 100 through the bottom wall 106 of the body 100 to be mounted on the circuit board. It should be understood that the present application is not intended to be limited thereto, and that in some embodiments, the power module 21 may be disposed completely within the space 11. For example, the power module 21 may be disposed at least partially within the space 11 .

[0128]

[0227] The signal module 22 may include a body 22a and a signal terminal carried by the body 22a. The signal terminal may be formed of a conductive material. The signal terminal may include a first end, a second end 22b opposite the first end, and an intermediate portion extending between the first end and the second end. The first end of the signal terminal is configured to be connected to a conductor 35a of a corresponding wire 35 of the signal cable 32. The second end 22b of the signal terminal may be configured to be mounted to a circuit board, such as a motherboard of an automotive LIDAR. As shown in FIG. 2 and FIG. 4-FIG. 7, when the signal module 22 is mounted to the housing 10, the body 22a is disposed within the space 11, and the second end 22b extends to the outside of the body 100 through the bottom wall 106 of the body 100 to be mounted to the circuit board. It should be understood that the present application is not intended to be limited thereto, and that in some embodiments, the signal module 22 may be disposed completely within the space 11. For example, the signal module 22 may be disposed at least partially within the space 11 .

[0129]

[0228] 4, the cable 30 extends from the exterior of the housing 10 through the first channel 210, the cavity 200a, and the second channel 220 of the rear cap 200 into the space 11 and is connected to the module 20 at its end. As shown in the illustrated example, the power cable 31 extends from the exterior of the housing 10 through the corresponding first channel 210, the cavity 200a, and the corresponding second channel 220 of the rear cap 200 into the space 11 and is connected to the power module 21 at its end 31a. The signal cable 32 extends from the exterior of the housing 10 through the corresponding first channel 210, the cavity 200a, and the corresponding second channel 220 of the rear cap 200 into the space 11 and is connected to the signal module 22 at its end 32a.

[0130]

[0229] In some embodiments, the cable 30 may extend through the first channel 210, the cavity 200a, and the second channel 220 of the rear cap 200 before the rear cap 200 is attached to the rear end 101 of the body 100. Optionally, the cable 30 may extend through the rear cap 200, the cavity 200a, and the second channel 220 of the rear cap 200 after the rear cap 200 is attached to the rear end 101 of the body 100.

[0131]

[0230] In some embodiments, the cable 30 may be connected to the module 20 before the module 20 is mounted to the body 100. Optionally, the cable 30 may be connected to the module 20 after the module 20 is mounted to the body 100.

[0132]

[0231] In some embodiments, the electrical connector 1 may include a first adhesive 41. As shown in FIG. 1, FIG. 7, and FIG. 12, the first adhesive 41 is filled in the cavity 200a of the rear cap 200 and disposed around the portion of the cable 30 (e.g., the power cable 31 and the signal cable 32) disposed in the cavity 200a to fix the cable 30 to the rear cap 200. The first adhesive 41 may be applied after the rear cap 200 is attached to the rear end 101 of the body 100 and the cable 30 is extended through the first channel 210, the cavity 200a, and the second channel 220 of the rear cap 200. Using the first adhesive 41 to fix the cable 30 to the rear cap 200 may improve the tensile strength of the cable 30 and the vibration resistance performance of the electrical connector 1, thereby improving the reliability of the electrical connector 1. Furthermore, using the first adhesive 41 to fix the cable 30 to the rear cap 200 can reduce the volume of the electrical connector 1, and can reduce the complexity of the manufacturing process and the manufacturing cost of the electrical connector 1, compared to using a strain relief (SR) mold to fix the cable 30. The first adhesive 41 can also be referred to as a "fixing member" or a "fixing adhesive".

[0133]

[0232] The first bonding agent 41 may be a UV bonding agent, a silicone, an epoxy bonding agent, or any other suitable type of bonding agent. For example, the first bonding agent 41 may be an underfill, such as a silicone underfill (e.g., polysiloxane, polydimethylsiloxane), an epoxy underfill (e.g., epoxy resin, epoxy acrylate), a urethane underfill (e.g., urethane resin, urethane acrylate), or an acrylate underfill (e.g., acrylate monomer, acrylate copolymer).

[0134]

[0233] In some embodiments, the rear cap 200 may be attached to the body 100 by any suitable means, such as a snap fit, a latch mechanism, heat fusion, etc. For example, the body 100 may be provided with a snap fit structure at its rear end 101 and the rear cap 200 may be provided with a mating snap fit structure. The snap fit structure of the body 100 and the mating snap fit structure of the rear cap 200 may cooperate with each other to securely attach the rear cap 200 to the rear end 101 of the body 100.

[0135]

[0234] As shown in Figures 4 to 6, when the rear cap 200 is attached to the rear end 101 of the main body 100, the front portion 202 of the rear cap 200 is positioned adjacent to the space 11, and the front surface 202a of the front portion 202 of the rear cap 200 faces toward the space 11.

[0136]

[0235] In some embodiments, the front portion 202 of the rear cap 200 includes a slot extending from the front surface 202a through the front portion 202 into the cavity 200a. The portion 101a (FIG. 5) of the rear end 101 of the body 100 can be inserted into the slot. The first adhesive 41 can engage with the portion 101a of the rear end 101 of the body 100. As an example, the first adhesive 41 can extend into the slot of the front portion 202 and engage with the portion 101a of the rear end 101 of the body 100. As another example, the first surface 101b of the portion 101a of the rear end 101 of the body 100 can be exposed in the cavity 200a of the rear cap 200, and the first adhesive 41 can be disposed on the first surface 101b. Engaging the first bonding agent 41 with the above-mentioned portion 101a of the rear end 101 of the body 100 can improve the connection strength between the rear cap 200 and the body 100, and improve the vibration resistance performance of the electrical connector 1. It should be understood that in other embodiments, the rear cap 200 can be held to the rear end 101 of the body 100 by engaging the first bonding agent 41 with the above-mentioned portion 101a of the rear end 101 of the body 100.

[0137]

[0236] Optionally, in an embodiment in which the first surface 101b of the portion 101a of the rear end 101 of the body 100 is exposed in the cavity 200a of the rear cap 200, the portion 101a of the rear end 101 of the body 100 may include a protrusion 101c that protrudes from the first surface 101b into the cavity 200a. The first bonding agent 41 may be disposed on the first surface 101b and engage with the protrusion 101c. In this manner, the connection strength between the rear cap 200 and the body 100 may be further improved. Furthermore, the deformation of the first bonding agent 41 when the cable 30 is pulled may be suppressed, thereby further improving the tensile strength of the cable 30. As an example, the protrusion 101c may be configured as a barb, as shown.

[0138]

[0237] Optionally or additionally, in an embodiment in which the first surface 101b of the above-mentioned portion 101a of the rear end 101 of the main body 100 is exposed in the cavity 200a of the rear cap 200, the above-mentioned portion 101a of the rear end 101 of the main body 100 may include a recess 101d recessed from the first surface 101b into the above-mentioned portion 101a. The first bonding agent 41 may be disposed on the first surface 101b and filled in the recess 101d. In this manner, the connection strength between the rear cap 200 and the main body 100 may be further improved. In addition, the deformation of the first bonding agent 41 may be suppressed when the cable 30 is pulled, thereby further improving the tensile strength of the cable 30.

[0139]

[0238] In some embodiments, as shown in FIG. 4, the portion of the cable 30 disposed in the cavity 200a may extend in a longitudinal direction XX. The rear cap 200 may include an opening 200b extending from the exterior of the housing 10 through a face portion 203 of the rear cap 200 into the cavity 200a in a lateral direction YY perpendicular to the longitudinal direction XX, allowing the first bonding agent 41 to be filled into the cavity 200a through the opening 200b. With such a configuration, it is possible to facilitate filling the first bonding agent 41 into the cavity 200a and disposing it around the portion of the cable 30 disposed in the cavity 200a. In addition, the opening 200b can be used as an inspection window to facilitate inspection of the filling of the first bonding agent 41 in the cavity 200a.

[0140]

[0239] In some embodiments, the rear portion 201 and the front portion 202 of the rear cap 200 face each other and may be spaced apart from each other in the longitudinal direction XX by the cavity 200a, and the surface portion 203 connects the rear portion 201 and the front portion 202. The first channel 210 and the second channel 220 may each extend in the longitudinal direction XX. The cross section of the cavity 200a perpendicular to the longitudinal direction XX may be larger than the cross section of the first channel 210 perpendicular to the longitudinal direction XX, and may be larger than the cross section of the second channel 220 perpendicular to the longitudinal direction XX. With such a configuration, the first bonding agent 41 can be reliably engaged with the inner wall of the cavity 200a, thereby increasing the tensile strength of the cable 30. In some examples, the first channel 210 and the second channel 220 are aligned with each other in the longitudinal direction XX. It should be understood that the application is not intended to be limited in this respect, and the first channel 210 and the second channel 220 may be partially or completely offset from one another in the longitudinal direction XX.

[0141]

[0240] Optionally or additionally, in an embodiment in which the first surface 101b of the aforementioned portion 101a of the rear end 101 of the body 100 is exposed in the cavity 200a of the rear cap 200, the first surface 101b of the aforementioned portion 101a of the rear end 101 of the body 100 may be exposed in the cavity 200a on a side of the portion of the cable 30 facing away from the opening 200b. The first bonding agent 41 may be disposed on and engage with the first surface 101b. As shown in Figures 5 and 6, the rear cap 200 may further include a bottom portion 204, where the bottom portion 204 and the face portion 203 are opposite each other and spaced apart from each other in the lateral direction YY by the cavity 200a. The bottom portion 204 may include an upper surface 204a facing toward the cavity 200a, and a groove 204b recessed from the upper surface 204a into the bottom portion 204 and connecting to the slot of the front portion 202. The aforementioned portion 101a of the rear end 101 of the body 100 is inserted into the groove 204b through the slot of the front portion 202 of the rear cap 200, and the first surface 101b of the aforementioned portion 101a is flush with the upper surface 204a of the bottom portion 204. In some embodiments, as described above, the aforementioned portion 101a of the rear end 101 of the body 100 may include a protrusion 101c protruding from the first surface 101b into the cavity 200a. The first bonding agent 41 may be disposed on the first surface 101b and engage with the protrusion 101c. For example, the protrusion 101c may be configured as a barb. Optionally or additionally, in some embodiments, as described above, the above-mentioned portion 101a of the rear end 101 of the main body 100 may include a recess 101d recessed from the first surface 101b into the above-mentioned portion 101a. The first bonding agent 41 may be disposed on the first surface 101b and filled into the recess 101d. By having at least one of these configurations, the connection strength between the rear cap 200 and the main body 100 may be further improved. In addition, the deformation of the first bonding agent 41 may be suppressed when the cable 30 is pulled, thereby further improving the tensile strength of the cable 30.

[0142]

[0241] In some embodiments, the first bonding agent 41 may form a seal within the cavity 200a of the rear cap 200 to prevent communication of the cavity 200a, the first channel 210, and the second channel 220 of the rear cap 200 with the outside of the housing 10 via the opening 200b.

[0143]

[0242] As shown in FIGS. 3-7 and 12, the body 100 also includes a first surface between the rear end 101 and the front end 102, which is opened to form an opening that communicates the space 11 with the outside of the housing 10. It should be understood that in other embodiments, the first surface may be partially opened to form an upper opening 108 that communicates the space 11 with the outside of the housing 10. For example, the body 100 may include a first surface between the rear end 101 and the front end 102, with the upper opening 108 communicating the space 11 with the outside of the housing 10 at the first surface. The body 100 also includes an edge portion that defines the upper opening 108. As shown in FIGS. 6 and 12, the upper opening 108 is defined by an edge portion 103a of the first side wall 103, an edge portion 104a of the second side wall 104, and an edge portion 105a of the third side wall 105 of the body 100. A bottom wall 106 of the main body 100 faces an upper opening 108 in the vertical direction ZZ.

[0144]

[0243] 15 and 16 show the top cover 300 of the housing 10 in detail. As shown in FIG. 15 and 16, the top cover 300 includes a top surface 301, a bottom surface 302 opposite the top surface 301, a side surface 303 extending between the top surface 301 and the bottom surface 302, and a flange 304 extending outward beyond the side surface 303. The flange 304 may extend from either the bottom surface 302 or the side surface 303. The flange 304 includes a top surface 304a, a bottom surface 304b opposite the top surface 304a, and a side surface 304c extending between the top surface 304a and the bottom surface 304b. The top surface 304a and the top surface 301 face in the same direction, and the bottom surface 304b and the bottom surface 302 face in the same direction. The top surface 304a is lower than the top surface 301.

[0145]

[0244] As shown in Figures 3, 7, 12, and 13, the top cover 300 is disposed in the top opening 108 of the body 100 to close the top opening 108. As described above, one of the walls of the housing 10 is formed by the top cover 300. The bottom surface 302 and the bottom surface 304b of the top cover 300 face toward the space 11. The edge portion 103a of the first side wall 103, the edge portion 104a of the second side wall 104, and the edge portion 105a of the third side wall 105 of the body 100 form a groove 60 together with the side surface 303 and the top surface 304a of the top cover 300. The side surface 304c may engage with the edge portion or may be directly adjacent to the edge portion.

[0146]

[0245] In some embodiments, the electrical connector 1 may include a second adhesive 42 filled in the groove 60 to provide a seal. For example, the second adhesive 42 may prevent communication from the space 11 to the outside of the housing 10 through a gap between the top cover 300 and the edge portion of the main body 100 that defines the top opening 108 (the edge portion 103a of the first side wall 103, the edge portion 104a of the second side wall 104, and the edge portion 105a of the third side wall 105). With this configuration, it is possible to improve the sealing performance of the electrical connector 1. In addition, with this configuration, the reliability of the connection between the top cover 300 and the main body 100 may be improved.

[0147]

[0246] The second bonding agent 42 may be a UV bonding agent, a silicone, an epoxy bonding agent, or any other suitable type of bonding agent. For example, the second bonding agent 42 may be an underfill, such as a silicone underfill (e.g., polysiloxane, polydimethylsiloxane), an epoxy underfill (e.g., epoxy resin, epoxy acrylate), a urethane underfill (e.g., urethane resin, urethane acrylate), or an acrylate underfill (e.g., acrylate monomer, acrylate copolymer).

[0148]

[0247] In some embodiments, as shown in Figures 8 and 9, the body 100 may include a latch 109 extending from the bottom wall 106 into the space 11. The top cover 300 may include a corresponding engagement mechanism on the bottom surface 302. When the top cover 300 is disposed in the top opening 108 of the body 100, the latch 109 of the body 100 may engage with the corresponding engagement mechanism of the top cover 300 to secure the top cover 300 in the top opening 108. It should be understood that the present application is not intended to be limited in this respect, and the top cover 300 may be secured in the top opening 108 by any suitable securing mechanism or feature. For example, in some other embodiments, the top cover 300 may be secured in the top opening 108 by only the second adhesive 42.

[0149]

[0248] In some embodiments, as shown in FIGS. 6-9 and 12-13, the body 100 also includes a flange 120 that protrudes into the top opening 108. As an example, the flange 120 may protrude into the top opening 108 from the first side wall 103, the second side wall 104, and the third side wall 105. As another example, the flange 120 may protrude into the top opening 108 from the bottom wall 106. As shown in FIG. 13, the bottom surface 304b of the flange 304 of the top cover 300 is supported on the flange 120 of the body 100. With such a configuration, it is possible to form a labyrinth-type seal at the position of the groove 60, thereby further improving the sealing performance of the electrical connector 1. Optionally or additionally, the body 100 may also be formed to support the top cover 300 in the top opening 108 by any other suitable structure.

[0150]

[0249] In some embodiments, as shown in Figs. 6-9 and 12, the main body 100 may also include a rib 130 protruding from the bottom wall 106 into the space 11. The rib 130 divides the space 11 into a first space 11a between the rear end 101 (or the rear cap 200) and the rib 130, and a second space 11b between the rib 130 and the front end 102 (or the first side wall 103). The modules 20 (e.g., the power module 21 and the signal module 22) may be disposed in the second space 11b, and the cables 30 extend from the outside of the housing 10 through the rear cap 200 and the first space 11a into the second space 11b. As shown in Fig. 12, the top cover 300 is disposed above the second space 11b and separates the second space 11b from the outside of the main body 100. In addition, the top cover 300 engages the rib 130 and together with the rib 130 separates the second space 11b from the first space 11a.

[0151]

[0250] The electrical connector 1 may also include a third adhesive 43 filled in the first space 11a to provide a seal. For example, the third adhesive 43 may prevent communication from the joint between the top cover 300 and the rib 130 and the second space 11b through the first space 11a to the outside of the housing 10. With this configuration, the sealing performance of the electrical connector 1 may be improved. In addition, with this configuration, the reliability of the connection between the top cover 300 and the main body 100 may be improved.

[0152]

[0251] The third bonding agent 43 may be a UV bonding agent, a silicone, an epoxy bonding agent, or any other suitable type of bonding agent. For example, the third bonding agent 43 may be an underfill, such as a silicone underfill (e.g., polysiloxane, polydimethylsiloxane), an epoxy underfill (e.g., epoxy resin, epoxy acrylate), a urethane underfill (e.g., urethane resin, urethane acrylate), or an acrylate underfill (e.g., acrylate monomer, acrylate copolymer).

[0153]

[0252] In some embodiments, as shown in FIG. 12, the groove 60 can extend to and connect to the first space 11a, allowing the second adhesive 42 and the third adhesive 43 to be applied integrally. For example, the second adhesive 42 and the third adhesive 43 can be applied and integrally formed by a single adhesive dropping process. With such a configuration, the sealing performance of the electrical connector 1 can be further improved. In addition, with such a configuration, the reliability of the connection between the top cover 300 and the main body 100 can be further improved.

[0154]

[0253] As an example, as shown in Figs. 15 and 16, the top cover 300 may include a rear flange 305 extending downward from the bottom surface 302 or flange 304 toward the rib 130 of the body 100. The rear flange 305 engages with the rib 130. A passage 70 may be formed at the engagement portion of the rear flange 305 and the rib 130 (e.g., as shown, the rear flange 305 and the rib 130 each define half of each passage 70), and the cable 30 extends through the passage 70 into the second space 11b. The third bonding agent 43 may prevent communication from the second space 11b to the outside of the housing 10 through the passage 70. The electrical connector 1 is shown in the figures to include two passages 70 corresponding to the power cable 31 and the signal cable 32 of the cable 30, respectively, thereby allowing the power cable 31 and the signal cable 32 to extend through the passage 70 into the second space 11b, respectively. It should be understood that the application is not intended to be so limited and that the number of passages 70 may be one or more than two, and that in other examples, the passages 70 may be formed within the ribs 130.

[0155]

[0254] In some embodiments, as shown in Figures 3-5, 8, and 11, and as described above, the power cable 31 is connected to the power module 21 at its end 31a. As shown in the illustrated example, a portion of the sheath 34 of the power cable 31 at its end 31a is removed to allow the wires 33 to extend beyond the end 34a of the sheath 34. The end 34a of the sheath 34 is disposed within the space 11, and in Figures 3-5, 8, and 11, is disposed within the second space 11b of the space 11. If the end 34a of the sheath 34 is not sealed, water vapor may enter the second space 11b along the inside of the sheath 34, such as if there is a break in the sheath 34 of the portion of the power cable 31 that is outside the housing 10 of the electrical connector 1, or if the end of the sheath 34 opposite the end 34a is not sealed. To reduce the risk of this, the electrical connector 1 may include a fourth bonding agent 44 disposed around the end 34a of the sheath 34 in the space 11 (in the second space 11b) and forming a seal at the end 34a of the sheath 34. For example, the fourth bonding agent 44 may prevent communication from the second space 11b through the inside of the sheath 34 to the outside of the housing 10. By having such a configuration, the sealing performance of the electrical connector 1 may be improved. In some embodiments, a bonding agent may be disposed at the end 36a of the sheath 36 of the signal cable 32 to form a seal, similar to the power cable 31.

[0156]

[0255] The fourth bonding agent 44 may be a UV bonding agent, a silicone, an epoxy bonding agent, or any other suitable type of bonding agent. For example, the fourth bonding agent 44 may be an underfill, such as a silicone underfill (e.g., polysiloxane, polydimethylsiloxane), an epoxy underfill (e.g., epoxy resin, epoxy acrylate), a urethane underfill (e.g., urethane resin, urethane acrylate), or an acrylate underfill (e.g., acrylate monomer, acrylate copolymer).

[0157]

[0256] 8, the main body 100 may include a chamber 140 formed around the end 34a of the sheath 34 of the power cable 31 in the space 11, and the fourth bonding agent 44 is filled in the chamber 140. By having such a configuration, it is possible to facilitate application of the fourth bonding agent 44.

[0158]

[0257] In some embodiments, as shown in Figs. 3, 7, and 9, the electrical connector 1 may include a hoop 400. The hoop 400 is attached onto the sheath 34 of the power cable 31 to fix the power cable 31 in the space 11 (in the second space 11b). With such a configuration, in one aspect, the application of the fourth bonding agent 44 may be facilitated by fixing the power cable 31, and the risk of any displacement of the fourth bonding agent 44 due to vibration of the power cable 31 may be reduced, in another aspect, the tensile strength of the power cable 31 may be increased, thereby improving the vibration resistance performance, and in yet another aspect, the sheath 34 may be tightened by attaching the hoop 400 to the sheath 34 of the power cable 31, thereby further improving the sealing. These may improve the reliability of the electrical connector 1. The hoop 400 may be utilized to fix the power cable 31 in the space 11 (in the second chamber portion 11b) before applying the fourth bonding agent 44.

[0159]

[0258] 10 and 11, the hoop 400 includes an annular body 401 that is attached to the sheath 34 of the power cable 31, and a tab 402 that extends outwardly from the annular body 401. As shown in FIGS. 6 and 7, the body 10 may include a receiving area 150 formed in the space 11, and the tab 402 of the hoop 400 is received in the receiving area 150 to secure the first cable 31 in the space 11. For example, the hoop 400 may be formed from a metallic material. It should be understood that the hoop 400 may be of any other suitable form.

[0160]

[0259] In other embodiments, a hoop may be provided for the signal cables 32, similar to the power cables 31.

[0161]

[0260] By having at least one of the above-mentioned configurations, the reliability of the electrical connector 1 can be improved.

[0162]

[0261] Although a particular configuration of the electrical connector 1 has been described above with respect to an example in which the electrical connector 1 is a connector for an Ethernet connection, it should be understood that the electrical connector 1 may be any suitable type of electrical connector and may be used in any other application.

[0163]

[0262] It should be understood that the above-described features may be used alone or in any suitable combination. The above summary is provided by way of example and is not intended to be limiting.

[0164]

[0263] As an example, while the rear cap 200 is described above as a member that is separate from and attached to the body 100, it should be understood that the rear cap 200 may be integrally formed with the body 100. For example, the rear cap 200 is one of the walls of the body 100. In this case, the rear cap 200 may still be formed to have the cavity 200a, first channel 210, second channel 220, and opening 200b described above, and protrusions and recesses similar to the protrusions 101c and recesses 101d may be formed on the inner walls of the cavity 200a of the rear cap 200 to provide the various advantages described above.

[0165]

[0264] As another example, the top cover 300 may be used separately to cooperate with the main body 100 to provide the various advantages described above. Therefore, the present application also provides an electrical connector, comprising: a housing, a main body, the main body including a plurality of walls surrounding a space, an opening in a first surface of the main body that communicates the space with the outside of the housing, and an edge portion defining the opening; and a top cover, the main body including a top surface, a bottom surface opposite the top surface, a side surface extending between the top surface and the bottom surface, and a flange extending outward beyond the side surface, the flange including the top surface and the bottom surface opposite the top surface, the top surface being lower than the top surface; a module at least partially disposed in the space; and a cable extending from the outside of the housing through a rear cap of the plurality of walls into the space and connected at its end to the module. The top cover is disposed in the opening of the main body to close the opening, the bottom surface and the bottom surface facing toward the space, and the edge portion of the main body forming a groove together with the side surface and the top surface of the top cover. The electrical connector further includes a first bonding agent filled in the groove to form a seal.

[0166]

[0265] As yet another example, the fourth bonding agent 44 and the hoop 400 may be used individually or in combination to cooperate with the cable 30 to provide the various advantages described above. The present application therefore also provides an electrical connector including a housing including a plurality of walls surrounding a space, a module at least partially disposed within the space, a cable extending from the exterior of the housing through a rear cap of the plurality of walls into the space and connected at its end to the module, the cable including a wire and a sheath surrounding the wire, a portion of the cable at the end of the cable being removed to allow the wire to extend beyond the end of the sheath, the end of the sheath being disposed within the space, and a bonding agent disposed around the end of the sheath within the space and forming a seal at the end of the sheath. The hoop may be configured in the manner described above.

[0167]

[0266] Although one cavity 200a is shown, it should be understood that there may be multiple cavities 200a to accommodate the power cables 31 and the signal cables 32, respectively.

[0168]

[0267] It should also be understood that the above directions and orientation relationships are exemplary and that the present application is not intended to be limited thereto.

[0169]

[0268] As an example, the portion of cable 30 disposed within cavity 200a has been described above as extending in a longitudinal direction XX, but it should be understood that the portion of cable 30 disposed within cavity 200a may extend in any other suitable direction. For example, the portion may be curved within cavity 200a.

[0170]

[0269] As another example, although the opening 200b of the rear cap 200 has been described above as extending through the face portion 203 of the rear cap 200 into the cavity 200a in a lateral direction YY perpendicular to the longitudinal direction XX, it should be understood that the opening 200b of the rear cap 200 may extend in any other direction perpendicular to the longitudinal direction XX, or in a direction that is not perpendicular to the longitudinal direction XX.

[0171]

[0270] As yet another example, although the rear portion 201 and the front portion 202 of the rear cap 200 have been described above as facing each other in the longitudinal direction XX, it should be understood that the rear portion 201 and the front portion 202 of the rear cap 200 may be disposed in any other suitable orientation relationship.

[0172]

[0271] Aspects of the present application relate to methods for making electrical connectors, such as electrical connector 1 described above.

[0173]

[0272] In one aspect, the present application provides a method for manufacturing an electrical connector, which may include providing a housing 10; disposing a module 20 (power module 21 and signal module 22) at least partially within a space 11; extending a cable 30 (power cable 31 and signal cable 32) from outside the housing 10 through a first channel 210, a cavity 200a, and a second channel 220 of a first wall (e.g., a rear cap 200) of the housing 10 into the space 11 and connecting the cable 30 at its end to the module 20; and filling a first adhesive 41 into the cavity 200a and disposing the first adhesive 41 around a portion of the cable 30 disposed within the cavity 200a to fix the cable 30 to the rear cap 200.

[0174]

[0273] In some embodiments, the first wall of the housing 10 is formed by a rear cap 200. In this case, the method may also include attaching the rear cap 200 to the rear end 101 of the body 100 to close the rear opening 107.

[0175]

[0274] In some embodiments, the method may further include inserting the portion 101a of the rear end 101 of the body 100 into a slot in the front portion 202 of the rear cap 200 and engaging the first bonding agent 41 with the portion 101a of the rear end 101 of the body 100. In some embodiments, engaging the first bonding agent 41 with the portion 101a of the rear end 101 includes disposing the first bonding agent 41 on the first surface 101b of the portion 101a of the rear end 101 of the body 100 and engaging the protrusion 101c. In other of these embodiments, engaging the first bonding agent 41 with the portion 101a of the rear end 101 includes disposing the first bonding agent 41 on the first surface 101b of the portion 101a of the rear end 101 of the body 100 and filling the first bonding agent 41 into the recess 101d.

[0176]

[0275] In some embodiments, filling the cavity 200a with the first adhesive 41 includes filling the cavity 200a with the first adhesive 41 through the opening 200b of the back cap 200. In other of these embodiments, the method may further include inserting the portion 101a of the rear end 101 of the body 100 into a slot in the front portion 202 of the back cap 200 such that a first surface 101b of the portion 101a is exposed in the cavity 200a on a side of the portion of the cable 30 facing away from the opening 200b, and disposing the first adhesive 41 on and engaging the first surface 101b.

[0177]

[0276] In some embodiments, inserting portion 101a of rear end 101 of body 100 into the slot includes inserting portion 101a of rear end 101 of body 100 into groove 204b of bottom portion 204 through the slot, wherein first surface 101b is flush with top surface 204a of bottom portion 204.

[0178]

[0277] In some embodiments, the method may further include disposing a top cover 300 in the top opening 108 of the main body 100 to close the top opening 108, with the bottom surface 302 and the bottom surface 304b of the top cover 300 facing toward the space 11 and the above-mentioned edge portion of the main body 100 forming a groove 60 together with the side surface 303 and the top surface 304a of the top cover 300, and filling the second adhesive 42 in the groove 60 to provide the above-mentioned seal.

[0179]

[0278] In some embodiments, disposing the top cover 300 in the top opening 108 of the body 100 includes disposing a bottom surface 304 b of a flange 304 of the top cover 300 over the flange 120 of the body 100 .

[0180]

[0279] In some embodiments, the method may further include filling a third bonding agent 43 into the first space 11a of the space 11 of the housing 10 to provide the above-mentioned seal.

[0181]

[0280] In some embodiments, the method may further include applying the second bonding agent 42 and the third bonding agent 43 together.

[0182]

[0281] In some embodiments, the method may further include removing a portion of the sheath 34 at the end 31a of the power cable 31 to allow the wire 33 to extend beyond the end 34a of the sheath 34, the end 34a of the sheath 34 being disposed within the space 11, and disposing a fourth bonding agent 44 around the end 34a of the sheath 34 within the space 11 to form the above-mentioned seal at the end 34a of the sheath 34. In some embodiments, the method may further include, prior to disposing the fourth bonding agent, placing a hoop 400 over the sheath 34 of the power cable 31 and securing the first cable 30 within the space 11 with the hoop 400. It should be understood that a similar method may be performed for the signal cable 32.

[0183]

[0282] It should be understood that the above methods may be used individually or in any suitable combination. The above summary is provided by way of example and is not intended to be limiting.

[0184]

[0283] As an example, the manufacturing methods for the top cover 300 may be used individually to provide the various advantages discussed above. Therefore, the present application also provides a method for making an electrical connector, the method including: providing a housing including a body including a plurality of walls surrounding a space, an opening in a first side of the body communicating the space with an exterior of the housing, and an edge portion defining the opening, and a top cover including a top surface, a bottom surface opposite the top surface, a side extending between the top surface and the bottom surface, and a flange extending outward beyond the side surface, the flange including the top surface, and the bottom surface opposite the top surface, the top surface being lower than the top surface; disposing a module at least partially within the space; extending a cable from the exterior of the housing through a first wall of the plurality of walls into the space and connecting the cable at an end thereof to the module; disposing the top cover within the opening of the body to close the opening, the bottom surface and the bottom surface facing toward the space, and the edge portion of the body forming a groove together with the side surface and the top surface of the top cover; and filling a first bonding agent within the groove to form a seal.

[0185]

[0284] As another example, the fabrication methods for the fourth bonding agent 44 and the hoop 400 may be used separately to provide the various advantages described above. Thus, the present application also provides a method for fabricating an electrical connector, comprising: providing a housing including a plurality of walls surrounding a space; disposing a module at least partially within the space; extending a cable from the exterior of the housing through a first wall of the plurality of walls into the space and connecting the cable at an end thereof to the module, the cable including a wire and a sheath surrounding the wire, a portion of the sheath at the end of the cable being removed such that the wire extends beyond the end of the sheath, and the end of the sheath being disposed within the space; and disposing a first bonding agent around the end of the sheath within the space to form a seal at the end of the sheath. The hoop may be constructed in the manner described above.

[0186]

[0285] Electrical connectors made according to any of the above described methods exhibit high reliability.

[0187]

[0286] It should be understood that steps in these methods are capable of being performed in any suitable order, and are not limited to the order as set forth above. EXAMPLES

[0188]

[0287] Working Example

[0288] In one embodiment, an electrical connector may include a housing including a plurality of walls surrounding a space, a first wall of the plurality of walls including a cavity formed therein, a first channel extending from the cavity through a rear portion of the first wall to an exterior of the housing, and a second channel extending from the cavity through a front portion of the first wall to the space; a module at least partially disposed within the space; a cable extending from the exterior of the housing through the first channel, the cavity, and the second channel of the first wall into the space, the cable connected at an end thereof to the module; and a first bonding agent filled within the cavity, the first bonding agent disposed around a portion of the cable positioned within the cavity to secure the cable to the first wall.

[0189]

[0289] Such electrical connectors may optionally include one or more of the following characteristics: ● The housing includes at least a body, a space disposed within the body, the body including a rear end and a rear opening connecting to the space at the rear end, and a rear cap attached to the rear end of the body to close the rear opening, wherein a first wall of the housing is formed by the rear cap. ● The front portion of the first wall includes a front surface facing towards the space and a slot extending from the front surface through the front portion into the cavity, with a rear end portion of the body being inserted into the slot and the first bonding agent engaging the rear end portion. ● A rear end portion of the body includes a first surface exposed within the cavity and a protrusion protruding from the first surface into the cavity, and a first adhesive is disposed on the first surface and engages with the protrusion. ● The protrusions are configured as barbs. ● A portion of the rear end of the body includes a first surface exposed within the cavity and a recess recessed from the first surface into the portion, and a first bonding agent is disposed on the first surface and filled into the recess. ● A portion of the cable disposed within the cavity extends in a first direction, and the first wall includes an opening extending from the exterior of the housing through a face portion of the first wall into the cavity in a second direction perpendicular to the first direction, allowing a first bonding agent to be filled into the cavity through the opening. • The rear and front portions of the first wall oppose each other and are spaced apart in a first direction by a cavity, and the face portion connects the rear and front portions. ● The front portion of the first wall includes a front surface facing towards the space and a slot extending from the front surface through the front portion into the cavity, a rear end portion of the body is inserted into the slot and includes a first surface exposed in the cavity on a side of the portion of the cable facing away from the opening, and a first bonding agent is disposed on and engages the first surface. ● The first wall further includes a bottom portion, the bottom portion and the face portion opposing each other and spaced apart in the second direction by a cavity, the bottom portion including an upper surface facing towards the dispensing chamber and a groove recessed from the upper surface into the bottom portion and connecting to the slot, a portion of the rear end of the body being inserted into the groove through the slot, and the first surface being flush with the upper surface. ● The rear end portion of the body further includes a protrusion protruding from the first surface into the cavity, and the first bonding agent is disposed on the first surface and engages with the protrusion, and / or the rear end portion of the body further includes a recess recessed from the first surface into the portion, and the first bonding agent is disposed on the first surface and filled into the recess. ● The first channel and the second channel are aligned with each other in a first direction, and a cross-section of the cavity perpendicular to the first direction is larger than a cross-section of the first channel perpendicular to the first direction and larger than a cross-section of the second channel perpendicular to the first direction. ● the body further includes a front end opposite the rear end, a first surface between the rear end and the front end, a top opening at the first surface connecting the space with the outside of the housing, and an edge portion defining the top opening, the housing further includes a top cover including a top surface, a bottom surface opposite the top surface, a side surface extending between the top surface and the bottom surface, and a flange extending outward beyond the side surface, the flange including a top surface and a bottom surface opposite the top surface, the top surface being lower than the top surface, the top cover is disposed within the top opening of the body to close the top opening, the bottom surface and the bottom surface face toward the space, the edge portion of the body forms a groove together with the side surface and top surface of the top cover, and the electrical connector further includes a second bonding agent filled in the groove to provide a seal. - The body further includes a flange that protrudes into the upper opening, and a bottom surface of the flange of the upper cover is supported on the flange. ● The body includes a bottom wall opposite the upper opening and a rib protruding from the bottom wall into the space, the rib dividing the space into a first space between the rear end and the rib and a second space between the rib and the front end, the module is disposed in the second space, the cable extends from the outside of the housing through the first wall and the first space into the second space, the top cover is disposed over the second space to separate the second space from the outside of the housing, the top cover engages with the rib and, together with the rib, separates the second space from the first space, and the electrical connector further comprises a third bonding agent filled in the first space to provide a seal. - The groove extends into and communicates with the first space, allowing the second bonding agent and the third bonding agent to be applied together. ● The top cover further includes a rear flange extending downwardly from the bottom surface or flange toward the rib, the rear flange engaging the rib, a passage being formed at the engaged portion of the rear flange and the rib, and the cable extending through the passage into the second space. ● The cable includes a first cable including a wire and a sheath surrounding the wire, a portion of the sheath at an end of the first cable is removed to allow the wire to extend beyond the end of the sheath, the end of the sheath is disposed in the space, and the electrical connector further includes a fourth bonding agent disposed in the space around the end of the sheath and forming a seal at the end of the sheath. The housing includes a chamber formed around the end of the sheath within the space, and the fourth bonding agent is filled within the chamber. The electrical connector further comprises a hoop mounted on the sheath of the first cable to secure the first cable within the space. ● The hoop includes an annular body mounted on the sheath and a tab protruding outwardly from the annular body, and the housing includes a receiving area formed within the accommodating cavity, the tab being received within the receiving area to secure the first cable within the accommodating cavity. The first cable is a power cable configured to transmit power.

[0190]

[0290] In another example, an electrical connector may include a housing including a body including a plurality of walls surrounding a space, an opening in a first side of the body communicating the space with an exterior of the housing, and an edge portion defining the opening, and a top cover including a top surface, a bottom surface opposite the top surface, a side extending between the top surface and the bottom surface, and a flange extending outward beyond the side surface, the flange including the top surface, and the bottom surface opposite the top surface, the top surface being lower than the top surface; a module disposed at least partially within the space; and a cable extending from the exterior of the housing through a first wall of the plurality of walls into the space and connecting at an end thereof to the module, the top cover disposed within the opening of the body to close the opening, the bottom surface and the bottom surface facing toward the space, and the edge portion of the body forming a groove with the side surface and the top surface of the top cover, and the electrical connector further includes a first bonding agent filled in the groove to form a seal.

[0191]

[0291] Such electrical connectors may optionally include one or more of the following characteristics: - The body further includes a flange that protrudes into the opening, and a bottom surface of the flange of the top cover is supported on the flange. ● the multiple walls further include a second wall opposite the first wall and a bottom wall extending between the first wall and the second wall, the bottom wall opposite the opening, the body further includes a rib extending from the bottom wall into the space, the rib dividing the space into a first space between the first wall and the rib and a second space between the rib and the second wall, the module is disposed in the second space, the cable extends from the exterior of the housing through the first wall and the first space into the second space, the top cover is disposed over the second space to separate the second space from the exterior of the housing, the top cover engages with the rib and, together with the rib, separates the second space from the first space, and the electrical connector further comprises a second bonding agent filled in the first space to provide a seal. - The groove extends into and communicates with the first space, allowing the first bonding agent and the second bonding agent to be applied together. ● The top cover further includes a rear flange extending downwardly from the bottom surface or flange toward the rib, the rear flange engaging the rib, a passage being formed at the engaged portion of the rear flange and the rib, and the cable extending through the passage into the second space. ● The cable includes a first cable including a wire and a sheath surrounding the wire, a portion of the sheath at an end of the first cable is removed to allow the wire to extend beyond the end of the sheath, the end of the sheath is disposed in the space, and the electrical connector further includes a third bonding agent disposed in the space around the end of the sheath and forming a seal at the end of the sheath. ● The electrical connector further comprises a hoop mounted on a sheath of the first cable to secure the first cable in space, and / or the first cable is a power cable configured to transmit electrical power. ● The first wall includes a cavity formed in the first wall, a first channel extending from the cavity through a rear portion of the first wall to an exterior of the housing, and a second channel extending from the cavity through a front portion of the first wall to the space, a cable extending from the exterior of the housing through the first channel, the cavity, and the second channel in the first wall into the space, and a fourth bonding agent is filled in the cavity and disposed around a portion of the cable positioned within the cavity to secure the cable to the first wall.

[0192]

[0292] In another example, an electrical connector may include a housing including a plurality of walls surrounding a space, a module at least partially disposed within the space, a cable extending from an exterior of the housing through a first of the plurality of walls into the space and connected at an end thereof to the module, the cable including a wire and a sheath surrounding the wire, a portion of the sheath at an end of the cable being removed to allow the wire to extend beyond an end of the sheath, the end of the sheath being disposed within the space, and a first bonding agent disposed in the space around the end of the sheath and forming a seal at the end of the sheath.

[0193]

[0293] Such electrical connectors may optionally include one or more of the following characteristics: ● The housing includes a chamber formed around the end of the sheath within the space, the first bonding agent being filled within the chamber, and / or the cable being a power cable configured to transmit power. - The electrical connector further comprises a hoop that is mounted on the sheath of the cable and secures the cable in space. ● The hoop includes an annular body that is mounted on the sheath and a tab that projects outwardly from the annular body, and the housing includes a receiving area formed within the accommodating cavity, the tab being received within the receiving area to secure the cable within the accommodating cavity. ● The cable includes a power cable configured to transmit power and a signal cable configured to transmit a signal, and the module includes a power module configured to transmit power and a signal module configured to transmit a signal, and the power cable is connected to the power module and the signal cable is connected to the signal module. - The signal cable is configured to carry Ethernet electrical signals, and / or the portions of the power cable and the signal cable that extend outside the housing are surrounded by the same jacket. ● The module includes a conductive terminal including a first end and a second end opposite the first end, the first end being configured to be connected to a cable and the second end being configured to be mounted to a circuit board, and / or the housing further includes an outwardly protruding mounting portion and a hole formed in the mounting portion.

[0194]

[0294] In another example, a method for making an electrical connector may include providing a housing including a plurality of walls surrounding a space, a first wall of the plurality of walls including a cavity formed therein, a first channel extending from the cavity through a rear portion of the first wall to an exterior of the housing, and a second channel extending from the cavity through a front portion of the first wall to the space; disposing a module at least partially within the space; extending a cable from the exterior of the housing through the first channel, the cavity, and the second channel of the first wall into the space and connecting the cable at an end thereof to the module; and filling a first bonding agent into the cavity and disposing the first bonding agent around a portion of the cable positioned within the cavity to secure the cable to the first wall.

[0195]

[0295] Such a method for fabricating an electrical connector may optionally include one or more of the following features of characteristics: ● The housing includes at least a body and a rear cap, the space is disposed within the body, the body includes a rear end and a rear opening connecting to the space at the rear end, the rear cap is configured to form a first wall of the housing, and the method further includes attaching the rear cap to the rear end of the body to close the rear opening. ● The front portion of the first wall includes a front surface facing toward the space and a slot extending from the front surface through the front portion into the cavity, the method further including inserting a rear end portion of the body into the slot and engaging a first adhesive with the rear end portion. ● The rear end portion of the body includes a first surface exposed within the cavity and a protrusion protruding from the first surface into the cavity, and engaging the first adhesive with the rear end portion includes disposing the first adhesive on the first surface and engaging the protrusion. ● The rear end portion of the body includes a first surface exposed within the cavity and a recess recessed from the first surface into the portion, and engaging the first adhesive with the rear end portion includes disposing the first adhesive on the first surface and filling the first adhesive into the recess. ● a portion of the cable disposed within the cavity extends in a first direction, the first wall includes an opening extending from an exterior of the housing through a face portion of the first wall into the cavity in a second direction perpendicular to the first direction, allowing a first bonding agent to be filled into the cavity through the opening, and filling the cavity with the first bonding agent includes filling the cavity with the first bonding agent through the opening. ● the rear and front portions of the first wall face each other and are spaced apart in a first direction by a cavity, the face portion connecting the rear and front portions, the front portion of the first wall including a front surface facing toward the space and a slot extending from the front surface through the front portion into the cavity, the method further including inserting a portion of the rear end of the body into the slot such that a first surface of the portion is exposed in the cavity on a side of the portion of the cable facing away from the opening, and disposing a first bonding agent on and engaging the first surface. ● the first wall further includes a bottom portion, the bottom portion and the face portion opposing each other and spaced apart in the second direction by a cavity, the bottom portion including an upper surface facing toward the dispensing chamber and a groove recessed from the upper surface into the bottom portion and connecting to the slot, and inserting a portion of the rear end of the body into the slot includes inserting a portion of the rear end of the body into the groove through the slot, and the first surface is flush with the upper surface. ● the rear end portion of the body further includes a protrusion protruding from the first surface into the cavity, and disposing the first adhesive on the first surface and engaging with the first surface includes disposing the first adhesive on the first surface and engaging with the protrusion, and / or the rear end portion of the body further includes a recess recessed from the first surface into the portion, and disposing the first adhesive on the first surface and engaging with the first surface includes disposing the first adhesive on the first surface and filling the first adhesive into the recess. ● the body further includes a front end opposite the rear end, a first surface between the rear end and the front end, a top opening at the first surface connecting the space with the outside of the housing, and an edge portion defining the top opening, the housing further includes a top cover including a top surface, a bottom surface opposite the top surface, a side surface extending between the top surface and the bottom surface, and a flange extending outward beyond the side surface, the flange including a top surface and a bottom surface opposite the top surface, the top surface being lower than the top surface, and the method further includes disposing the top cover within the top opening of the body to close the top opening, the bottom surface and the bottom surface facing toward the space and the edge portion of the body forming a groove with the side surface and top surface of the top cover, and filling a second bonding agent into the groove to provide a seal. - the body further includes a flange protruding into the upper opening, and disposing the upper cover in the upper opening includes disposing a bottom surface of the flange of the upper cover on the flange. ● the body includes a bottom wall opposite the upper opening and a rib protruding from the bottom wall into the space, the rib dividing the space into a first space between the rear end and the rib and a second space between the rib and the front end, the module is disposed in the second space, the cable extends from the exterior of the housing through the first wall and the first space into the second space, the upper cover is disposed over the second space to separate the second space from the exterior of the housing, the upper cover engages with the rib and, together with the rib, separates the second space from the first space, and the method further includes filling a third bonding agent into the first space to provide a seal. ● the groove extends into and communicates with the first space, allowing a second bonding agent and a third bonding agent to be applied together, the method further including applying the second bonding agent and the third bonding agent together. ● the cable includes a first cable including a wire and a sheath surrounding the wire, the method further including removing a portion of the sheath at an end of the first cable to allow the wire to extend beyond an end of the sheath, the end of the sheath being disposed in the space, and disposing a fourth bonding agent in the space around the end of the sheath to form a seal at the end of the sheath. ● The method further includes, prior to disposing the fourth bonding agent, mounting a hoop on a sheath of the first cable and fixing the first cable in the space by the hoop, and / or the first cable is a power cable configured to transmit power.

[0196]

[0296] In another example, a method for making an electrical connector may include providing a housing including a body including a plurality of walls surrounding a space, an opening in a first side of the body communicating the space with an exterior of the housing, and an edge portion defining the opening, and a top cover including a top surface, a bottom surface opposite the top surface, a side extending between the top surface and the bottom surface, and a flange extending outward beyond the side surface, the flange including the top surface, and the bottom surface opposite the top surface, the top surface being lower than the top surface; disposing a module at least partially within the space; extending a cable from the exterior of the housing through a first wall of the plurality of walls into the space and connecting the cable at an end thereof to the module; disposing the top cover within the opening of the body to close the opening, the bottom surface and the bottom surface facing toward the space and the edge portion of the body forming a groove with the side surface and the top surface of the top cover; and filling a first bonding agent into the groove to form a seal.

[0197]

[0297] Such a method for fabricating an electrical connector may optionally include one or more of the following features of characteristics: - the body further includes a flange protruding into the upper opening, and disposing the upper cover in the upper opening includes disposing a bottom surface of the flange of the upper cover on the flange. ● the multiple walls further include a second wall opposite the first wall and a bottom wall extending between the first wall and the second wall, the bottom wall opposite the opening, the body further includes a rib extending from the bottom wall into the space, the rib dividing the space into a first space between the first wall and the rib and a second space between the rib and the second wall, the module is disposed in the second space, the cable extends from outside the housing through the first wall and the first space into the second space, the top cover is disposed over the second space to separate the second space from the outside of the housing, the top cover engages with the rib and, together with the rib, separates the second space from the first space, and the method further includes filling a second bonding agent into the first space to provide a seal. ● The groove extends into and communicates with the first space, allowing the first bonding agent and the second bonding agent to be applied together, and the method further includes applying the first bonding agent and the second bonding agent together. ● the cable includes a first cable including a wire and a sheath surrounding the wire, the method further including removing a portion of the sheath at an end of the first cable to allow the wire to extend beyond an end of the sheath, the end of the sheath being disposed in the space, and disposing a third bonding agent in the space around the end of the sheath to form a seal at the end of the sheath. ● The method further includes, prior to applying the third bonding agent, mounting a hoop on a sheath of the first cable and fixing the first cable in the space by the hoop, and / or the first cable is a power cable configured to transmit power. ● the first wall includes a cavity formed in the first wall, a first channel extending from the cavity through a rear portion of the first wall to an exterior of the housing, and a second channel extending from the cavity through a front portion of the first wall to the space, and extending the cable from outside the housing through the first wall and into the space includes extending the cable from outside the housing through the first channel, the cavity, and the second channel in the first wall and into the space, and the method further includes filling a fourth bonding agent into the cavity and disposing the fourth bonding agent around a portion of the cable positioned in the cavity to secure the cable to the first wall.

[0198]

[0298] In another embodiment, a method for making an electrical connector may include providing a housing including a plurality of walls surrounding a space; disposing a module at least partially within the space; extending a cable from an exterior of the housing through a first wall of the plurality of walls into the space and connecting the cable at an end thereof to the module, the cable including a wire and a sheath surrounding the wire, a portion of the sheath at the end of the cable being removed to allow the wire to extend beyond an end of the sheath, the end of the sheath being disposed within the space; and disposing a first bonding agent in the space around the end of the sheath to form a seal at the end of the sheath.

[0199]

[0299] Such a method for fabricating an electrical connector may optionally include one or more of the following features of characteristics: - Before the first bonding agent is applied, a hoop is placed over the sheath of the cable, and the cable is fixed in place within the space by the hoop. - The cable is a power cable configured to transmit electrical power.

[0200]

[0300] In another embodiment, an electrical connector may include a housing at least partially enclosing a space, the housing including an opening at an upper portion connected to the space, and a cap (e.g., 200) disposed at a rear portion of the housing, the cap including a cavity having first and second channels connected to the space; a first cable (e.g., 31) extending through the first channel of the cap into the space of the housing; a second cable extending through the second channel of the cap into the space of the housing; and a sealing material disposed within the cavity of the cap, whereby portions of the first and second cables extending through the first and second channels are fixedly disposed within the sealing material.

[0201]

[0301] Such electrical connectors may optionally include one or more of the following characteristics: ● The electrical connector may include a first module (e.g., 21) disposed within the space and including a first end connected to a first cable and a second end extending from the bottom of the housing to the outside of the housing and configured for attachment to a circuit board, and a second module (e.g., 22) disposed within the space and including a first end connected to a second cable and a second end extending from the bottom of the housing to the outside of the housing and configured for attachment to a circuit board. ● The first module is a power module configured to supply power and the second module is a signal module configured to transmit an Ethernet signal. - The cap includes a groove and a base having a protrusion that projects into the cavity and engages the sealing material. ● The electrical connector may include a cover (e.g., 300) disposed on the top of the housing and substantially covering an opening in the top of the housing, and the sealing material includes a first portion disposed around the cover to fill a groove between the cover and the housing. ● The cover is separated from the cap by a first portion of the housing space, and the sealing material includes a second portion disposed within the first portion of the housing space, and the portions of the first and second cables extending into the first portion of the space pass through and are retained by the second portion of the sealing material. ● The housing includes a rib, a first portion of the housing's space is between a rear of the housing and the rib, and the housing's space includes a second portion between the rib and a front of the housing, and the electrical connector includes one or more modules disposed in the second portion of the space, each of the one or more modules being a terminal subassembly. ● The first cable includes a sheath and a plurality of wires within the sheath, each of the plurality of wires including an end extending outside the sheath, the first module is connected to the first cable at the end extending outside the sheath, the housing includes a chamber (e.g., 140) through which the ends of the plurality of wires extend to the first module, and the sealing material includes a third portion disposed within the chamber of the housing, whereby the ends of the plurality of wires of the first cable are fixedly disposed within the third portion. - The encapsulation material includes a curable adhesive. - The electrical connector may include a hoop disposed adjacent the chamber of the housing and attached to the sheath of the first cable.

[0202]

[0302] In another embodiment, an electrical connector may include a housing including an opening at the rear and a number of mounting portions extending outward from the front and / or sides, a first module (e.g., 21) disposed within the housing, the first module including a number of first ends extending toward the rear of the housing and a number of second ends extending outward from a bottom of the housing, and a second module (e.g., 22) disposed within the housing, the second module including a number of first ends extending toward the rear of the housing and a number of second ends extending outward from the bottom of the housing.

[0203]

[0303] Such electrical connectors may optionally include one or more of the following characteristics: - Each of the plurality of mounting portions of the housing includes an aperture extending therethrough. - The plurality of mounting portions on the housing include a first pair of mounting portions extending outwardly from a front of the housing, and a second pair of mounting portions extending outwardly from opposing sides of the housing, respectively. ● The electrical connector may include a first cable (e.g., 31) attached to the multiple first ends of the first module and extending from the rear of the housing to the outside of the housing, and a second cable (e.g., 32) attached to the multiple first ends of the second module and extending from the rear of the housing to the outside of the housing, the second cable including a pair of signal wires. ● The rear of the housing includes a cap (e.g., 200) having a cavity through which the first and second cables extend, and the electrical connector includes a sealing member (e.g., 41) disposed within the cavity of the cap and surrounding the portions of the first and second cables extending therein. - The electrical connector may include a cover (eg, 300) disposed on top of the housing, and a second sealing member (eg, 42) disposed between the housing and the cover. ● The first cable includes two or more wires, a hoop disposed around the sheath of the first cable, and a third sealing member (e.g., 43) disposed between the first module and the hoop.

[0204]

[0304] In another embodiment, a method for fabricating an electrical connector may include providing a subassembly including a first module (e.g., 21) and a second module (e.g., 22), a rear cap of a housing (e.g., 200), and first and second cables (e.g., 31, 32) extending through the rear cap of the housing and into the housing, where the rear cap of the housing includes a cavity; providing adhesive within the cavity of the rear cap and around portions of the first and second cables extending through the cavity of the rear cap of the housing to form a seal between the housing and the first and second cables; positioning the first and second modules within the housing; and attaching the rear cap to the housing.

[0205]

[0305] Such a method for fabricating an electrical connector may optionally include one or more of the following features of characteristics: - The method may include providing an adhesive within an interior chamber (e.g., 140) of the housing and around portions of the wires of the first cable to form a seal between the housing and the first cable. ● The method may include disposing a cover (e.g., 300) on top of the housing and providing adhesive around the cover and in the gap between the cover and the housing to form a seal between the housing and the cover.

[0206]

[0306] Having thus described several aspects of several embodiments, it should be understood that various modifications, changes, and improvements will readily occur to those skilled in the art. Such modifications, changes, and improvements are intended to be part of this disclosure and are intended to be within the spirit and scope of the present invention. While the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those skilled in the art.

[0207]

[0307] By way of example, while many of the inventive aspects have been described above with reference to right-angle connectors, it should be understood that the aspects of the present disclosure are not so limited. Any of the inventive features, whether alone or in combination with one or more other inventive features, may also be used for other types of electrical connectors, such as vertical connectors, etc.

[0208]

[0308] Moreover, although several advantages of the present invention may be indicated, it should be understood that not all embodiments of the present invention will include all of the advantages described above. Some embodiments may not embody any of the features described as advantageous. Accordingly, the foregoing description and drawings are by way of example only.

[0209]

[0309] Also, the techniques described above may be embodied as a method, of which at least one example has been provided. The acts performed as part of the method may be ordered in any suitable manner. Thus, embodiments may be constructed in which the acts are performed in an order different from that illustrated. This may include performing some acts simultaneously, even if shown as sequential acts in the illustrated embodiment.

[0210]

[0310] All definitions, as defined and used, should be understood to take precedence over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0211]

[0311] In describing the present disclosure, it should be understood that the directions or orientations indicated by the directional terms "front," "rear," "upper," "lower," "left," "right," "transverse direction," "vertical direction," "perpendicular," "horizontal," "top," "bottom," and the like, are shown with reference to the accompanying drawings for purposes of facilitating and simplifying the description of the present disclosure. Unless otherwise stated, these directional terms do not indicate or imply that a specified device or element must be particularly disposed, structured, or operated in a particular orientation, and therefore should not be understood as a limitation of the present disclosure. The directional terms "inside" and "outside" refer to the interior and exterior relative to the exterior shape of each component itself.

[0212]

[0312] For ease of explanation, spatially relative terms such as "on," "above," "on an upper surface of," and "upper" may be used herein to describe the spatial relationship between one or more components or features and other components or features depicted in the accompanying drawings. It should be understood that spatially relative terms include not only the orientation of the components depicted in the accompanying drawings, but also different orientations during use or operation. For example, if the components in the accompanying drawings are completely upside down, a component "above other components or features" or "on top of other components or features" would include the case where the component is "below other components or features" or "under other components or features." Thus, the exemplary term "upper" can encompass both an orientation of "above" and "below." Additionally, these components or features may be oriented in other ways (e.g., rotated by 90 degrees or other angles), and the present disclosure is intended to include all these cases.

[0213]

[0313] It should be noted that the terms used herein are for the purpose of describing particular embodiments and are not intended to limit the exemplary embodiments of the present application. As used herein, the singular term includes the plural term unless otherwise specified. In addition, when the terms "including" and / or "comprising" are used herein, they are also understood to indicate the presence of features, steps, operations, parts, components, and / or combinations thereof.

[0214]

[0314] Numerical values ​​and ranges may be described herein and in the claims as approximate or exact values ​​or ranges. For example, in some cases, the terms "about," "approximately," and "substantially" may be used in reference to values. Such references are intended to encompass the referenced value, as well as reasonable variations in that value, plus and minus. For example, the expression "about 10 to about 20" is intended to mean, in some embodiments, "exactly 10 to exactly 20," and in some embodiments, "10±d1 to 20±d2." The amount of variation d1, d2 about the value may be less than 5% of the value in some embodiments, less than 10% of the value in some embodiments, and even less than 20% of the value in some embodiments. In embodiments where a large range of values ​​is given, e.g., a range including more than one order of magnitude, the amount of variation d1, d2 about the value could be as high as 50%. For example, if the operable range spans 2 to 200, then "about 80" could encompass values ​​from 40 to 120, and the range could be as large as 1 to 300. When only the exact value is intended, the term "exactly" is used, e.g., "exactly 2 to exactly 200." The term "essentially" is used to indicate that a value is the same as a target value or condition, or is within ±3% of the target value or condition.

[0215]

[0315] No The definite articles "a" and "an," as used in the specification and claims, unless clearly indicated to the contrary, should be understood to mean "at least one."

[0216]

[0316] The phrase "and / or," as used herein and in the claims, should be understood to mean "either or both" of the elements so conjoined, e.g., elements that are conjunctive in some cases and disjunctive in other cases. Multiple elements listed with "and / or" should be construed in the same manner, e.g., "one or more" of the elements so conjoined. Other elements other than the elements specifically identified by the "and / or" clause may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," may refer in one embodiment to only A (optionally including elements other than B), in another embodiment to only B (optionally including elements other than A), in yet another embodiment to both A and B (optionally including other elements), etc.

[0217]

[0317] As used in this specification and the 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" shall be construed to be inclusive, e.g., including not only the inclusion of at least one, but also two or more of a number of elements or list of elements, and optionally, additional unlisted items. Only terms with clear indications to the contrary, such as "only one of" or "exactly one of," or, when used in the claims, "consisting of," will refer to the inclusion of exactly one element of a number of elements or list of elements. In general, the term "or," as used herein, shall be construed to indicate exclusive alternatives (i.e., "one or the other but not both") only when preceded by terms of exclusivity, such as "either," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0218]

[0318] As used in this specification and claims, the phrase "at least one" referring to a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed in the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows that elements other than those specifically identified in the list of elements to which the phrase "at least one" refers may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B" or, equivalently, "at least one of A and / or B") can refer to, in one embodiment, at least one A, optionally including more than one, where B is not present (and optionally including elements other than B); in another embodiment, at least one B, optionally including more than one, where A is not present (and optionally including elements other than A); in yet another embodiment, at least one A, and optionally including more than one, at least one B (and optionally including other elements), etc.

[0219]

[0319] In the claims and in the above specification, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "composed of," and the like, are to be understood to be open-ended, e.g., to mean including but not limited to. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to those steps or units expressly recited, but instead, it may include other steps or units that are not expressly recited or that are inherent to those processes, methods, products, or devices. Only the transitional phrases "consisting of" and "consisting essentially of," respectively, are intended to be closed or semi-closed transitional phrases.

[0220]

[0320] The claims should not be construed as limited to the order or elements described above unless expressly stated to that effect. It is understood that various changes in form and detail may be made by those skilled in the art without departing from the spirit and scope of the appended claims. All embodiments that come within the spirit and scope of the appended claims and their equivalents are claimed.

[0221]

[0321] The use of ordinal terminology in the claims and in the specification above, such as "first," "second," "third," etc., does not, in itself, imply any priority, ranking, or order of an element relative to another, or the temporal order in which acts of a method are performed, but is merely used as a label to distinguish one element having a particular name from other elements having the same name (in the absence of the use of the ordinal terminology) and to distinguish the elements.

Claims

1. 1. An electrical connector comprising: a housing at least partially enclosing a space, the housing including an opening at an upper portion connected to the space, and a cap disposed at a rear portion of the housing, the cap including a cavity having first and second channels connected to the space; a first cable extending through the first channel of the cap and into the space of the housing; a second cable extending through the second channel of the cap and into the space of the housing; a sealing material disposed within the cavity of the cap, whereby portions of the first and second cables extending through the first and second channels are fixedly disposed within the sealing material; An electrical connector comprising:

2. a first module disposed within the space and including a first end connected to the first cable and a second end extending from a bottom of the housing out of the housing and configured to be mounted to a circuit board; a second module disposed within the space and including a first end connected to the second cable and a second end extending from the bottom of the housing out of the housing and configured to mount to a circuit board; The electrical connector of claim 1 , comprising:

3. the first module being a power module configured to supply power; 3. The electrical connector of claim 2, wherein the second module is a signal module configured to transmit an Ethernet signal.

4. 2. The electrical connector of claim 1, wherein the cap includes a bottom having a groove and a protrusion that projects into the cavity and engages the sealing material.

5. a cover disposed on the top of the housing and substantially covering the opening in the top of the housing; 2. The electrical connector of claim 1, wherein the sealing material includes a first portion disposed about the cover to fill a groove between the cover and the housing.

6. the cover is separated from the cap by a first portion of the space in the housing; the sealing material includes a second portion disposed within the first portion of the space of the housing; 6. The electrical connector of claim 5, wherein portions of the first and second cables extending into the first portion of the space pass through and are retained by the second portion of the sealing material.

7. the housing includes ribs; the first portion of the space in the housing is between the rear portion of the housing and the rib; the space in the housing includes a second portion between the rib and a front portion of the housing; the electrical connector includes one or more modules disposed within the second portion of the space; The electrical connector of claim 6 , wherein each of the one or more modules is a terminal subassembly.

8. the first cable includes a sheath and a plurality of wires within the sheath, each of the plurality of wires including an end portion extending outside the sheath; the first module is connected to the first cable at the end extending outside the sheath; the housing includes a chamber through which the ends of the plurality of wires extend to the first module; 3. The electrical connector of claim 2, wherein the sealing material includes a third portion disposed within the chamber of the housing, whereby the ends of the plurality of wires of the first cable are fixedly disposed within the third portion.

9. The electrical connector of claim 8 , wherein the sealing material comprises a curable adhesive.

10. 9. The electrical connector of claim 8, further comprising a hoop disposed adjacent the chamber of the housing and attached to the sheath of the first cable.

11. 1. An electrical connector comprising: a housing including an opening at a rear portion and a plurality of mounting portions extending outwardly from a front and / or sides; a first module disposed within the housing, the first module including a plurality of first ends extending toward the rear of the housing and a plurality of second ends extending outwardly from a bottom of the housing; a second module disposed within the housing, the second module including a plurality of first ends extending toward the rear of the housing and a plurality of second ends extending outwardly from the bottom of the housing; and An electrical connector comprising:

12. The electrical connector of claim 11 , wherein each of the plurality of mounting portions of the housing includes an aperture extending therethrough.

13. 12. The electrical connector of claim 11, wherein the plurality of mounting portions of the housing include a first pair of mounting portions extending outwardly from the front of the housing and a second pair of mounting portions extending outwardly from opposing sides of the housing, respectively.

14. a first cable attached to the first ends of the first module and extending from the rear of the housing out of the housing; a second cable attached to the plurality of first ends of the second module and extending from the rear of the housing out of the housing, the second cable including a pair of signal wires; The electrical connector of claim 11 comprising:

15. the rear portion of the housing includes a cap having a cavity through which the first and second cables extend; The electrical connector of claim 14 , wherein the electrical connector includes a sealing member disposed within the cavity of the cap and surrounding portions of the first and second cables extending therethrough.

16. A cover disposed on an upper portion of the housing; a second sealing member disposed between the housing and the cover; 16. The electrical connector of claim 15 comprising:

17. The first cable comprises two or more wires; a hoop disposed around the sheath of the first cable; and 17. The electrical connector of claim 16, including a third sealing member disposed between the first module and the hoop.

18. 1. A method of making an electrical connector, comprising: providing a subassembly including a first module and a second module, a rear cap of a housing, and first and second cables extending through the rear cap of the housing and into the housing, the rear cap of the housing including a cavity; providing an adhesive within the cavity of the rear cap and around portions of the first and second cables extending through the cavity of the rear cap of the housing to form a seal between the housing and the first and second cables; Positioning the first module and the second module within the housing; attaching the rear cap to the housing; A method comprising:

19. 20. The method of claim 18, comprising providing an adhesive within an interior chamber of the housing and around a portion of a wire of the first cable to form a seal between the housing and the first cable.

20. disposing a cover on an upper portion of the housing; providing an adhesive around the cover and in a gap between the cover and the housing to form a seal between the housing and the cover; 20. The method of claim 19, comprising:

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