Single Pair Ethernet Connection System

Abstract

The single pair Ethernet connector (101) may include a female connector portion and a male connector portion. The female connector portion may include a first electrical contact having a first contact tine and a first receiving portion, and a second electrical contact having a second contact tine and a second receiving portion. The male connector portion may include a third electrical contact comprising a first insulation displacement contact (IDC) portion (733) and a third contact tine, a fourth electrical contact comprising a second IDC portion (733) and a fourth contact tine, and a second inner housing (226) having a first wire retention groove (611), a second wire retention groove (811), and an opening structured to allow the SPE cable (104) to extend therethrough.

Description

[Technical field]

[0001] This application relates generally to the field of electrical connectors, and more specifically to single pair Ethernet (SPE) connection systems. [Background technology]

[0002] The following explanation is provided to aid the reader's understanding. None of the information provided or references cited are admitted to be prior art.

[0003] Various types of connectors are used to form connections between wires and any manner of electronic or electrical components. For example, an electrical connection may be formed between a printed circuit board (PCB) of a controller and a sensor assembly. Traditionally, the electrical connection between the wire and the (PCB) is formed by soldering the core of the wire to an electrical pad or core of the PCB. The wire may be similarly soldered to an electrical pad of the sensor assembly to form an electrical connection between the sensor assembly and the controller. This process can be tedious, inefficient, undesirable, and can result in a high scrap rate that can be expensive. Furthermore, once the solder is made, the connection cannot be repaired and replacement requires a new part. This is undesirable in applications where the parts are not easily reachable (e.g., connection to a PCB in a vehicle). Therefore, a fast, efficient, and reliable device that can be used to connect two or more devices together for communication and / or power sharing between them is desirable. Summary of the Invention

[0004] The systems, methods, and devices of the present disclosure each have several innovative aspects, no single one of which is solely responsible for the desirable attributes disclosed herein.

[0005] A single pair Ethernet (SPE) connector is disclosed. In one implementation, the SPE connector includes a female connector portion and a male connector portion. The female connector portion can include a first electrical contact having a first contact tine and a first receiving portion, and a second electrical contact having a second contact tine and a second receiving portion. The male connector portion includes a third electrical contact comprising a first insulation displacement contact (IDC) portion and a third contact tine, a fourth electrical contact comprising a second IDC portion and a fourth male portion, and a second inner housing having a first wire retention groove, a second wire retention groove, and an opening structured to allow an SPE cable to extend therethrough.

[0006] In another implementation, the SPE connector includes a female connector portion and a male connector portion that are structured to be selectively matable. The female connector portion includes a first contact having a first contact tine, a second contact having a second contact tine, and a first insulating housing having a first contact retention recess and a second contact retention recess. In one embodiment, the first contact is at least partially disposed within the first contact retention recess and the second contact is at least partially positioned within the second contact retention recess. In some embodiments, the first contact tine and the second contact tine extend from the first insulating housing and are configured to electrically and mechanically connect to respective openings in the electrical component. The male connector portion includes a second inner housing having a first insulation displacement contact (IDC), a second IDC contact, a first slot intersecting the first wire retention groove and structured to receive a blade from the first IDC contact, and a second slot intersecting the second wire retention groove structured to receive a blade from the second IDC contact.

[0007] Another implementation relates to an assembly method, which may include extending an SPE cable through a second inner housing, positioning a first wire of the SPE cable in a first wire retaining groove of the second inner housing and positioning a second wire of the SPE cable in a second wire retaining groove of the second inner housing, pressing the first housing against the second inner housing such that a first electrical connection is made between the first wire and the first IDC contact and a second electrical connection is made between the second wire and the second IDC, mating an outer housing and a pressure nut together over the first housing and the second inner housing such that the first housing and the second inner housing are mechanically secured within the outer housing and pressure nut, and mating the outer housing to the female connector such that the first IDC contact is mechanically and electrically connected to the first female contact and the second IDC contact is mechanically and electrically connected to the second female contact.

[0008] The electrical connector is not limited by the number of its wire openings or other components.Specific embodiments of the electrical connector are described in more detail below with reference to examples illustrated in the various drawing figures. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 illustrates an isometric view of a single pair Ethernet (SPE) connector according to an exemplary embodiment. [Diagram 2] 1 is a cross-sectional view of an SPE connector according to an exemplary embodiment. [Figure 3A] 1 is an isometric view of a female contact of a female connector of an SPE connector according to an exemplary embodiment. [Figure 3B] 2 is an exploded view of a female connector of an SPE connector according to an exemplary embodiment. [Figure 4A] FIG. 2 is an isometric view of a contact of a female connector according to an exemplary embodiment. [Figure 4B] FIG. 2 is a cross-sectional view of a female connector according to an exemplary embodiment. [Diagram 5]1 is an exploded view of a male connector of an SPE connector according to an exemplary embodiment. [Figure 6] FIG. 2 is an assembly view of a male connector with corresponding wires according to an exemplary embodiment. [Figure 7] 1A-1C show various views of a male connector and contacts of the male connector according to an exemplary embodiment. [Figure 8A] FIG. 2 is an isometric view of a portion of a male connector according to an exemplary embodiment. [Figure 8B] FIG. 13 is a top-down view of a portion of a male connector according to an exemplary embodiment. [Figure 9A] FIG. 2 is an assembly view of a male connector according to an exemplary embodiment. [Figure 9B] FIG. 2 is an assembly view of a male connector according to an exemplary embodiment. [Figure 10] 1 is a flow diagram of a method of use (assembly) of an SPE connector, according to an exemplary embodiment. [Figure 11A] 1 is an exploded view of a second example of a female connector of an SPE connector, according to an exemplary embodiment. FIG. [Figure 11B] 1A-1C are end views of a female connector of an SPE connector, according to various exemplary embodiments. [Figure 11C] 1A-1C are end views of a female connector of an SPE connector, according to various exemplary embodiments. [Figure 11D] 1 is a perspective view of an inner shell within a female connector of an SPE connector according to an exemplary embodiment. [Figure 12A] FIG. 13 is an assembly view of a second example of a male connector according to an exemplary embodiment. [Figure 12B] FIG. 13 is an assembly view of a second example of a male connector according to an exemplary embodiment. [Figure 12C] 1A-1C are end views of a male connector of an SPE connector, according to various exemplary embodiments. [Figure 12D] 1A-1C are end views of a male connector of an SPE connector, according to various exemplary embodiments. [Figure 12E]1 is a perspective view of an inner shell within a male connector of an SPE connector according to an exemplary embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Reference will now be made to various embodiments, one or more examples of which are illustrated in the drawings. These embodiments are provided as an illustration of the invention and are not meant to be limitations of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a further embodiment. This application is intended to cover these and other modifications and variations that are within the scope and spirit of the invention.

[0011] Disclosed herein is a Single Pair Ethernet (SPE) connector. In various embodiments, the SPE connector is circular in that the various components have a circular outer housing. The circular connector allows for a secure mechanical connection to be formed via threading, as described herein. The SPE connector can be used with a variety of corresponding connectors and electrical components. For example, the SPE connector can be used with corresponding electrical components, such as a printed circuit board (PCB) and / or an electrical plug. In one embodiment, the SPE connector includes a male connector portion and a female connector portion. The female connector is configured to connect to an electrical plug via an electrical connection between contact tines of the respective electrical contacts, and the male connector is configured to connect to two wires of an SPE cable via insulation displacement ends of the respective electrical contacts. In various embodiments, the SPE cable can include any type of wire or cable having, for example, two conductive elements. The female connector and the male connector are configured to mate together such that a first electrical connection is formed between a first contact of the electrical component and a first wire of the SPE cable, and a second electrical connection is formed between a second contact of the electrical component and a second wire of the SPE cable.

[0012] The unique design of the male and female connectors enhances the versatility of the SPE connector. For example, the male connector allows the SPE cable to be easily disconnected and reconnected to and from the female end, and the IDC contact portion of the male connector allows the user to efficiently and reliably connect between the male connector and the wires of the SPE (or other) cable. Furthermore, the unique design of the female connector allows for a quick and reliable connection to the male connector via allowing the outer housing to rotate freely around the inner housing. This versatility therefore allows for a wide range of possible connection, reconnection, replacement, and / or addition options between devices. For example, traditionally, the user must manually handle each wire and solder the wire to the contact pads of a PCB, the PCB must be pre-manufactured to accept a particular plug or socket, and / or the SPE cable must be stripped, connected to a corresponding plug or socket, and secured. However, the design of this SPE connector allows for efficient and reliable connection and / or disconnection of SPE cables to electrical components such as PCBs, which allows for versatility in multifaceted applications such as industrial applications where updates, modifications, and inclusion of devices within a system are constantly changing. In addition, the design of the SPE ensures a reliable electrical connection between the PCB (or other electrical component) and the wires (e.g., via protrusions on the inner housing that provide additional mechanical support) that is resistant to thermal changes and / or vibrations that can crack, rust, and / or break soldered electrical connections. Such a design is advantageous in certain applications such as, for example, vehicles where temperature fluctuations and mechanical vibrations are present.

[0013] Additionally, particularly for communications connections such as Ethernet, the SPE connector allows a single conductive wire pair to transmit data while simultaneously delivering power between devices. The shielding components of the SPE connector (e.g., the outer female and male housings) ensure the integrity of the data communications by reducing potential electromagnetic interference.

[0014] Various embodiments of SPE connectors and various corresponding electrical components are illustrated throughout Figures 1-10. The SPE connectors disclosed in these figures are configured to support electrical and mechanical connection of multiple wires to corresponding electrical components. In one embodiment, the SPE connector may have additional electrical contacts. It should be understood that the SPE connectors disclosed herein are not limited by a maximum number of wire positions, corresponding electrical contacts, press-fit pins, or the type of connection that couples the components together.

[0015] 1 is an isometric view 100 of a single-pair Ethernet (SPE) connector 101 connected to an SPE cable 104, according to an exemplary embodiment. The SPE connector 101 includes a female connector 102 and a male connector 103 that mate together. In particular, the SPE cable 104 is mechanically connected to the male connector 103, which is mechanically connected to the female connector 102.

[0016] In some embodiments, the male connector 103 and the female connector 102 may be mechanically secured together via a latching mechanism. In various embodiments, the latching mechanism may include a lock-and-pin configuration, a threaded configuration, and / or other types of mechanical connections. The male connector 103 is connected to the SPE cable 104 by a mechanical force. In various embodiments, the mechanical force may include a friction fit, a compression force, or a combination thereof. The latching mechanism and the mechanical force ensure that the electrical connection formed by the SPE connector 101 remains secure once assembled.

[0017] The female connector 102 is further structured to mechanically and electrically connect to a corresponding electronic device. In various embodiments, the corresponding electronic device may include a printed circuit board (PCB), a corresponding connector, or any other type of electronic device that may implement single pair Ethernet. In one example, the female connector 102 includes two contacts each protruding from a bottom edge of the female connector 102. Additionally, the female connector 102 may include one or more protrusions extending from the bottom edge of the female connector 102 parallel to the two contacts. In this example, the two contacts may be inserted into respective conductive through-holes on the PCB. In various embodiments, the two contacts may include press-fit pins or may otherwise be structured to be mechanically and electrically connected to the respective conductive through-holes via, for example, soldering. The one or more protrusions may be inserted into respective openings on the PCB to provide mechanical support to the SPE connector 101. In some embodiments, the one or more protrusions may be structured to mechanically secure the SPE connector 101 to the respective electronic device via, for example, a mechanical latching mechanism. In this manner, the reliability of the electrical connection made through the SPE connector 101 is ensured due to the rigid structure of the male connector 103 and the female connector 102 .

[0018] 2 is a cross-sectional view 200 of an SPE connector 101 according to an exemplary embodiment. The SPE connector 101 includes a male connector 103 and a female connector 102. The cross-sectional view 200 of the SPE connector 101 illustrates an electrical connection between a conductive element of a first wire 131 of the SPE cable 104 and a first female contact 211 of the female connector 102 via an electrical connection formed by a first male contact 224 of the male connector 103. Additionally, the cross-sectional view 200 of the SPE connector 101 illustrates an electrical connection between a conductive element of a second wire 132 of the SPE cable 104 and a second female contact 212 of the female connector 102 via an electrical connection formed by a second male contact 223 of the male connector 103.

[0019] The female connector 102 includes an inner female housing 210 (e.g., a first insulating housing) having a first contact retention recess structured to accommodate a first female contact 211 and a second contact retention recess structured to accommodate a second female contact 212. The first and second contact retention recesses provide support for the respective first and second female contacts 211 and 212 and also electrically insulate the first and second female contacts 211 and 212 from one another. In some embodiments, the first and second contact retention recesses extend completely through the inner female housing 210 such that a portion of each of the first and second female contacts 211 and 212 extends from the inner female housing 210 on a first side and provides openings for the respective male contacts 224 and 223 to mate with the first and second female contacts 211 and 212 on a second side. The inner female housing 210 may be formed from a single element or composition of elements that is electrically insulating. Further features of the inner female housing 210 in various embodiments are described in further detail below.

[0020] The female connector 102 also includes an outer female housing 214 (e.g., an outer shield), a first female gasket 213, and a second female gasket 215. The outer female housing 214 is structured to receive at least a portion of the inner female housing 210 therein. The outer female housing 214 may be formed of a material such as a polymer, metal, or a combination thereof that provides rigid structural support. The outer female housing 214 may include one or more latches or mechanical connection structures that allow the outer female housing 214 to selectively couple and uncouple with the respective male connector 103. For example, as shown, the outer female housing 214 includes threads within a portion of the inner diameter of the outer female housing 214 that are structured to mechanically couple the outer female housing 214 (and thereby the female connector 102) to the respective male connector 103. In alternative embodiments, other forms of mechanical connection may be used depending on the application of the SPE connector 101. In various embodiments, the outer female housing 214 may be made of copper, nickel, alloys thereof, or any conductive material configured to attenuate or block electromagnetic radiation. The thickness of the shield may be selected based on the application and material used.

[0021] The first female gasket 213 is structured to be disposed or positioned within a first female gasket retaining recess of the inner female housing 210. For example, as described in additional detail below, the first female gasket 213 is structured to be disposed on a first side of the inner female housing 210 (e.g., the same side from which the first female contacts 211 and the second female contacts 212 extend) to allow the first female contacts 211 and the second female contacts 212 to extend therethrough. In this manner, the structure of the first female gasket 213 provides a seal to the first and second contact retaining recesses of the inner female housing 210 on the first side. The seal ensures that moisture, dirt, or other particulates in the environment cannot enter the SPE connector 101 on the first side. This may be particularly important because the first side of the female connector 102 is structured to mate with a respective electrical component (e.g., a PCB board) that may have moisture or particulates from the environment thereon.

[0022] The second female gasket 215 is disposed or positioned around a portion of the inner female housing 210 on the second side and is structured to extend from the portion of the inner female housing 210 to the inner portion of the outer female housing 214. The second female gasket 215 is positioned such that each portion of the male connector 103 contacts the second female gasket 215 and a compressive force between the female connector 102 and the male connector 103 forms a seal therebetween. The seal ensures that when assembled, the exposed portions of the contacts in the SPE connector 101 are isolated from the outside environment. Thus, the second female gasket 215 provides a barrier for the electrical connection between the contacts of the male connector 103 and the female connector 102, which reduces the possibility of moisture or other particulates from the environment causing an electrical short, thereby improving the safety and integrity of the electronic connection.

[0023] The male connector 103 includes a front nut 220, a first inner housing 222, a first male contact 224, a second male contact 223, a first outer housing 225, a second inner housing 226, a male gasket 227, a cable seal 228, and a pressure nut 229. The front nut 220 is structured to accommodate a portion of the first inner housing 222 and has a mechanical connection mechanism structured to allow mechanical coupling and decoupling of the male connector 103 to the respective female connector 102. In this example, the mechanical connection mechanism includes threads around an outer portion of the front nut 220. The threads are structured to be directed toward each end of the outer female housing 214 to mechanically couple the male connector 103 with the female connector 102. In alternative embodiments, the mechanical connection mechanism may be any structure that allows the male connector 103 to mechanically couple to the female connector 102. Front nut 220 is also structured to allow front nut 220 to rotate independently of other components of male connector 103. For example, this independent rotation allows male connector 103 to be secured and tightened to female connector 102 without male electrical contacts 224 and 223 rotating and potentially causing misalignment with their respective female contacts 211 and 212.

[0024] The first inner housing 222 is structured to be at least partially inserted into the front nut 220. The first inner housing 222 includes a base that allows a portion of the first male contact 224 and the second male contact 223 to extend into a cage-like structure defined by the outer walls of the first inner housing 222. For example, the base includes an opening that extends in all directions through the base such that a portion of each of the contacts 224 and 223 extends from the bottom of the base into the cage-like structure. The first inner housing 222 is structured to provide mechanical support to the first male contact 224 and the second male contact 223 and to electrically insulate the first male contact 224 and the second male contact 223. The outer walls that define the cage-like structure are structured to prevent the first male contact 224 and the second male contact 223 from bending or deforming when the male connector 103 is disconnected from the female connector 102. Furthermore, the first inner housing 222 ensures that the first male contacts 224 and the second male contacts 223 are properly aligned with the respective contacts 211 and 212 of the female connector 102 when mated with the male connector 103.

[0025] The first outer housing 225 may include an insulating portion. The insulating portion is structured to provide mechanical support to the insulation displacement contact (IDC) portions of the first and second male contacts 224 and 223. The first outer housing 225 is structured to be positioned over the second inner housing 226 such that the IDC portions of the first and second male contacts 224 and 223 are mechanically and electrically connected to the first and second wires 131 and 132 when pressed together. This connection is discussed in more detail below with reference to FIGS. 6 and 7. In various embodiments, the first outer housing 225 includes an outer shell that is structured to attenuate or block electromagnetic radiation. For example, the outer shell is configured to provide structural protection to at least a portion of the second inner housing 226, the insulating portion of the first outer housing 225, and a portion of the first inner housing 222, and to sufficiently encapsulate the contacts mounted therein to protect them from electromagnetic radiation. In various embodiments, the outer shell may be made of copper, nickel, alloys thereof, or any conductive material configured to attenuate or block electromagnetic radiation. The thickness of the shield may be selected based on the application and materials used.

[0026] The cable seal 228 is structured to fit within the cable recess of the second inner housing 226 and to allow the SPE cable 104 to extend therethrough from the environment into the second inner housing 226. A pressure nut 229 is disposed over the cable recess and is structured to create a compressive force around the cable recess to mechanically compress the cable seal 228 against the SPE cable 104, thereby forming a mechanical frictional connection between the male connector 103 and the SPE cable 104. In addition to the mechanical frictional connection, the cable seal 228 may also form a hermetic seal between the environment and the internal components of the SPE connector 101. In this manner, the cable seal 228 improves the reliability and integrity of the electrical connection within the SPE connector 101. Additional details of the various components and assembly of the male connector 103 are described below with reference to Figures 5-10.

[0027] FIG. 3A illustrates a side view 300 of the female connector 102 of the SPE connector 101 according to an exemplary embodiment. FIG. 3B illustrates an exploded view 350 of the female connector 102 according to an exemplary embodiment. FIG. 3A and FIG. 3B are considered in parallel for purposes of explanation. The female connector 102 includes an outer female housing 214, an inner female housing 210, a first female contact 211, and a second female contact 212. In various embodiments, the female connector 102 may include a first female gasket 213 and a second female gasket 215. The first female contact 211 and the second female contact 212 extend in parallel directions along a first axis 380 from a first side 340 of the female connector 102.

[0028] The inner female housing 210 includes a buffer portion 301 on a first side 340 structured to isolate the outer female housing 214 from the respective electrical components. For example, the inner female housing 210 may be formed of an electrically insulating material to isolate the first and second female contacts 211 and 212 and the conductive outer female housing 214 from one another. Additionally, the buffer portion 301 extends outward from the first axis 380 to a diameter equal to or greater than the diameter of the outer female housing 214 to electrically insulate the outer female housing 214 from the respective electrical components (e.g., PCB board). The inner female housing 210 may also include one or more protrusions 302a-302c extending from the first side 340 (e.g., buffer portion 301) in a direction parallel to the first axis 380 (e.g., a direction parallel to the direction in which the first and second female contacts 211 and 212 extend). One or more protrusions 302a-302c are structured to be inserted into respective retention recesses or openings on respective electrical components to provide support to the female connector 102 and ensure that the first female contact 211 and the second female contact 212 do not deform due to environmental turbulence or abuse.

[0029] The outer female housing 214 includes a first portion 351, a fastening portion 352, and a second portion 353. The first portion 351 is structured to mechanically connect to the male connector 103. As shown in additional detail in FIG. 4B, the first portion 351 includes a mechanical coupling mechanism. In this example, the mechanical coupling mechanism includes threads on an inner diameter of the first portion 351 that are structured to threadably mate with a corresponding portion (e.g., front nut 220) of the male connector 103. The outer female housing 214 also includes a retention rib (e.g., described in additional detail with reference to FIG. 4B) that allows the outer female housing 214 to be mechanically secured via frictional forces and / or latching mechanisms formed between the retention rib and the retention spine 362 of the inner female housing 210. The mechanical latch ensures that the outer female housing 214 is secured in place to the inner female housing 210 about the first axis 380 while at the same time allowing the outer female housing 214 to rotate about the first axis 380 without movement of the inner female housing 210. Thus, in this example, the structure of female connector 102 allows outer female housing 214 to rotate when assembled with male connector 103, allowing the threads to be tightened while ensuring that female contacts 211 and 212 and inner female housing 210 remain aligned with corresponding contacts of male connector 103. Fastening portion 352 is structured as a polygonal shape that allows a user to achieve a good grip on outer female housing 214 to mechanically tighten the threads to the corresponding male connector 103 and form a hermetic seal between male connector 103, second female gasket 215, and inner female housing 210.

[0030] The second portion 353 includes threads 358 on an outer diameter of the outer female housing 214. The threads 358 allow the female connector 102 to be mechanically secured to a corresponding electrical component via tightening the threads 358 with threads of a corresponding device. As described above, the mechanical connection between the outer female housing 214 and the inner female housing 210 formed by the retention ribs and retention spines 362 allows the pins of the first female contact 211 and the second female contact 212 to be positioned in a stationary position relative to corresponding through holes on a corresponding electrical component while the outer female housing 214 is rotated (e.g., the threads 358 are tightened) and secured to the corresponding electrical component.

[0031] Inner female housing 210 includes first portion 361, base portion 363, retention spine 362, buffer portion 301, and one or more protrusions 302a-302c. First portion 361 includes an extension of inner female housing 210 from base portion 363, the extension being structured to be at least partially disposed within outer female housing 214 and having second female gasket 215 disposed near or on base portion 363. For example, first portion 361 has a reduced cross-sectional area compared to base portion 363, which allows second female gasket 215 to be disposed about first portion 361 and supported by base portion 363 along first axis 380. Base portion 363 is also structured to be at least partially contained within outer female housing 214. Base portion 363 includes retention spine 362 disposed about an outer diameter of base portion 363 near buffer portion 301. In various embodiments, the buffer portion 301 is positioned on the opposite side from the first portion 361 .

[0032] First and second female contacts 211, 212 are structured to be mounted within respective contact retention recesses of inner female housing 210. Similarly, first female gasket 213 is structured to be mounted within a gasket recess of inner female housing 210 to seal the interior of SPE connector 101 when assembled. The structure of first and second female contacts 211, 212, first female gasket 213, the gasket recess, and the respective contact retention recesses are described in additional detail with reference to Figures 4A and 4B.

[0033] 4A is an isometric view 400 of a female contact 401 of female connector 102, according to an exemplary embodiment. For example, female contact 401 may be similar to first female contact 211 and second female contact 212. Isometric view 400 includes an isometric view of female contact 401 and a close-up view 425 of a female contact portion (e.g., receiving portion) 410 of female contact 401.

[0034] The female contact 401 includes a receiving portion 410, a connecting portion 411, and contact tines 412, all of which extend parallel to one another. The contact tines 412 extend away from the connecting portion 411 and are structured to protrude from the inner female housing 210 such that the contact tines 412 can form a mechanical and electrical connection when inserted into a respective receptacle of a corresponding electrical component. The receiving portion 410 extends from an opposite side of the connecting portion 411. The distal end of the receiving portion 410 may be hollow with a tapered edge 480 toward the hollow portion such that the respective male contacts may be inserted therein. The hollow portion may also include a first slit 421 and a second slit 422 that extend the distance of the hollow portion. The first slit 421 and the second slit 422 define a first protrusion 431 and a second protrusion 432 of the receiving portion 410. The first protrusion 431 and the second protrusion 432 may allow the respective male contacts to be inserted therebetween (e.g., into the hollow portion) and may compress the male contacts with a resilient force, thereby forming a secure mechanical and electrical connection between the male contacts and the female contacts 401. The connecting portion 411 may have an outer diameter larger than the outer diameters of the receiving portion 410 and the connecting portion 411. Furthermore, the outer diameter of the connecting portion 411 may have wear thereon such that the female contacts 401 may be fixedly mounted within respective contact retaining recesses of the inner female housing 210.

[0035] 4B is a cross-sectional view 450 of the female connector 102 according to an exemplary embodiment. The cross-sectional view 450 shows the first female contact retention recess 451, the second female contact retention recess 452, the first female gasket 213, and the second female gasket 215. Additionally, the cross-sectional view 450 shows the outer female housing 214 mechanically connected to the inner female housing 210 by mechanical frictional forces created between the retention spines 362 of the inner female housing 210 and the retention ribs 462 of the outer female housing 214. As discussed above, the mechanical connection created between the retention ribs 462 and the retention spines 362 allows the outer female housing 214 to rotate about the inner female housing 210, which improves the ability of the female connector 102 to be connected to the male connector 103. The threads 472 on the inner diameter of the first portion of the outer female housing 214 allow for mechanical connection and disconnection to the respective male connector 103.

[0036] The first and second female contacts 211 and 212 (such as the female contact 401) can be inserted into the respective first and second female contact retaining recesses 451 and 452 by a squeezing force until the female contacts 211 and 212 are stopped by the tapered openings 465 of the first portion of the inner female housing 210. The connector portion 411 of each female contact 211 and 212 creates a frictional force within the inner diameter of the respective contact retaining recesses 451 and 452, ensuring that they are fixedly held in place. The respective tapered openings 465 act as stops for the first and second female contacts 211 and 212, preventing over-insertion, thereby improving the reliability of the assembly process and the overall structure of the female connector 102. Furthermore, the tapered openings 465 also act as guides for the respective male contacts 224 and 223 to be guided and inserted into the receiving portions of the first and second female contacts 211 and 212.

[0037] The inner female housing 210 also includes a gasket retaining recess 475 structured to receive the first female gasket 213. The first female gasket 213 may be disposed in the gasket retaining recess 475, for example, after the first and second female contacts 211 and 212 are compressed into the respective first and second female contact retaining recesses 451 and 452. The first female gasket 213 is structured to create a seal around the contact tines 412 of the first and second female contacts 211 and 212 and the inner female housing 210. In this manner, the first female gasket 213 provides a seal, such as a hermetic seal, that blocks moisture or particulates from entering the first and second contact retaining recesses 451 and 452.

[0038] 5 is an exploded view 500 of the male connector 103 of the SPE connector 101, according to an exemplary embodiment. The exploded view 500 includes the SPE cable 104 and male connector 103 with the front nut 220, the first male gasket 501, the first inner housing 222, the first male contact 224, the second male contact 223, the first outer housing 225, the second inner housing 226, the second male gasket 227, the cable seal 228, and the pressure nut 229 exploded.

[0039] The first male gasket 501 is structured to fit with a first end of the front nut 220, and the first inner housing 222 is structured to be at least partially contained within the front nut 220 with the first male gasket 501 disposed therebetween to create a seal. The first male contact 224 and the second male contact 223 are structured to be positioned partially within the first inner housing 222 and partially within the second inner housing 226. The first outer housing 225 is structured to mechanically connect to the front nut 220 on a first side and the pressure nut 229 on a second side. Additionally, the first outer housing 225 is structured to fit or partially encapsulate a portion of the second inner housing 226 and a portion of the first inner housing 222. The second male gasket 227 is structured to fit around an outer diameter of the second inner housing 226 to create a second seal. The cable seal 228 is structured to be at least partially contained within the cable end of the second inner housing 226 through which the SPE cable 104 extends, such that the pressure nut 229 creates a compressive force on the cable end of the second inner housing 226 and the cable seal 228, thereby creating a mechanical connection between the male connector 103 and the SPE cable 104. The various connections of the male connector 103 are discussed in further detail with reference to Figures 6-9B.

[0040] 6 is an assembly diagram 600 of a male connector 103 with a corresponding SPE cable 104 according to an exemplary embodiment. The assembly diagram 600 includes a process flow of assembly from a first state 601 to an assembled state 605. The first state 601 shows the SPE cable 104 inserted through the second inner housing 226. The second inner housing 226 includes a first wire retention groove 611 and a second wire retention groove 811 positioned on the opposite side of the second inner housing 226.

[0041] In the second state 602, the first wire 131 is bent perpendicular to the direction in which the SPE cable 104 extends through the second inner housing 226 such that the first wire is aligned with the first wire retention groove 611. Additionally, the second wire 132 is bent perpendicular to the direction in which the SPE cable 104 extends through the second inner housing 226 such that the second wire 132 is positioned above the second wire retention groove 811. The first wire retention groove 611 and the second wire retention groove 811 are tapered such that the grooves narrow from a wide portion near the edge of the second inner housing 226 to a narrow portion as the first wire retention groove 611 and the second wire retention groove 811 extend into the second inner housing 226 from the edge. This narrowing enables a frictional force to mechanically secure the first wire 131 within the first wire retaining groove 611 and the second wire 132 within the second wire retaining groove 811 when the first wire 131 and the second wire 132 are compressed into their respective first wire retaining groove 611 and second wire retaining groove 811.

[0042] In some embodiments, the first wire retention groove 611 and the second wire retention groove 811 may include a first member 621 and a second member 622 that extend inwardly toward a centerline axis (e.g., toward the wire retention groove 611) on each side of the groove as the first member 621 and the second member 622 extend from an end of the second inner housing 226. The first member 621 and the second member 622 may be disposed on each side of the retention grooves 611 and 811 and cantilevered in the same direction (e.g., toward the fingers) that the wire retention groove extends into the second inner housing 226. During insertion or compression of a wire into the wire retaining groove 611, the first member 621 and the second member 622 may be forced away from the centerline axis of the groove (e.g., wire retaining groove 611) as the respective wire (e.g., first wire 131) is compressed into the groove (e.g., wire retaining groove 611) and relax to a rest position after the wire (e.g., first wire 131) is fully inserted. The relaxation of the first member 621 and the second member 622 makes the space between the distal ends of the members smaller, thereby locking the wire into place within the wire retaining groove 611 once the wire is compressed beyond the distal ends (e.g., furthest extents) of the first member 621 and the second member 622. Alternatively or additionally, a friction fit between the wire and the outer edge of the wire retaining groove 611 may mechanically secure the wire therein. For example, the outer edge may have a thickness less than the thickness of the outer wall of the second inner housing 226. In some embodiments, the outer edge may be beveled or tapered such that the thickness towards the bottom of the wire retaining groove 611 creates a blade-like structure that can increase friction between the wire's insulation and the outer edge, thereby providing a secure mechanical connection between the wire and the second inner housing 226. In various embodiments, the first member 621 and the second member 622 also ensure that the wire (e.g., first wire 131) is mechanically secured within the respective groove (e.g., wire retaining groove 611).

[0043] In the third state 603, the first wire 131 is compressed into the first wire retaining groove 611 and the second wire 132 is compressed into the second wire retaining groove 811. For example, in the third state 603, the first wire retaining groove 611 forms a mechanical connection with the first wire 131 by frictional forces and / or is locked into the first wire retaining groove 611 via the first member 621 and the second member 622. The second wire 132 is similarly mechanically secured within the second wire retaining groove 811.

[0044] In the fourth state 604, the first outer housing 225 having the first male contact 224 and the second male contact 223 disposed therein is positioned adjacent to the second inner housing 226 such that the IDC portions of the first contact 224 are aligned with the first wire retention groove 611 and the IDC portions of the second contact 223 are aligned with the second wire retention groove 811. The alignment of the IDC portions adjacent the respective wire retention grooves (e.g., wire retention groove 611) ensures that when the first outer housing 225 is compressed onto the second inner housing 226, the IDC contact portions (e.g., blades of the IDC contact portions) displace insulation on the respective wires (e.g., first wire 131) and electrically connect to the conductive cores of the respective wires (e.g., first wire 131). Compression of a first outer housing 225 having a first male contact 224 and a second male contact 223 disposed on a second inner housing 226 having a first wire 131 and a second wire 132 positioned in their respective grooves (e.g., first wire retaining groove 611) forms a mechanical and electrical connection between the first male contact 224 and the conductive core of the first wire 131, and forms a mechanical and electrical connection between the second male contact 223 and the conductive core of the second wire 132.

[0045] In the assembled state 605, the pressure nut 229 and the cable seal 228 are coupled with threads 648 on the first outer housing 225. For example, the pressure nut 229 includes threads on an inner diameter that are structured to be threadedly engaged with the threads 648 of the first outer housing 225. When the pressure nut 229 is tightened onto the first outer housing 225, the second inner housing 226 is squeezed therebetween, forming a mechanical and electrical connection between the first male contact 224 and the second male contact 223 and their respective wires 131 and 132. Furthermore, the tightening mechanically secures the pressure nut 229 to the first outer housing 225, which in this example is already mechanically secured to the front nut 220. The front nut 220, the first outer housing 225, and the pressure nut 229 form an outer housing into which the remaining portion of the male connector 103 is secured. In some embodiments, the front nut 220, the first outer housing 225, and the pressure nut 229 are each made from an electrically conductive material so that the outer housing can protect the electrical connections therein from RF radiation or interference. In various embodiments, the front nut 220, the first outer housing 225, and the pressure nut 229 are each made from an electrically insulating material, while a rigid element such as the outer housing can protect the structural integrity of the male connector 103. For example, the front nut 220, the first outer housing 225, and the pressure nut 229 are each made from a polymer, a metal such as copper, or a combination thereof, depending on the application.

[0046] 7 shows various views 700 of a male connector 103 and a male contact 730 of the male connector 103 according to an exemplary embodiment. In various embodiments, the male contact 730 is similar to the first male contact 224 and the second male contact 223 described herein. The various views 700 include a first view of the male contact 730, a first cross-sectional view 702 of a first connection process, a second cross-sectional view 703 of a second connection process, and a third cross-sectional view 704 that is a perpendicular cross-sectional view to the second cross-sectional view 703. The various views 700 show an assembly process of the male connector 103 with the SPE cable 104 and the resulting structural assembly.

[0047] The male contacts 730 include contact tines 731, a transition portion 732, and an IDC portion 733. The contact tines 731 extend in a first direction from a first end (e.g., a proximal end) of the transition portion 732. The contact tines 731 are structured to be inserted into receiving portions of respective female contacts. The transition portion 732 extends perpendicular to the first direction. The overall shape of the transition portion 732 and the male contacts 730 allows the contact tines 731 to be fixedly mounted within the male connector 103 and ensures that the contact tines 731 align with the receiving portions of the respective female contacts and that the IDC portion 733 aligns with respective IDC slots on the second inner housing 226 and corresponding wires (e.g., first wire 131). For example, the shape of the male contacts 730 (e.g., the transition portion 732 extending perpendicular to the contact tines 731 and IDC portion 733) allows the male contacts 730 to be mechanically secured within the male connector 103. In some embodiments, the transition portion 732 is mechanically secured between the first inner housing 222 and the first outer housing 225 by an interference fit that properly aligns the IDC portion 733 and the male contact tines 731 within the male connector 102. In this manner, a secure and reliable mechanical and electrical connection can be formed between each wire (e.g., the first wire 131) of the SPE cable 104, the female contacts, and the male contacts 730 when the SPE connector 101 is assembled. The contact tines 731 extend along a first plane that is perpendicular from the plane in which the transition portion 732 extends. The contact tines 731 also include tapered edges at their distal ends that allow the contact tines 731 to be received by respective tapered portions of the receiving portion of the female contact.

[0048] The IDC portion 733 extends from a second end (e.g., distal end) of the transition portion 732 along a direction opposite to the first direction. For example, the IDC portion 733 extends along a plane parallel to the first plane in which the contact tines 731 extend. In various embodiments, the IDC portion 733 extends along a plane parallel to the first plane in which the contact tines 731 extend. The IDC portion 733 includes a first blade 741 and a second blade 742 at a distal end that includes a taper 751 to allow a respective wire (e.g., first wire 131) to be guided between the first blade 741 and the second blade 742 when the male contact 730 is pressed downwardly onto the respective wire (e.g., first wire 131). The first blade 741 and the second blade 742 are structured to displace insulation on their respective wires (e.g., the first wire 131) to form a mechanical and electrical connection therebetween.

[0049] In the first cross-sectional view 702, a first portion 711 of the male connector 103 is shown separated from a second portion 712 of the male connector 103. The first portion 711 includes a front nut 220 and a first male contact 224 and a second male contact 223 disposed between an inner portion of a first inner housing 222 and a first outer housing 225 such that respective transition portions 732 are mounted within respective grooves (e.g., first wire retaining groove 611) and secured therebetween. The second portion 711 includes a second inner housing 226 with a first wire 131 and a second wire 132 mounted within respective wire retaining grooves (e.g., wire retaining groove 611). In the first cross-sectional view 702, the first portion 711 is positioned adjacent to the second portion 712 such that the IDC portions 733 of the first male contact 224 and the second male contact 223 are positioned adjacent to their respective IDC slots on the second inner housing 226.

[0050] In the second cross-sectional view 703, the first portion 711 is coupled with the second portion 712. For example, the first portion 711 can be compressed onto the second portion 712 such that the IDC portions 733 enter respective IDC slots on the second inner housing 226 so that the first blade 741 and the second blade 742 are mechanically and electrically secured to respective wires (e.g., the first wire 131). Additionally, the cable seal 228 is also positioned within a cage-like structure formed by the multiple fingers of the second inner housing 226.

[0051] In the third cross-sectional view 704, the pressure nut 229 is coupled with the remaining components of the male connector 103. In the third cross-sectional view 704, the first wire 131 is mechanically and electrically connected to the first male contact 224 and the second wire 132 is mechanically and electrically connected to the second male contact 223. The IDC portion 733 of the first male contact 224 is positioned within the first IDC slot 736 of the second inner housing 226 and the IDC portion 733 of the second male contact 223 is positioned within the second IDC slot 737 of the second inner housing 226. Additionally, the third cross-sectional view 704 shows the transition portion 732a of the first male contact 224 and the transition portion 732b of the second male contact 223 in a configuration in which the transition portions 732a, 732b are mechanically fixed (e.g., attached) between the first inner housing 222 and the first outer housing 225, enabling the respective IDC portions 733 of the male contacts (e.g., the first male contact 224) to be aligned with the respective IDC slots 736 and 737.

[0052] Figure 8A is an isometric view 800 of a portion of the male connector 103, according to an exemplary embodiment. Figure 8B is a top-down view 850 of a portion of the male connector 103, according to an exemplary embodiment. Figures 8A and 8B illustrate the coupling of the second inner housing 226 of the male connector 103 with the respective SPE cable 104 and are considered in tandem for purposes of explanation. For example, the isometric view 800 and the top-down view 850 show various additional angles relative to the third state 603 described with reference to Figure 6.

[0053] The portion of the male connector 103 shown includes a second inner housing 226 to which the SPE cable 104 is mechanically attached. A first wire 131 is mounted in a first wire retention groove 611 and a second wire 132 is mounted in a second wire retention groove 811. The first wire retention groove 611 and the second wire retention groove 811 also have IDC slots 812a-812b structured to receive respective IDC portions 733 of male contacts (e.g., male contacts 224). The IDC slots 812a-812b extend in a plane perpendicular to the plane in which the first wire retention groove 611 and the second wire retention groove 811 extend such that the IDC slots 812a-812b intersect with their respective wire retention grooves. The IDC slots 812a-b are located radially from the centerline axis of the second inner housing 226 such that the bottoms of the first and second wire retention grooves 611, 811 can support the first and second wires 131, 132 when the respective IDC contacts (e.g., first male contacts 224) are pressed onto the first and second wires 131, 132. The openings 840 extend completely through the second inner housing 226 such that the respective SPE cables 104 can be inserted therethrough.

[0054] 9A and 9B are assembly views 900 and 950 of the male connector 103 according to an exemplary embodiment. FIG. 9A illustrates an assembly process 900 for assembling the SPE cable 104 with the male connector 103. FIG. 9B illustrates a cross-sectional view 950 of the assembly process between the second inner housing 226 and the pressure nut 229 of the male connector 103. For example, the second inner housing 226 includes a first portion 901, a gasket retaining trench 902, and a seal portion 903. The first portion 901 includes the first wire retaining groove 611 and the second wire retaining groove 811. Additionally, first portion 901 may include one or more notches or channels 951 such that first inner housing 222 and first outer housing 225 can couple with second inner housing 226 only in a configuration that aligns IDC portions 733 of first male contacts 224 and second male contacts 223 with respective first wire retention grooves 611 and second wire retention grooves 811. In this manner, the notches or channels 951 and corresponding shapes of first inner housing 222 and first outer housing 225 ensure proper alignment during assembly.

[0055] The gasket retaining trench 902 is structured to reliably seal the second male gasket 227 when the male connector 103 is assembled, thereby ensuring that the male connector 103 is properly sealed from environmental conditions. The seal portion includes a plurality of fingers 922a-922f extending in a direction parallel to the direction in which the SPE cable 104 extends through the second inner housing 226. The plurality of fingers 922a-922f form a cage-like structure structured to receive a cable seal 228 positioned around the SPE cable 104. Additionally, the plurality of fingers 922a-922f allows a tapered portion 940 of the pressure nut 229 to compress the plurality of fingers 922a-922f toward the SPE cable 104 when tightened or compressed on the plurality of fingers 922a-922f, thereby creating a frictional force between the cable seal 228 and the SPE cable 104. The frictional force creates a rigid mechanical connection between the SPE cable 104 and the male connector 103 in addition to the electrical and mechanical connections formed to the first wire 131 and the second wire 132 in the respective first wire retaining groove 611 and second wire retaining groove 811.

[0056] The pressure nut 229 also includes threads 941 along an inner diameter along the first portion 939 adjacent the tapered portion 940, as described above. The threads 941 along the first portion 939 are structured to threadably mate with the exterior threads 648 of the first outer housing 225 to mechanically secure the pressure nut 229 to the first outer housing 225.

[0057] 10 is a flow diagram of a method 1000 of using (assembling) an SPE connector 101, according to an example embodiment. For example, method 1000 discusses various processes or operations of assembling an SPE connector 101 to form the electrical and mechanical connections discussed herein.

[0058] In process 1001, the SPE cable 104 is inserted through the second inner housing 226 of the male connector 103. The SPE cable 104 extends through an opening in the second inner housing 226 at the wire seal portion to a second end of the second inner housing 226. In various embodiments, the opening extends along a first axis 380 along which the SPE cable 104 extends once inserted through the second inner housing 226.

[0059] In process 1002, a first wire 131 of the SPE cable 104 is compressed into a first wire retaining groove 611 of the second inner housing 226, and a second wire 132 of the SPE cable 104 is compressed into a second wire retaining groove 811 of the second inner housing 226. In various embodiments, the first wire 131 is bent perpendicular to the first axis 380 and compressed into the first wire retaining groove 611 such that frictional forces mechanically secure the first wire 131 in the first wire retaining groove 611. Similarly, the second wire 132 may be bent perpendicular to the first axis 380 and compressed into the second wire retaining groove 811 such that frictional forces mechanically secure the second wire 132 in the second wire retaining groove 811. In some embodiments, the first wire 131 and the second wire 132 may be mechanically secured in the respective first wire retaining groove 611 and second wire retaining groove 811 via a locking mechanism of the first wire retaining groove 611 and the second wire retaining groove 811 having the first member 621 and the second member 622. In some embodiments, the first wire 131 and the second wire 132 are bent such that they extend along the same plane but in opposite directions.

[0060] In process 1003, the first IDC portion 733 of the first male contact 224 is positioned adjacent to the first wire retention groove 611 and the second IDC portion 733 of the second male contact 223 is positioned adjacent to the second wire retention groove 811. In various embodiments, the first male contact 224 and the second male contact 223 are secured within the first IDC portion 733 of the male contact 224 such that the transition portion of the first male contact 224 and the second male contact 223 mechanically secures the first male contact 224 and the second male contact 223 within the first portion. In one embodiment, the transition portion is retained between the first inner housing 222 and the first outer housing 225 of the first portion. The first portion of the male connector 103 may be positioned adjacent to the second inner housing 226 such that the first IDC portion aligns with the first IDC slot 736 and the second IDC portion 733 aligns with the second IDC slot 737 of the second inner housing 226. The first IDC slot 736 and the second IDC slot 737 are structured to receive the respective IDC portions 733 (e.g., the first slot and the second slot intersect with the respective wire retention grooves) such that the first blade 741 and the second blade 742 of the IDC portion 733 can enter the first IDC slot 736 and the second IDC slot 737 and contact the respective wires (e.g., the first wire 131) retained therein.

[0061] In process 1004, the first male contact 224 and the second male contact 223 are pressed into the respective wire retaining grooves 611 and 811. In various embodiments, the first portion of the male connector 103 is pressed or mated with the second inner housing 226 such that the first and second IDC portions 733 contact the respective wires (e.g., the first wire 131) disposed in the wire retaining grooves 611 and 811. The IDC portions 733 displace the insulation of the wires (e.g., the first wire 131) via one or more blades (e.g., the first blade 741) and form an electrical and mechanical connection with the wires (e.g., the first wire 131). In some embodiments, the cable seal 228 is positioned at an end of the second inner housing 226 opposite the first portion of the male connector 103 with the pressure nut 229. The pressure nut 229 can be tightened onto a first portion of the male contact (e.g., male contact 224) such that the second inner housing 226 is mechanically secured therein. Additionally, in one embodiment, the pressure nut 229 can compress the cable seal 228 inwardly toward the SPE cable 104 to form a mechanical connection between the SPE cable 104 and the male connector 103.

[0062] In process 1005, the male connector 103 is positioned adjacent to the female connector 102. The male connector 103 is positioned adjacent to the female connector 102 such that the contact tines of the first male contact 224 and the second male contact 223 are aligned with respective receiving portions of the female contacts 211 and 212 housed within the female connector 102. In various embodiments, the female connector 102 includes an outer female housing 214 that can rotate about an inner insulating female housing 210 that holds the female contacts 211 and 212. The male connector 103 is positioned such that threads on the male connector 103 can mate with threads on the outer female housing 214 and be tightened.

[0063] In process 1006, the male connector 103 is mated with the female connector 102 such that a first contact tine of the first male contact 224 is mechanically and electrically connected to a first receiving portion of the first female contact 211 and a second contact tine of the second male contact 223 is mechanically and electrically connected to a second receiving portion of the second female contact 212. For example, the outer female housing 214 can rotate freely about the inner female housing 210 of the female connector 102 such that the outer female housing 214 can be tightened via respective threads on the male connector 103 and the female connector 102 without causing misalignment between the contact tines of the first male contact 224 and the second male contact 223 and the receiving portions of the first female contact 211 and the second female contact 212, respectively.

[0064] In various embodiments, the female connector 102 may be mechanically and electrically connected to a corresponding electrical device. For example, the contact tines of the first female contact 211 may be inserted into the through-hole or receiving portion of the first male contact 224 on the corresponding device, and the contact tines of the second female contact 212 may be inserted into the through-hole or receiving portion of the second male contact 223 on the corresponding device. In such an example, the first contact of the device is electrically connected to the first wire 131 of the SPE cable 104 via the first male contact 224 and the first female contact 211, and the second contact of the device is electrically connected to the second wire 132 of the SPE cable 104 via the second male contact 223 and the second female contact 212. In this configuration, electrical connections can be easily and reliably formed and deformed via mating and separation of the male connector 103 and the female connector 102.

[0065] Further, in one embodiment, the insulating housing may be mechanically secured to the outer shield of the male connector 103 such that when the insulating housing is pressed onto the IDC contacts, the insulating housing and the IDC contacts are at least partially enclosed within the outer shield. For example, the insulated housing may be pressed onto the IDC contacts positioned on the base portion of the outer shield. A first portion (e.g., a first wing) of the outer shield may then be folded around and / or folded around the insulating housing, and a second portion (e.g., a second wing) may be folded around and / or folded around the insulating housing such that the insulating housing and the IDC contacts are mechanically secured within the insulating housing and the IDC contacts. In some embodiments, the first portion and the second portion are made of a flexible material that can be deformed to wrap around the insulating housing. In this configuration, the insulating housing is mechanically secured to the outer shield by at least the wire retaining portion, the base portion, the first portion, and the second portion of the outer shield. The outer shield encapsulation provides RF protection to the contacts positioned therein to ensure the integrity of any electrical signals carried by the IDC contacts.

[0066] In operation 1406, the male connector 103 is mated with the female connector 102 such that an electrical connection is formed between the first conductive hole of the printed circuit board and the first wire 131 and an electrical connection is formed between the second conductive hole of the printed circuit board and the second wire 132. In one embodiment, the male connector 103 is positioned adjacent to the female connector 102 such that the pins of the male connector 103 are aligned with the openings of the recesses of the female connector 102. The male connector 103 is pressed into the female connector 102 such that electrical and mechanical connections of the contacts of the male connector 103 are formed with the respective contacts in the female connector 102. In some embodiments, the latch pins of the male connector 103 may mate with the openings of the female connector 102 to mechanically secure the male connector 103 with the female connector 102.

[0067] 11 is an exploded view 1100 of a second example of a female connector 102 of an SPE connector alongside a view of the assembled female connector 102 according to an exemplary embodiment. In this embodiment, the female connector 102 includes an outer female housing 1101, an inner female housing 1102, a contact shell 1103, a first female contact 1111, and a second female contact 1112. In some embodiments, the first female contact 1111 and the second female contact 1112 may be similar to the female contacts 211, 212, and 401 described herein. Additionally, the outer female housing 1101 may be similar to the outer female housing 214 described herein.

[0068] The contact shell 1103 includes a cage-like structure 1130 having openings on either side of the cage-like structure 1130 and having a first tine 1131 extending from a first wall of the cage-like structure 1130 and a second tine 1132 extending from a second wall of the cage-like structure 1130. The first tine 1131 and the second tine 1132 extend in a parallel direction relative to one another. The first tine 1131 and the second tine 1132 are configured to extend through openings in the inner female housing 1102 and create a friction fit with respective female contacts inserted on opposite sides of the inner female housing 1102. The cage-like structure 1130 is structured to be mounted (e.g., wrapped) over the extended portion 1120 of the inner female housing 1130. In this manner, the contact shell 1130 can retain the arrangement of the female contacts 1111 and 112 within the inner female housing 1102 when assembled. Additionally, the contact shell 1103 or portions thereof may be formed of a metallic material such as copper or an alloy thereof, thereby improving radio frequency (RF) shielding of the SPE connector 101 by shielding portions of the first female contact 1111 and the second female contact 1112.

[0069] In various embodiments, the female connector 102 may be assembled by mating the contact shell 1103 with the inner female housing 1102 such that the tines 1131 and 1132 extend through respective openings on the inner female housing 1102. The first and second female contact tines 1111 and 1112 may be inserted into respective openings on opposite sides of the inner female housing 1102 such that contact is made between the tines 1131 and 1132 and the respective contacts 1111 and 1112. The first gasket 1105 may be placed in a groove in the inner female housing 1102 and the second gasket 1106 may be positioned between the outer female housing 1101 and the inner female housing 1102 before the outer female housing 1101 and the inner female housing 1102 are mated together in a manner similar to that described above.

[0070] 11B, the contact shell 1103 of the female connector 102 can be structured to have a shape generally complementary to the shape of the extension portion 1120. In particular, the cage-like structure 1130 can have a rounded rectangular shape. In other embodiments, the cage-like structure 1130 can have an oval shape. In other embodiments, such as the embodiment shown in FIG. 11C, the contact shell 1103 can be structured to have one or more support or retention features configured to facilitate a secure coupling between the female connector 102 and the male connector 103.

[0071] In some embodiments, the female connector 102 may also include a contoured gasket 1135 configured to have a generally complementary shape to the contact shell 1103 and configured to facilitate a seal between the female connector 102 and the mating respective male connector 103. The gasket 1135 may be generally disk-shaped and may be disposed to contact or rest on a top surface of the inner female housing 1102. The gasket 1135 may include a generally central aperture that is configured to receive or match the contour of the contact shell 1103.

[0072] 11D illustrates a perspective view of the contact shell 1103, according to an exemplary embodiment. As shown, the contact shell 1103 may be structured to include two opposing walls 1140 and 1147 that may be generally parallel to one another. Each of the walls 1140 and 1143 may include at least one retention feature 1145 and 1147, respectively, that may extend into the interior of the cage-like structure 1130 to facilitate mating and / or retention of the male connector 103 with the female connector 102. In various embodiments, the retention features 1145 and 1147 may be configured as cantilevered tabs and may be contoured to facilitate mating between the male connector 103 and the female connector 102. The cage-like structure 1130 may also include a contoured upper wall 1150 disposed between the walls 1140 and 1143, the wall 1150 configured to enhance stability and ease of insertion of the male connector 103 within the female connector 102. 11D , the contoured wall 1150 can define a ridge 1153 that extends along the length of the cage-like structure 1130 in a direction parallel to each of the walls 1140, 1143. The ridge 1153 can include at least one aperture or recess 1155 disposed therein or therethrough that is configured to facilitate retention of one or more components of the male connector 102.

[0073] 12A and 12B are assembly views 1200 and 1250 of a second example of a male connector 103, according to an exemplary embodiment. In this embodiment, the male connector 103 includes a front nut 1220 (e.g., similar to the front nut 220), a first male gasket 1201 (e.g., similar to the first male gasket 501), a first inner housing 1222, a first male contact 1224 (e.g., similar to the first male contact 224), a second male contact 1223 (e.g., similar to the second male contact 223), a first outer housing 1225, a second inner housing 1226, a second male gasket 1227, a cable seal 1228 (e.g., similar to the cable seal 228), and a pressure nut 1229 (e.g., similar to the pressure nut 229).

[0074] 12A, the first inner housing 1222 includes recesses on an outer wall configured to receive at least a portion of the first male contact tines 1224 and the second male contact tines 1223. The first inner housing 1222 is structured to be positioned within the second inner housing 1226. The second inner housing 1226 is structured to be positioned within the first outer housing 1225 having the first male gasket 1201 positioned therebetween. The top nut 1220 is structured to secure (e.g., via threads) to the first outer housing 1225 on the second inner housing 1226, thereby securing the second inner housing 1226 therebetween.

[0075] 12B, the cable housing 1251 is structured to be positioned in the first outer housing 1225 opposite the top nut 1220, and the ground ring 1252 is structured to mate with the cable housing 1251 on the side inserted into the first outer housing. In one embodiment, the cable housing 1251 is similar to the wire retention portion of the second inner housing 1226 described with reference to FIG. 2. The cable retention housing 1252 is structured to be positioned above the ground ring 1252 and adjacent to the cable housing 1241. The cable retention housing 1252 is structured similar to the cable retention portion of the second inner housing 226 described with reference to FIG. 2. For example, the second inner housing 1226 of FIGS. 12A and 12B includes multiple components that improve assembly efficiency, reduce stress on the cable, and reduce the possibility of SPE cable stress pulling on the wires secured in the male connector 103 when the SPE cable is secured to the male connector 103. The cable seal 1228, second male gasket 1227, and pressure nut 1229 all abut the first outer housing 1225, thereby securing the joint with the respective wires, as described above. A third male gasket 1255 may be positioned over the outward facing portion of the top nut, thereby ensuring a seal between the male connector 103 and the respective female connector 102.

[0076] 12C and 12D show end views of the male connector 103 according to various exemplary embodiments. As shown in FIG. 12C, the male connector 103 is configured such that the front nut 1220, the first inner housing 1222, and the second inner housing 1226 are each configured to engage or interface with a mating surface of the mated female connector 102. In various embodiments, such as the embodiment shown in FIG. 12D, the male connector 103 may include an inner shell 1260 that is structured to surround a portion of the first male contacts 1223 and the second male contacts 1224 and may be received within the contact shell 1103 of the female connector 102.

[0077] As shown in FIG. 12E, the inner shell 1260 of the male connector 103 may include a cage-like structure ("structure") 1263 having a generally rounded rectangular shape. The structure 1263 includes two opposing parallel side walls 1266 and 1267. On at least one connecting wall 1269 coupled between the side walls 1266 and 1267, the inner shell 1260 may include one or more features to facilitate retention of the male connector 103 within the respective coupled female connector 102. As shown in FIG. 12E, the wall 1269 may include a cantilevered tab 1275 secured (e.g., coupled, integrally formed) to an end of the structure 1263 and extending away from the structure 1263. The tab 1275 may be configured to elastically deform such that upon insertion of the male connector 103 within the female connector 102, the tab 1275 may bear against the structure 1263 to form a friction or interference fit. In various embodiments, the tab 1275 can be received within the ridge 1153 of the contact shell 1103 of the female connector 102. The tab 1275 can include one or more ridges or protrusions 1277 disposed at or near the end of the tab 1275 on a surface of the tab 1275 away from the structure 1263. Thus, the ridge 1277 can be received within at least one aperture or recess 1155 of the ridge 1153 to prevent separation or movement when the male connector 103 and the female connector 102 are coupled together. In various embodiments, the inner shell 1260 can be coupled to the second inner housing 1226. As shown, the inner shell 1260 may include a post 1280 extending from the structure 1263 at an end opposite the tab 1275, the post 1280 being configured to be received (i.e., via a press fit, a friction fit, an interference fit, etc.) within a portion of the second inner housing 1280 oriented toward the mating interface between the male connector 103 and the female connector 102.

[0078] With respect to the use of substantially any plural and / or singular terms herein, one of ordinary skill in the art can convert from the plural to the singular and / or from the singular to the plural as appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for clarity.

[0079] Generally, the terms used herein, and particularly in the appended claims (e.g., the body of the appended claims), are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "including" should be interpreted as "including but not limited to," etc.). It will be further understood by those skilled in the art that where a particular number of introduced claim recitations are intended, such intention will be explicitly set forth in the claim, and in the absence of such recitation, no such intention exists. For example, to aid in understanding, the following appended claims can be introduced with the use of the introductory phrases "at least one" and "one or more." However, the use of such phrases should not be construed as implying that the introduction of a claim statement by the indefinite article "a" or "an" limits any particular claim that includes such an introduced claim statement to an invention that includes only one such statement, and the same claim still remains true in the case of a definite article used to introduce a claim statement, even if the same claim includes the introductory phrase "one or more" or "at least one" and the indefinite article "a" or "an" (e.g., "a" and / or "an" should be interpreted to mean "at least one" or "one or more"). In addition, even if a specific number of introduced claim statements is explicitly recited, one of ordinary skill in the art will recognize that such a statement should typically be interpreted to mean at least the recited number (e.g., a bare statement without other modifiers of "two statements" typically means at least two statements, or more than two statements).Furthermore, when a convention similar to "at least one of A, B, and C, etc." is used, such a structure is generally intended in the sense that one of ordinary skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" includes, but is not limited to, a system having only A, a system having only B, a system having only C, a system having both A and B, a system having both A and C, a system having both B and C, and / or a system having both A, B, and C, etc.). When a convention similar to "at least one of A, B, or C, etc." is used, such a structure is generally intended in the sense that one of ordinary skill in the art would understand the convention. (For example, "a system having at least one of A, B, or C" includes, but is not limited to, a system having only A, a system having only B, a system having only C, a system having both A and B, a system having both A and C, a system having both B and C, and / or a system having both A, B, and C, etc.) It will be further understood by those skilled in the art that substantially any disjunction word and / or phrase indicating two or more alternative terms, whether in the specification, claims, or drawings, should be understood to contemplate the possibility of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

[0080] The foregoing description of exemplary embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to be limited to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the disclosed embodiments. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.

Claims

1. 1. A single pair Ethernet (SPE) connector, comprising: A female connector portion, a first electrical contact having a first contact tine and a first receiving portion, the first electrical contact being partially positioned within a first insulating housing; a second electrical contact having a second contact tine and a second receiving portion, the second electrical contact being positioned partially within the first insulating housing; a female connector portion comprising: a first outer housing, the first outer housing being mechanically secured to the first insulating housing; a male connector portion structured to selectively mate with the female connector portion, a third electrical contact having a first insulation displacement contact (IDC) portion and a third contact tine; a fourth electrical contact comprising a second IDC portion and a fourth contact tine; a second inner housing, a first wire retention groove on a first side of the second inner housing; a second wire retention groove on a second side of the second inner housing; and a male connector portion comprising a second inner housing having an opening extending a length of the second inner housing; 1. A single pair Ethernet (SPE) connector comprising:

2. The second inner housing comprises: a first slot intersecting the first wire retention groove, the first slot being structured to receive the first IDC portion; 2. The SPE connector of claim 1, further comprising: a second slot intersecting said second wire retention groove, said first slot being structured to receive said second IDC portion.

3. 2. The SPE connector of claim 1, wherein a portion of the first contact tines extend from the first insulating housing parallel to a portion of the second contact tines extending from the first insulating housing.

4. 2. The SPE connector of claim 1, wherein the first insulating housing comprises a buffer portion that extends outwardly to a diameter equal to or greater than a diameter of an outer shield on a first side of the outer housing.

5. 2. The SPE connector of claim 1, wherein the opening is structured to allow an SPE cable to extend through the second inner housing, the first wire retention groove is structured to retain a first wire of the SPE cable that extends perpendicular to the direction in which the opening extends, and the second wire retention groove is structured to retain a second wire of the SPE cable that extends perpendicular to the direction in which the opening extends.

6. 2. The SPE connector of claim 1, wherein the male connector further comprises a first inner housing, the third electrical contact and the fourth electrical contact being at least partially disposed within the first inner housing.

7. 2. The SPE connector of claim 1, wherein the second inner housing further comprises a plurality of fingers extending from opposite sides of the first wire retention groove, the plurality of fingers forming a cage-like structure.

8. The SPE connector of claim 7 , wherein the male connector further comprises a cable seal at least partially disposed within the cage-like structure.

9. 9. The SPE connector of claim 8, wherein the male connector further comprises an outer housing and a pressure nut threaded together to mechanically secure the second inner housing therein.

10. 10. The SPE connector of claim 9, wherein the pressure nut has a tapered portion that contacts and compresses the plurality of fingers toward a centerline axis.

11. 2. The SPE connector of claim 1, wherein the male connector is structured to be mechanically connected via threads on the male connector and threads on the female connector.

12. 2. The SPE connector of claim 1, wherein the first and second wire retention grooves are located on edges of the second inner housing, and the first and second wire retention grooves include beveled edges structured to create a frictional force with the respective wires.

13. 2. The SPE connector of claim 1, wherein the first insulating housing comprises a retention spine and the first outer housing comprises a retention rib, the retention spine and the retention rib being structured to mechanically connect the first insulating housing and the first outer housing.

14. 14. The SPE connector of claim 13, wherein the retention spine and the retention rib are structured to allow the first outer housing to rotatably move about the first insulating housing.

15. 1. A single pair Ethernet (SPE) connector, comprising: A female connector portion, a first contact having a first contact tine; a second contact having a second contact tine; a first insulating housing having a first contact retention recess and a second contact retention recess, the first contact being at least partially positioned within the first contact retention recess and the second contact being at least partially positioned within the second contact retention recess; a female connector portion, the first contact tines and the second contact tines extending from the first insulating housing and configured to electrically and mechanically connect to respective openings in an electrical component; a male connector portion structured to selectively mate with the female connector portion, a first insulation displacement contact (IDC); A second IDC contact; and a second inner housing including a first slot intersecting a first wire retention groove and structured to receive a blade from the first IDC contact, and a second slot intersecting a second wire retention groove structured to receive a blade from the second IDC contact; 1. A single pair Ethernet (SPE) connector comprising:

16. The SPE connector of claim 15 , wherein the male connector portion is configured to connect to the female connector portion.

17. 17. The SPE connector of claim 16, wherein the first contact is configured to connect with the first IDC and the second contact is configured to connect with the second IDC.

18. 16. The SPE connector of claim 15, wherein the female connector portion further comprises an outer shield mechanically secured to the first insulating housing, the outer shield comprising threads configured to mechanically secure to the threads of the male connector portion.

19. 16. The SPE connector of claim 15, wherein the first IDC comprises contact tines extending along a first plane, a transition portion connected to the contact tines at a proximal end, the transition portion extending along a second plane perpendicular to the first plane, and an IDC portion extending from a distal end of the transition portion along a third plane parallel to the first plane.

20. 1. A method comprising: Extending the SPE cable through the second inner housing; Positioning a first wire of the SPE cable in a first wire retention groove of the second inner housing and positioning a second wire of the SPE cable in a second wire retention groove of the second inner housing; compressing the first housing against the second inner housing such that a first electrical connection is made between the first wire and a first IDC contact and a second electrical connection is made between the second wire and a second IDC contact; joining the outer housing and the pressure nut together over the first housing and the second inner housing such that the first housing and the second inner housing are mechanically secured within the outer housing and the pressure nut; mating the outer housing to a female connector such that the first IDC contacts are mechanically and electrically connected to first female contacts and the second IDC contacts are mechanically and electrically connected to second female contacts; A method comprising:

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