High-speed, ruggedized connectors

Abstract

A modular connector economically provides high signal integrity in harsh environments, such as automotive. The connector may include structures that provide accurate and stable conductor positioning relative to the grounding structure, even for press-fit connectors that subject conductors to significant force when attached to a PCB. Such features may include a modular housing for a terminal assembly that holds one or more conductors, including orthogonal portions. Multiple parts of the housing may be slidably engaged. One of the multiple parts may comprise a channel with a closed top that slides over a portion of the conductor and restrains the conductor when the connector is pressed against the PCB. Other features may include a hold-down with high retention force and a shield that functions to accurately and stably position the terminal assembly relative to the conductive housing.

Description

[Technical Field]

[0001]

[0001] This patent application relates generally to interconnection systems used to interconnect electronic assemblies, for example, interconnection systems including electrical connectors, and more particularly to interconnection systems for harsh environments such as within vehicles. [Background technology]

[0002]

[0002] Electrical connectors are used in many electronic systems. It is generally easier and more cost-effective to manufacture a system as separate electronic assemblies that can be coupled together by electrical connectors. Connectors may be used to interconnect assemblies so that they can work together as part of a single system. For example, two assemblies may be connected by mounting connectors on printed circuit boards within the assemblies and mating the connectors. In other systems, it may not be practical to join two printed circuit boards by directly mating the connectors on the two printed circuit boards. For example, when the system is assembled, the printed circuit boards may be too far apart to directly connect the connectors mounted on the printed circuit boards.

[0003]

[0003] In some systems, connections between assemblies may be made via cables. The cables may be terminated with connectors that mate with connectors mounted on printed circuit boards. In this manner, connections between assemblies may be made by plugging a connector that is part of a cable assembly into a connector mounted on the printed circuit board. In other system architectures, a connector terminating a cable may mate with another connector terminating another cable.

[0004]

[0004] A modern automobile is an example of a system in which assemblies are connected together via cables. For example, an automobile includes electronic control units (ECUs) for controlling various vehicle systems, such as the engine, transmission (TCU), safety systems, emission control, lighting, advanced driver assistance systems (ADAS), entertainment systems, navigation systems, and cameras. The ECUs may be manufactured as separate assemblies and connected through one or more vehicle networks formed by cables routed between these assemblies. To simplify automobile manufacturing, the assemblies may be formed separately and then connected through cables that terminate in connectors that allow connection to mating connectors terminating other cables or to mating connectors mounted on printed circuit boards within the assembly.

[0005]

[0005] Automobiles present a harsh environment for electrical connectors. Automobiles can vibrate, potentially causing connectors to unmate and fail completely. Even when vibrations do not completely disrupt connector operation, they can generate electrical noise that can interfere with the operation of electronic devices joined through interconnections that include the connector. For example, noise can be generated by relative motion of components within a connector, which can alter the electrical characteristics of the connector. Variations in electrical characteristics, in turn, cause variations in signals passing through the interconnection, which is a form of noise that interferes with the processing of the underlying signals.

[0006]

[0006] In an automotive environment, electrical noise can also arise from automotive components that generate electromagnetic radiation. The radiation can couple to the conductive structures of connectors and introduce noise into signals passing through those conductive structures. In an automobile, electromagnetic radiation can be generated by any of a number of components, such as spark plugs, alternators, or power switches. Noise can be particularly disruptive to high-speed signals, such as those used to communicate data over an automotive network. Summary of the Invention

[0007]

[0007] The concepts disclosed herein can be embodied as an electrical connector comprising (i) a conductive housing having a chamber; and (ii) a terminal assembly disposed within the chamber, the terminal assembly comprising (a) a first insulating member, (b) a second insulating member engaged with the first insulating member, and (c) an electrical conductor comprising (1) a mating contact portion, (2) a contact tail, and (3) an intermediate portion connecting the mating contact portion and the contact tail, the electrical conductor comprising (a) a first portion at least partially retained by the first insulating member and (b) a second portion at least partially retained by the second insulating member.

[0008]

[0008] In another aspect, an electrical connector may include (i) a conductive housing having a chamber; and (ii) a terminal assembly disposed within the chamber, the terminal assembly including: (a) an insulating housing having a first insulating member and a second insulating member; and (b) an electrical conductor having (1) a mating contact portion extending from the insulating housing in a first direction and (2) a contact tail extending from the insulating housing in a second direction, and (3) an intermediate portion connecting the mating contact portion and the contact tail, the electrical conductor having (a) a first portion held by the first insulating member and (b) a second portion held between the first insulating member and the second insulating member.

[0009]

[0009] In yet another aspect, an electrical connector may include (i) a conductive housing having a chamber; (ii) a shield member within the conductive housing that is electrically and mechanically engaged with the conductive housing; and (iii) a terminal assembly disposed within the chamber, the terminal assembly including (a) an insulating housing and (b) an electrical conductor held by the insulating housing, wherein the shield member is configured to apply pressure to the terminal assembly.

[0010]

[0010] In yet another aspect, an electrical connector may include (i) a conductive housing having a chamber; (ii) a shield member within the conductive housing, the shield member being electrically and mechanically removably couplable to the conductive housing, the removably couplable shield member being separable from the conductive housing; and (iii) a terminal assembly disposed within the chamber and removably couplable to the conductive housing, the terminal assembly being separate from the conductive housing, the terminal assembly including: (a) a first insulating member; (b) a second insulating member engaged with the first insulating member; and (c) an electrical conductor having (1) a mating contact portion, (2) a contact tail, and (3) an intermediate portion connecting the mating contact portion and the contact tail, the mating contact portion extending from the first insulating member and the contact tail extending from the second insulating member.

[0011]

[0011] In yet another aspect, an electrical connector may include (i) a conductive housing having a chamber, and (ii) a terminal assembly disposed within the chamber, the terminal assembly including (a) an insulating housing, and (b) an electrical conductor, the electrical conductor including (1) a mating contact portion extending from the insulating housing, (2) a contact tail extending from the insulating housing, and (3) an intermediate portion connecting the mating contact portion and the contact tail, and (4) a hold-down having (a) a first end engaged with the conductive housing and (b) a second end extending from the second housing, the first end including a first flexible arm and a second flexible arm separated by an opening. [Brief explanation of the drawings]

[0012]

[0012] The accompanying drawings are not limited to the scale shown, and for clarity, not all components may be labeled with reference numerals in each drawing. [Figure 1]

[0013] FIG. 1 is a perspective view of an exemplary interconnect system, according to some embodiments. [Figure 2]

[0014] 2 is an exploded perspective view of the exemplary board connector 100 of FIG. 1. [Figure 3A]

[0015] 2 is a cross-sectional view of the exemplary board connector 100 of FIG. 1. [Figure 3B]

[0016] FIG. 3B is a rear view of the exemplary board connector of FIG. 3A. [Figure 4A]

[0017] 1 is a perspective view of an exemplary multi-port board connector. [Figure 4B]

[0018] 4B is a cross-sectional view of the exemplary multi-port board connector of FIG. 4A. [Figure 5]

[0019] FIG. 2 is a perspective view of the cable connector 200 of FIG. [Figure 6]

[0020] FIG. 6 is an exploded perspective view of the exemplary cable connector of FIG. 5. [Figure 7]

[0021] 6 is a cross-sectional view of the exemplary cable connector of FIG. 5. [Figure 8]

[0021] FIG. 1 is a front perspective view of an exemplary multi-port board connector having a 2x2 mating interface mounted to a printed circuit board with press-fit contact tails. [Figure 9]

[0022] FIG. 9 is an exploded perspective view of the exemplary compression-fit connector of FIG. 8. [Figure 10A]

[0023] 1 is a perspective view of an exemplary terminal assembly for a compression-fit connector, showing the terminal assembly in an as-manufactured state with the terminals inserted into the first insulating member. [Figure 10B]

[0024] 10B is a perspective view of the exemplary terminal assembly of FIG. 10A in a post-manufacturing state where a second insulating member is attached to the first insulating member; [Figure 10C]

[0025] FIG. 10C is a cross-sectional view of the exemplary terminal assembly of FIG. 10B taken along line CC. [Figure 10D]

[0026] FIG. 10C is a side cross-sectional view of the exemplary terminal assembly of FIG. 10B taken along line DD. [Figure 10E]

[0027] FIG. 10C is a top view of the example terminal assembly of FIG. 10B. [Figure 11]

[0028] FIG. 1 is an exploded perspective view of two terminal assemblies of a press-fit connector. [Figure 12]

[0029] 1 is a cross-sectional view of a portion of a conductive housing of a compression-fit connector showing a hold-down. [Figure 13A]

[0030] FIG. 1 is a rear view of an exemplary conductive housing of a 2x2 connector showing a shield with retention barbs. [Figure 13B]

[0031] FIG. 13B is an enlarged view of a portion of the shield indicated by the box labeled "13B" in FIG. 13A. [Figure 14A]

[0032] 1 is a perspective view of an exemplary conductive housing of a 2x2 connector shown in phantom, depicting one row of terminal assemblies and one shield installed; [Figure 14B]

[0033] 14B is a perspective view of the exemplary conductive housing of FIG. 14A, showing two rows of terminal assemblies and two shields installed therein. [Figure 15]

[0034] FIG. 14B is an enlarged side view of a portion of the conductive housing of FIG. 14A illustrating the positioning of the terminal assembly within the conductive housing by a dimple on the shield and a flexible tab. DETAILED DESCRIPTION OF THE INVENTION

[0013]

[0035] The present inventors have recognized and appreciated techniques for producing connectors that provide high data rate transmission that can be manufactured economically while still operating reliably in the harsh environments presented by automobiles. Such connectors would be suitable, for example, for interconnecting assemblies within an automobile network. These techniques can be applied to modular connector systems in which a series of components can be combined to form connectors in any of multiple configurations. Costs associated with manufacturing connectors of the type described herein can be reduced by modularly designing the connector components.

[0014]

[0036] Each connector configuration may be formed from at least an insulating outer housing that establishes the connector's mating interface. The insulating outer housing may provide a latching mechanism. A series of components may include insulating outer housings with complementary configurations that can be used to form two connector configurations that mate and latch together.

[0015]

[0037] A conductive structure may be positioned within the outer housing, at least partially surrounding a cavity. The cavity may open at a mating end that extends into the mating interface. A series of components may include one or more mating conductive structures. For example, the conductive structures may be die-cast to include a cavity or formed from one or more metal sheets into a tube. To allow the conductive structures to mate, a tube forming a conductive structure of one component in the series may be sized to fit within an opening within a cavity of another conductive structure. Alternatively, a series of components may include multiple tubes having one radius sized to fit within a single tube having a larger radius. In some embodiments, multiple conductive structures may be incorporated into the same insulative outer housing to form connectors of different sizes. Alternatively or additionally, the die-cast conductive structure may be formed with a different number of cavities.

[0016]

[0038] Regardless of the number of cavities incorporated within the housing, terminal assemblies may be inserted into the cavities. Each terminal assembly may have an insulating member that houses one or more electrical conductors, each of which may function as a terminal for the connector. The series of connector components may include at least two types of terminals (e.g., pin-type and receptacle-type terminals) configured to mate with each other. The terminals may be provided with different types of tails, including tails configured for attachment to a printed circuit board and tails configured for attachment to a conductor of a cable.

[0017]

[0039] Various mating and mounting configurations can be used in combination to form board or cable connectors with a mating interface that allows for inter-mating of the connectors. For example, a board connector may mate with a cable connector, or two cable connectors may mate with each other. Additionally, different terminal assemblies can be used to configure board connectors for different mounting techniques. For example, terminal assemblies can be configured for pin-in paste or through-hole soldering to a PCB. Differently configured terminal assemblies can also be used to configure board connectors for press-fit mounting.

[0018]

[0040] Modularity between components of an electrical connector can be provided, for example, by a conductive housing having a chamber and a shield member disposed within the conductive housing, the shield member being removably electrically and mechanically coupleable to the conductive housing and therefore separable from the conductive housing. A terminal assembly disposed within the chamber can be removably coupleable to the conductive housing, thereby allowing the terminal assembly to be separated from the conductive housing. This arrangement allows the connector to be assembled into one of several configurations by inserting different terminal assemblies, which can then be locked into place by inserting a shield. For example, the terminal assembly can include a first insulating member, a second insulating member engaged with the first insulating member, and an electrical conductor having a mating contact portion extending from the first insulating member, a contact tail extending from the second insulating member, and an intermediate portion connecting the mating contact portion and the contact tail. The first and second insulating members can be engaged with each other such that each insulating member holds a different portion of the conductor. Such a terminal assembly can be used with a press-fit board connector. Terminal assemblies with a single insulating member holding multiple conductors may also be used in other mounting configurations.

[0019]

[0041] Optionally, each terminal assembly may be configured to carry one signal, whether as a single-ended signal or a differential signal. In the exemplary embodiment described below, each terminal carrier has a pair of electrical conductors suitable for carrying differential signals. A conductive structure surrounding the cavity into which the terminal carrier is inserted may act as a shield for the differential signals. The mating interface may be such that the terminals of the mating connectors mate mechanically and electrically, and the conductive structure forming a shield around the terminals also mate mechanically and electrically.

[0020]

[0042] The inventors have recognized and appreciated various techniques that can be applied to the components of a connector system to provide connections with high signal integrity (SI). Improved SI may result from controlling the electrical characteristics of the signal path through the connector and / or configuring the connector to operate effectively in the harsh automotive environment in which it is used.

[0021]

[0043] For example, the techniques described herein may enable a terminal assembly for press-fit mounting to be easily assembled while providing sufficient mechanical integrity to ensure that the relative positions of the electrical conductors of the terminal assembly and the grounding structures within the connector are precisely controlled, even after the connector is subjected to stresses from press-fit mounting and use. Using these techniques, the electrical conductors may present a uniform and stable impedance through the connector, which may enable high-speed operation in harsh environments.

[0022]

[0044] One such technique provides mechanical and / or electrical stability for electrical conductors within a terminal assembly by retaining them within first and second insulating members. The terminal assembly may be positioned within a chamber formed by a conductive housing that may serve as a ground around the conductor. The first and second insulating members may be engaged with one another such that each insulating member retains a different portion of the conductor. The first and second insulating members may be configured to provide stable positioning of the conductor relative to the conductive housing regardless of forces applied to the conductor during press-fit installation of the connector or use of the connector in harsh environments with significant vibration.

[0023]

[0045] Another technique for providing additional mechanical and / or electrical stability to an electrical connector includes a conductive housing including a chamber, a shield member within the conductive housing that is electrically and mechanically engaged with the conductive housing, and a terminal assembly disposed within the chamber. The shield member may be configured to apply pressure to the terminal assembly, forcing it into a position determined by the structure of the conductive housing. The shield member may include a dimple that engages with an insulating housing within the terminal assembly to apply pressure to the terminal assembly. The shield may further include a flexible tab that fits within a groove in the conductive housing and biases the shield toward the terminal assembly.

[0024]

[0046] Another technique that may provide additional mechanical and / or electrical stability to the electrical connector includes a shelf drilled into the conductive housing adjacent the mounting interface and further includes hold-downs that extend through the shelf holes and hold the electrical connector to the printed circuit board (PCB). The hold-downs may include a first end that extends through a first surface of the shelf and one or more barbs that engage the first surface of the shelf.

[0025]

[0047] Another technique for providing additional mechanical and / or electrical stability to an electrical connector configured for use as a board connector may involve hold-downs for holding the connector against the PCB to which it is attached. The hold-downs may be configured to provide a strong retention force with little play between the connector housing and the hold-down while facilitating insertion. For example, the hold-downs may engage with the connector's conductive housing, which may be formed of metal by die casting or the like, thereby providing mechanical stability to the housing. The end of the hold-down that is inserted into the opening in the conductive housing may be designed with flexibility so that the hold-down can be compressed when inserted through a hole that extends through a conductive shelf. The flexible portion of the hold-down may include barbs that engage with the top surface of the shelf. The barbs may compress toward the center of the hold-down for insertion through the hole and spring outward to engage the shelf when pushed through the hole. Such a connector may include a conductive housing having a chamber; a terminal assembly having an insulating housing and an electrical conductor disposed within the chamber, the electrical conductor having a mating contact portion extending from the insulating housing, a contact tail extending from the insulating housing, and an intermediate portion connecting the mating contact portion and the contact tail; and a hold-down having a first end engaged with the conductive housing and a second end extending from an insulating second housing, the first end including a first flexible arm and a second flexible arm separated by an opening.

[0026]

[0048] These techniques may be used alone or in combination and are described below in the context of an interconnection system that may be used to make physical connections between assemblies, for example, in an automobile.

[0027]

[0049] 1 is a perspective view of an exemplary interconnect system, according to some embodiments. The interconnect system may be used to connect two electronic devices to each other. In some embodiments, the interconnect system 100 is used in high data rate transmission applications (e.g., applications involving automotive ECUs). In this example, the interconnect system includes a board connector 100 and a cable connector 200.

[0028]

[0050] 2 is an exploded perspective view of the exemplary board connector 100 of FIG. 1 when not mated with a cable connector 200, according to some embodiments. The board connector 100 includes an opening 158 in the housing 150, which may be positioned to allow mating contacts to pass through. A mating interface of the board connector 100 may be provided within the opening 158.

[0029]

[0051] The board connector 100 also includes a conductive housing 140. The conductive housing 140 may be, for example, a die-cast part. In this example, the conductive housing has a mating portion 146 that extends into an opening 158 when the insulating housing 150 is attached to the conductive housing 140.

[0030]

[0052] The conductive housing 140 may include a chamber into which a terminal assembly is inserted. In this example, the terminal assembly may be formed by an insulator 120 and one or more electrical conductors carried by the insulator 120. As shown, the board connector 100 includes electrical conductors that can function as signal conductors. In this example, a pair of electrical conductors is shown, with the illustrated terminal assembly configured to pass differential signals. In addition to transmitting one or more signals through the connector, the electrical conductors may have a mating contact portion at one end, a tail at the opposite end, and an intermediate portion therebetween. Thus, the electrical conductors can function as contacts for the connector.

[0031]

[0053] In the example of FIG. 2, the mating contact portions of the electrical conductors are pin-shaped so that the board connector 100 is configured as a header. In other embodiments, the mating contact portions of the electrical conductors in a header connector can be blade-shaped or have other shapes. Alternatively or additionally, in some embodiments, the board connector may have electrical conductors with mating contact portions that are receptacle-shaped. In the example of FIG. 2, the tails of the electrical conductors are post-shaped. For example, the posts can be attached to a printed circuit board using plated-through-hole or pin-in-paste soldering techniques.

[0032]

[0054] 2 shows multiple mating contacts, including contacts 110A and 110B (also referred to herein as "terminals"). Mating contact portions of these terminals extend into opening 158. Tails of contacts 110A and 110B extend from a mounting interface of board connector 100 for mounting to printed circuit board 160. Contacts 110A and 110B may be electrically connected to holes 162 and 163 on board 160. In some examples, board 160 may be a printed circuit board (PCB).

[0033]

[0055] Opening 158 may be shaped and sized to receive a mating connector therein. The mating connector may include mating contacts configured to electrically connect to contacts 110A and 110B when the interconnection system is in a mated configuration.

[0034]

[0056] One or more mating contacts may be held within insulator 120 to form a terminal assembly. The insulator may be shaped and sized to accommodate the mating contacts. For example, contacts 110A and 110B may pass through openings in insulator 120. Insulator 120 may be inserted into a cavity within conductive housing 140. In this manner, the conductive housing partially encloses the terminal assembly and the electrical conductors within the terminal assembly.

[0035]

[0057] Conductive housing 140 may further include mounting posts 140 configured to electrically and mechanically connect conductive housing 140 to substrate 160. For example, mounting posts may extend into holes 160, which may be ground vias. By grounding conductive housing 140, conductive housing 140 may act as a shield for the terminal assembly and the pair of conductors within the terminal assembly.

[0036]

[0058] The board connector 100 may include one or more additional shielding members (shown here as shield 130). The shield 130 is also inserted into the cavity of the conductive housing 140 to further enclose the terminal assembly. The shield 130 is electrically and mechanically coupled to the conductive housing 140, and therefore may also be grounded. The shield 130, together with the spacer on the insulator 120, may also function to position the terminal assembly within the cavity, thereby establishing signal-to-ground spacing for the electrical conductors within the terminal assembly. This configuration may provide a desired stable impedance.

[0037]

[0059] FIG. 3A is a cross-sectional view of the exemplary board connector 100 of FIGS. 1 and 2, taken along line 3A-3A of FIG. 2. As described herein, the board connector 100 includes an insulator 120. The insulator may include ribs 121. The ribs 121 may function as spacers to position the terminal assembly relative to the shield 130. The spacers may be sized and positioned to establish a designed spacing between the shield 130 and the terminals 110A and 110B. The appropriate size and shape of the spacers may be determined based on the desired impedance. The shield 130 may contact one side of the ribs 121.

[0038]

[0060] As described herein, the insulator 120 and the shield 130 may be engaged within the conductive housing 140. The conductive housing 140 may include a retention feature 141 to prevent movement of the insulator 120 and absorb forces thereof. The retention feature 141 may be a rib configured to contact a wall of the insulator 120. The conductive housing 140 may further include recesses 152. The housing 150 may include the retention features 151 configured to engage with respective recesses 152 of the conductive housing 140.

[0039]

[0061] 3B is a rear view of the board connector 100 of FIG. 3A, according to some embodiments. The conductive housing 140 may also include retention mechanisms 142 and 143 for retaining the shield 130.

[0040]

[0062] Contacts 110A and 110B may each include one or more retention features configured to prevent movement of the contacts within insulator 120 of connector 100. For example, contact 110A includes a barb configured to provide retention of the contacts within the insulator. For example, insulator 120 may include a channel that receives each of contacts 110A and 110B. The barbs securely hold the contacts by biting into the insulator on the sides of the channel. The channel is narrower closer to the barb and wider away from the barb.

[0041]

[0063] In some embodiments, the width of the barb and / or channel can significantly affect the impedance along contact 110A or 110B. Therefore, the contact may be provided with an impedance compensation section near the retention feature. In this example, the impedance compensation section is formed by a narrowed portion 111.

[0042]

[0064] In the illustrated embodiment, contact 110A or 110B has the same shape. Therefore, the contacts may have the same retention feature and the same impedance-compensating section. It should also be understood that there may be more than one retention feature along the length of contact 110A. Each retention feature and the impedance-compensating section adjacent to the retention feature may be similarly shaped. However, in some embodiments, the retention features along the length of the contact may have different sizes or shapes.

[0043]

[0065] FIG. 4A is a perspective view of an exemplary multi-port board connector 400, according to some embodiments. For example, FIG. 4A shows a 2x2 connector 400 that includes four ports arranged in two rows of two ports per row. A conductive housing is shown with ports 470A-D, each shaped and sized to receive a mating element therein. Each port may be configured identically to mating portion 146 of board connector 100, allowing the same mating element to mate with either connector. Similar to board connector 100, conductive housing 440 is configured to mount to board 460. Insulating housing 450, which provides the same function as insulating housing 150 for the larger connector, is attached to conductive housing 440.

[0044]

[0066] FIG. 4B shows a portion of a cross-section taken along line 4B-4B of FIG. 4A, according to some embodiments. In the example of FIG. 4B, contacts in two ports are visible. Similar to connector 100, connector 400 has a pair of contacts for each port. In this example, the contacts for each port are held within separate insulators, forming a terminal assembly for each port. These insulators may have the same function as described above for connector 100. For example, mating contact 410A is disposed within insulator 420A with rib 421A. Mating contact 410B is disposed within insulator 420B with rib 421B. Ribs 421A and 421B each position the respective terminal assembly relative to a respective shield 430A and 430B. Each shield and each insulator is engaged within conductive housing 440, which is further disposed within insulator housing 450.

[0045]

[0067] FIG. 5 is a perspective view of a cable connector 200 according to some embodiments. The cable connector 200 may have components similar to those described above for the board connector 100, including an outer insulating housing, an inner conductive housing that acts as a shield, and a terminal assembly within a cavity in the shield. However, the outer insulating housing may have a mating interface and latching mechanism complementary to those of the board connector 100 so that the cable connector 200 can mate with the board connector 100. Similarly, the inner conductive housing may have a mating portion configured to mate with the mating portion 146. Furthermore, the terminal assembly and other components may be configured to terminate to a cable rather than being mounted to a printed circuit board. For example, the contacts may be electrically coupled to one or more conductors of the cable.

[0046]

[0068] Figure 6 is an exploded perspective view of an exemplary cable connector 200, according to some embodiments. As shown in Figures 5 and 6, the exemplary cable connector 200 is configured to terminate a cable 210. The cable connector 200 includes a mating end 520 and a cable termination end 522 opposite the mating end. A cavity opens into the mating end 520. The connector terminates the cable at the cable termination end 522, where the cable is manipulated to facilitate termination.

[0047]

[0069] The bulk of the cable 210 may include one or more insulated conductors. In the example shown, the cable includes a pair of insulated conductors surrounded by a cable shield, which is further covered by an insulating jacket. For example, the cable shield may be a braided shield or a conductive foil. For termination, the jacket may be removed to expose the cable shield. The insulated conductors may be separated and the insulation removed at the end. For cables in which the insulated conductors are twisted together within the bulk cable, separating the insulated conductors may involve untwisting the conductors. This manipulation of the cable allows the conductors of the insulated conductors to be attached to the terminals of a connector. The cable shield may be attached to the connector shield.

[0048]

[0070] Cable connector 200 further includes a ferrule 220 and an impedance adapter 230 that may be disposed around cable 210. According to some embodiments, the impedance adapter may be metallic. Terminal 240 may be crimped onto the conductor portion of the cable. The terminal may be part of a terminal assembly (shown here as contact carrier housing 250) that includes an insulator. The conductive inner housing of the cable connector may be formed from a back shield 260 and a front shield 270 that may be electrically and mechanically coupled. Front shield 270 may include a mating interface, and back shield 260 may be crimped onto the cable and electrically coupled to the cable shield. These components may be at least partially enclosed within cable connector housing 290.

[0049]

[0071] Cable terminating components 220, 230, 240, 250, 260, and 270 shown in Figure 6 provide contact carriers. In this example, the contact carriers are provided with shields. The position of the contact carriers within the housing can be assured using a Contact Carrier Position Assurance Device (CCPA) 280.

[0050]

[0072] FIG. 7 is a cross-sectional view of the exemplary cable connector of FIG. 6 , according to some embodiments. An impedance adapter 230 is located in a separated and / or untwisted area 231 of the cable termination. This manipulated area 231 provides space for the process of crimping contacts onto the cable conductors. However, this manipulation of the cable changes the impedance of the conductors. Metal is placed near the cable to create a compensatory, opposite change in impedance. The impedance adapter brings the metal closer to the cable core. In the illustrated embodiment, the impedance adapter also contacts the rear shield, which connects the impedance adapter to ground to establish signal-to-ground spacing for the cable conductors, thereby establishing a desired impedance that matches the impedance of the bulk cable. As used herein, impedances do not need to be identical to be matched. Rather, the impedances can be close enough to avoid introducing impedance discontinuities that disrupt performance. For example, in some embodiments, the matched impedance may be within + / - 5% or + / - 3 ohms.

[0051]

[0073] To terminate cable 210, the end of the cable may be prepared for termination and inserted into ferrule 220 and impedance adapter 230. The cable shield may be folded over ferrule 220, and the conductors of cable 210 may be crimped to terminals 240. Terminals 240 may then be inserted into contact carrier housing 250. Rear shield 260 may then be crimped around ferrule 220. Front shield 270 may then engage with rear shield 260 and latch into place. These components may form a terminated cable assembly that is inserted into housing 290. Housing 290 may include an opening 292 to receive the terminated cable assembly.

[0052]

[0074] A terminated cable assembly can be latched to housing 290, such as by latching a beam within the housing to a tab extending from one of the connector shields. For example, housing 290 can include a beam 294 with a cantilevered end 291 and a latch 293 on cantilevered end 291 that extends into opening 292. Latch 293 can have a camming surface 295, and a tab on the terminated cable assembly can have a tapered forward edge. When a terminated cable assembly is inserted into housing 290, the tapered surface of the tab can engage the camming surface of latch 293, pushing latch 293 upward until the rear edge of the tab clears the camming surface. At that position, the spring force of deflected beam 294 forces the beam downward, latching the tab in place.

[0053]

[0075] Figure 7 shows a connector having one contact carrier held within an insulating housing. Such a connector may be configured to mate with a single-port board connector, such as that shown in Figure 1. By incorporating multiple contact carriers within the insulating housing, a plug connector can be constructed to mate with a multi-port connector, such as that shown in Figure 4A.

[0054]

[0076] 8 is a perspective view of an exemplary multi-port board connector 800. In this example, connector 800 has a mating interface consisting of two rows with two ports each. 8018, providing a 2x2 connector. This connector 800 may be constructed using some or all of the techniques described above in connection with board connectors 100 or 400. For example, connector 800 may include a conductive housing 802 having a mating portion 804, conductors 806 in a terminal assembly, and a front housing 808. This connector is shown mounted to a printed circuit board 810. Conductive housing 802 may be a die-cast component with a cavity having openings for receiving multiple terminal assemblies. In contrast to connector 400 (FIG. 4A), some or all of the components of connector 800 may be configured for press-fit mounting to a printed circuit board.

[0055]

[0077] FIG. 9 is an exploded perspective view of connector 800. In this view, the electrical conductor tails are visible, and these tails are press-fit, as opposed to the post-shaped tails described above. Other connector components may be adapted to provide a stable and reliable electrical and mechanical connection between components, both when the connector is mounted to a PCB and during use. For example, the insulating housing of the terminal assembly may be different from that described above. The terminal subassembly may be adapted to withstand forces exerted on the terminal assembly during mounting or to withstand vibration during use. Other board mounting mechanisms may also be used. For example, FIG. 9 shows connector 800 having hold-downs 1200 rather than mounting posts such as posts 140.

[0056]

[0078] The connector includes a conductive housing 802 having a mating portion 804. The connector 800 includes a front housing 808 that covers the mating portion 804 and includes terminal assemblies 902 and 952 within the conductive housing 802. In this example, the terminal assembly 902 is taller and configured to form the upper stage of the mating interface. In contrast, the terminal subassembly 952 is shorter and configured to form the lower stage of the mating interface. Each terminal assembly 902 includes a conductor 806 having a tail portion 906 and a mating contact 908. Each terminal assembly 902 further includes an insulator 904. The conductor 806 may be positioned within the insulator 904 with the mating contact and tail portions exposed at two opposing ends of the conductor. The connector may further include hold-downs 1200 that attach the conductive housing 802 to the printed circuit board 810. Each terminal assembly 902 may be disposed within a chamber of the conductive housing 802. Terminal subassembly 952 similarly holds conductors within conductive housing 802 , but has different dimensions than terminal subassembly 902 .

[0057]

[0079] FIG. 10A is a perspective view of a terminal assembly 902 of a compression-fit connector. Terminal assembly 902 may represent either terminal assembly 902 or 952, which may have different horizontal and / or vertical dimensions to position the mating contacts and tail portions of the conductors in desired locations. In this example, terminal assembly 902 is shown sized for use in the upper row of a 2x2 mating interface. Terminal assemblies used in the lower row may be of a similar construction with shorter horizontal and vertical dimensions. Conversely, terminal assemblies used in higher rows of connectors having more rows at the mating interface may also use similar construction techniques with longer horizontal and vertical dimensions.

[0058]

[0080] In this example, the terminal assembly is Interface and mounting interface 901Even with a right-angle configuration configured to hold mating contacts and tail portions for incorporation into a terminal assembly 902, which are at right angles to one another, terminal assembly 902 can be constructed to facilitate easy assembly of the conductors with the insulating housing of the terminal assembly. As shown, the insulating housing can include two or more interlocking parts capable of holding one or more conductors (e.g., two conductors) in a stable relationship relative to one another and to the surrounding conductive housing of the terminal assembly.

[0059]

[0081] The terminal assembly 902 may include a first insulating member 1002 and a second insulating member 1004. The first insulating member 1002 may be engaged with the second insulating member 1004. The terminal assembly 902 may include conductors 806, each having a tail portion 906, a mating contact portion 908, and an intermediate portion 1006. In this example, the mating contact portion 908 is pin-shaped. The intermediate portion 1006 may connect the mating contact portion 908 and the tail portion 906 of the conductor 806. Optionally, the first insulating member 1002 may at least partially hold a portion of the conductor 806, while the second insulating member 1004 may at least partially hold another portion of the conductor 806. These two portions may extend in orthogonal directions. In the illustrated example, the two portions extend in orthogonal directions (e.g., vertically). 10A shows a first portion 1102 of a conductor inserted through a hole extending through a first region of a first portion of insulator, with a second portion 1104 of the conductor being partially supported by a second region of the first portion of insulator.

[0060]

[0082] 10A, the second portion 1104 of the conductor is held between the first and second portions of the insulating housing. This configuration allows the conductor to be inserted into the first portion, and then the second portion of the insulating housing can be engaged with the first portion and slid into place, sandwiching the second portion of the conductor between the first and second portions of the insulating housing to support the conductor even when forces are applied to the conductor when the connector is pressed against a printed circuit board.

[0061]

[0083] Figure 10B is a perspective view of terminal assembly 902 with second insulating portion 1004 engaged with first insulating portion 1002. Figure 10C is a cross-sectional view of terminal assembly 902 taken through line CC of Figure 10B. In this view, the portion of the conductor extending through the opening in the first insulating member and the portion of the conductor sandwiched between the first insulating member and the second insulating member are visible.

[0062]

[0084] Optionally, the second insulating member may have a rounded top to match the shape of the opening in the conductive housing through which the terminal assembly is inserted.

[0063]

[0085] The conductors 806 may have press-fit tails. FIG. 10D is a cross-sectional view of the terminal assembly 902 taken along line DD in FIG. 10B. In this view, a portion of a pair of conductors 806 can be seen positioned within the channel 1110 of the second insulating member. As can be seen, the top of the channel is closed, and the surface of the second insulating member facing the first insulating member is configured in a T-shape. The second insulating member acts as a sleeve to support the conductors 806. Lateral movement of the portion of the conductor sandwiched between the first and second insulating members is prevented. Furthermore, when the terminal assembly is inserted into the chamber in the conductive housing, the upper wall of the chamber prevents upward movement of the upper portion of the second insulating member 1004. Upward movement of the conductors 806 is prevented by the closed top end of the second insulating member 1004.

[0064]

[0086] The second insulating member 1004 may be positioned as shown by engaging the second insulating member 1004 with the first insulating member 1002 after the conductor 806 has been inserted into the first insulating member 1002. In this example, the second insulating member 1004 is slid into place once engaged with the first insulating member 1002. Optionally, each press-fit pin 910 is provided with a shoulder 1012. The second insulating member 1004 may engage the shoulder area 1012 of the press-fit pin 910 to further prevent upward movement of the conductor when the tail end is pressed into the printed circuit board.

[0065]

[0087] FIG. 10E is a top view of the terminal assembly 902 of FIG. 10B. In this view, a gap 1050 between the first insulating member and the second insulating member is visible. The gap 1050 can equalize impedance along the length of the conductor 806 by introducing a low-dielectric-constant material adjacent to selected portions of the conductor 806. For example, the gap 1050 can be adjacent to a widened portion with a barb or other feature that engages with either or both of the insulating members of the terminal assembly housing. In some embodiments, the terminal subassembly can be configured for a specific impedance (e.g., 100 ohms for a differential pair). Instead of or in addition to one or more gaps, such as the gap 1050, the first insulating member and / or the second insulating member can be molded from an insulating material having a low dielectric constant, such as in the range of 2.5 or lower.

[0066]

[0088] FIG. 11 shows an exploded perspective view of terminal assembly 902 and terminal assembly 952 with press-fit conductors. These terminal assemblies may be two of the terminal assemblies in a 2×2 connector such as that shown in FIG. 8. Terminal assembly 902 is longer, and terminal assembly 952 is shorter. Each of the two terminal assemblies may include an electrical conductor 806 having a first portion 1102 and a second portion 1104. Each of the two terminal assemblies may also include a first insulating member 1002 and a second insulating member 1004. The first insulating member 1002 may be engaged with the second insulating member 1004 via a first coupling mechanism 1106 on the first insulating member 1002 and a second coupling mechanism 1108 on the second insulating member 1004. The second insulating member 1004 may have a channel 1110 for receiving the second portion 1104 of the electrical conductor 806. The first insulating member 1002 may also have channels (not shown) for receiving the first and second portions 1102, 1104 of the electrical conductor 806. The second portion 1104 of the electrical conductor may be parallel to the contact tail of the electrical conductor. The contact tail of the electrical conductor may be disposed at the mounting interface. The contact tail may be a press-fit tail. The first insulating member 1002 may have openings or holes 1112 through which the mating contacts 908 of the electrical conductor 806 may be placed.

[0067]

[0089] FIG. 12 is a side cross-sectional view of a hold-down 1200 that can be used with a press-fit connector, such as connector 800. The hold-down 1200 extends through a hole 1220 in the shelf 914 of the conductive housing 802. The hold-down 1200 is configured to hold the electrical connector to a printed circuit board (PCB). The shelf 914 of the conductive housing 802 can have a first surface 1204 and a second surface 1205. The hold-down 1200 can be blocked downwardly by the first surface 1204 of the shelf 914 of the conductive housing 802. The hold-down 1200 can be blocked upwardly by the second surface 1205 of the shelf 914 of the conductive housing 802. Thus, when a press-fit portion 1250 extending beyond the conductive housing at the lower end of the hold-down 1200 is inserted into a hole in the printed circuit board, the conductive housing 802 can be firmly held against the surface of the printed circuit board.

[0068]

[0090] The hold-down 1200 may be stamped from sheet metal. When attached to the conductive housing 802, the hold-down 1200 may include a first end 1212 that extends through the first surface 1204 of the shelf 914 of the conductive housing 802 and one or more barbs 1210 that engage the first surface 1204 of the shelf 914 of the conductive housing 802. The hold-down 1200 may also include one or more shoulders 1252 that abut the second surface 1205. Opposite the first end 1214, the hold-down 1200 may include a second end 1214 with a press-fit portion 1250 configured to be press-fit into a hole in a printed circuit board.

[0069]

[0091] To facilitate insertion of first end 1212 through hole 1220, hold-down 1200 may include a first flexible arm 1206 and a second flexible arm 1207 separated by an opening 1208 through hold-down 1200. Flexing of first arm 1206 and / or second arm 1207 toward opening 1208 may compress hold-down 1200 for insertion through hole 1220 in the shelf. Configuring the hold-down with flexible arms that can be flexed to insert the hold-down into a conductive housing, which may be made of die-cast metal, allows barb 12110 to engage surface 1204 over a relatively wide area, providing stable connector retention.

[0070]

[0092] FIG. 13A is a rear view of an exemplary conductive housing 802 of a 2x2 connector, showing a shield 1300. When a terminal assembly is inserted into a cavity of the conductive housing, one or more shields can be inserted into the cavity. Each shield can close the opening through which one or more terminals are inserted. In combination with the conductive housing, the shields provide shielding around the terminal assemblies. The shield 1300 can be positioned within the conductive housing 802 and can be electrically and mechanically engaged to the conductive housing 802. This shielding can also mechanically retain one or more terminal assemblies within the cavity of the conductive housing. In the example of FIG. 13A, two short terminal assemblies 952 are inserted before the shield 1300 is attached. In other examples, two shields, each corresponding to one terminal assembly, can be inserted.

[0071]

[0093] The shield may include one or more features that strengthen the electrical and / or mechanical connection between the shield and the conductive housing. Such features can enhance the signal integrity of the connector by urging the terminal assembly into a desired position relative to its surrounding ground structure (whether that ground structure is the conductive housing 802 or the shield itself) and / or by preventing relative movement between the terminal assembly and the ground structure.

[0072]

[0094] One such feature on the shield may be a tab cut from the shield that is bent to act as a barb that engages with the conductive housing. For example, the shield may be stamped from a stainless steel sheet or other metal sheet with similar spring properties. Thus, a tab cut from the shield and bent from the shield face to engage a corresponding feature on the conductive housing may bias the shield plate in a predetermined direction.

[0073]

[0095] FIG. 13B is an enlarged view of a portion of the shield 1300 shown in frame 13B of FIG. 13A. In this example, portion 13B includes an edge 1310 of the shield 1300. As can be seen in FIG. 13B, a tab 1302 may be cut out of the shield body at or adjacent to the edge. In this example, the tab 1302 is bent backward. When the edge of the shield is inserted into the groove of the conductive housing 806, the tab 1302 is pushed back toward the plane of the body of the shield 1300, generating a spring force against the inner surface of the groove. In this example, the tab 1302 is bent backward, urging the shield 1300 forward. In this manner, the shield urges the terminal assembly against the rearward-facing surface of the forward portion of the conductive housing. The position of the terminal assembly 952 is stably established relative to the forward inner surface of the conductive housing, and the shield 1300 can be accurately positioned near and relative to the rearward surface of the terminal assembly. Shield 1300 may include one or more other such retention features. For example, regions 13B1, 13B2, and 13B3 may each be formed with a similar tab that acts as a barb that engages with a groove in conductive housing 802.

[0074]

[0096] 14A is a perspective view of two short terminal assemblies 952 held in place by shield 1300. In this view, conductive housing 802 is shown in phantom.

[0075]

[0097] 14B shows a later manufacturing stage of the connector of FIG. 14A, in which two long terminal subassemblies 902 are inserted into conductive housing 806 and held in place with shield 1410. Shield 1410 may have the features described in connection with shield 1300, but may be a taller shield so as to cover substantially all of the back surface of taller subassembly 902. Shield 1410 may also be inserted into grooves (e.g., groove 1412 (FIG. 14A)) and may also include features along one or more of the edges that are inserted into such grooves, which may be as described above in connection with FIG. 13B.

[0076]

[0098] As another example of a feature that can be incorporated into the shield to accurately and stably position the terminal subassembly relative to the grounding structure, the shield may include a dimple 1502. FIG. 15 is a side view of portion 15 of the press-fit connector of FIG. 14A or 14B , showing a dimple 1502 on the shield 1300. The dimple 1502 may be formed as a protrusion embossed on the body of the shield. The dimple 1502 may press against the rear surface of the insulating member of the terminal assembly, in this example, the rear surface of the second insulating member 1004. The dimple 1502 on the shield 1300 may apply a force to the terminal assembly, urging the terminal assembly toward the mating portion 804 of the conductive housing 802, when the shield 1300 is inserted. This configuration ensures accurate and stable positioning of the terminal assembly 952 relative to the conductive housing 802. It should be noted that dimple 1502 may be distorted if manufacturing tolerances of one or more components cause the body of shield 1300 to be closer to terminal assembly 952 than designed, making insertion difficult or impossible.

[0077]

[0099] In connectors in which a single shield seals two or more terminal assemblies within a conductive housing, the shield may have multiple dimples, with at least one dimple aligned with each such terminal assembly. Furthermore, when multiple shields are used, such as in connectors with multiple rows, each shield may have one or more dimples. For example, although not visible in FIG. 14B , shield 1410 may have two dimples similar to dimple 1502 on shield 1300. Even in embodiments in which a single shield seals a single terminal assembly within a conductive housing, the shield may have multiple dimples that press against the terminal assembly, thereby providing a more uniform force on the terminal assembly. Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art.

[0078]

[0100] For example, the techniques described herein may be used with connectors having configurations other than those described above. For example, the techniques described herein may be used with mezzanine connectors or backplane connectors. Such alternative connector configurations may be used with all of the features described herein, or with any suitable number of sub-features. Furthermore, it should be understood that while all of the structures, materials, and construction techniques described herein may be used together, in some embodiments, some or all of the structures, materials, or techniques may be omitted.

[0079]

[0101] Such changes or modifications are intended to be part of this disclosure and are intended to be within the spirit and scope of the present invention. Moreover, although advantages of the present invention have been pointed out, it should be understood that not all embodiments of the present invention will include every described advantage. Some embodiments may not implement every feature described herein, and in some instances, as an advantage. Accordingly, the foregoing description and drawings are for illustrative purposes only.

[0080]

[0102] Various aspects of the present invention may be used alone or in combination, or in a variety of arrangements not specifically discussed in the embodiments described above, and therefore are not limited in their application to the details and arrangements of each component set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments.

[0081]

[0103] In the claims, the use of ordinal terms such as "first," "second," "third," etc. to modify claim elements does not, by itself, imply a preference, precedence, or ordering of one claim element over another, or the chronological order in which method actions are performed, but is merely used as a label to distinguish one claim element having a particular name from another element having the same name (if no ordinal term is used) and to distinguish between claim elements.

[0082]

[0104] All definitions defined and used herein should be understood to supersede dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0083]

[0105] The indefinite 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."

[0084]

[0106] As used herein and in the claims, the phrase "at least one" in reference 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 all elements specifically listed in the list of elements, nor excluding any combination of elements in the list of elements. This definition also allows for elements other than those specifically identified in the list of elements to which the phrase "at least one" refers, whether related or unrelated to those specifically identified elements, may optionally be present.

[0085]

[0107] The phrase "and / or," as used in the specification and claims, should be understood to mean "either or both" of the elements so coordinated, i.e., elements that are present in conjunction in some cases and in conjunction in other cases. Multiple elements listed with "and / or" should be interpreted similarly, i.e., "one or more" of the elements so coordinated. Other elements, whether related or unrelated to those specifically identified elements, may optionally be present other than the elements specifically identified by the "and / or" clause. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," can, in one embodiment, be a reference to A only (optionally including elements other than B); in another embodiment, a reference to B only (optionally including elements other than A); in yet another embodiment, a reference to both A and B (optionally including other elements), etc.

[0086]

[0108] As used in this specification and in the claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when items in a list are separated by "or" or "and / or," this shall be interpreted as being inclusive, i.e., including not only at least one of a number or list of elements, but also two or more of those elements, and optionally, additional unlisted items. Only terms clearly indicating 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 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 indicating 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.

[0087]

[0109] Moreover, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the use of "including," "comprising," "having," "containing," "involving," and variations thereof, is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items.

Claims

1. 1. An electrical connector comprising: a conductive housing having a chamber; a terminal assembly disposed within the chamber; The terminal assembly includes: a first insulating member; a second insulating member engaged with the first insulating member; an electrical conductor comprising a mating contact portion, a contact tail, and an intermediate portion connecting the mating contact portion and the contact tail, the electrical conductor comprising a first portion at least partially held by the first insulating member and a second portion at least partially held by the second insulating member; Electrical connector.

2. 2. The electrical connector of claim 1, wherein the second portion of the electrical conductor is disposed between the second insulating member and the first insulating member.

3. 1. An electrical connector comprising: a conductive housing having a chamber; a terminal assembly disposed within the chamber; The terminal assembly includes: an insulating housing including a first insulating member and a second insulating member; an electrical conductor having a mating contact portion extending in a first direction from the insulating housing and a contact tail extending in a second direction from the insulating housing, and having an intermediate portion connecting the mating contact portion and the contact tail, the electrical conductor having a first portion held by the first insulating member and a second portion held between the first insulating member and the second insulating member; Electrical connector.

4. 1. An electrical connector comprising: a conductive housing having a chamber; a shield member disposed within the conductive housing and electrically and mechanically engaged with the conductive housing; a terminal assembly disposed within the chamber; The terminal assembly includes: an insulating housing; an electrical conductor carried by the insulating housing; the shield member includes a dimple configured to apply a force to the terminal assembly. Electrical connector.

5. the shield member has a first side and a second side opposite the first side; the dimple extends from the first side; The electrical connector of claim 4 , wherein the shield member further comprises a flexible tab extending from the second side.

6. the conductive housing includes a groove; 6. The electrical connector of claim 5, wherein the flexible tab is at least partially disposed within the groove such that the flexible tab biases the shield member toward the terminal assembly, thereby applying a force from the shield member to the terminal assembly.

7. the insulating housing includes a first insulating member and a second insulating member; 5. The electrical connector of claim 4, wherein the electrical conductor comprises a mating contact portion extending in a first direction from the insulating housing, a contact tail extending in a second direction from the insulating housing, and an intermediate portion connecting the mating contact portion and the contact tail, and the electrical conductor comprises a first portion held by the first insulating member and a second portion held between the first insulating member and the second insulating member.

8. 1. An electrical connector comprising: a conductive housing having a chamber; a shielding member disposed within the conductive housing and removably coupled electrically and mechanically to the conductive housing, the removably coupled shielding member being separable from the conductive housing; and a terminal assembly disposed within the chamber and removably matable with the conductive housing, the terminal assembly being separate from the conductive housing; The terminal assembly includes: a first insulating member; a second insulating member engaged with the first insulating member; an electrical conductor including a mating contact portion, a contact tail, and an intermediate portion connecting the mating contact portion and the contact tail, wherein the mating contact portion extends from the first insulating member and the contact tail extends from the second insulating member; Electrical connector.

9. 9. The electrical connector of claim 8, wherein the mating contact portion extends in a first direction from the first insulating member and the contact tail extends in a second direction from the second insulating member.

10. 10. The electrical connector of claim 1, 3, 7 or 9, wherein the first direction and the second direction are substantially perpendicular to each other.

11. the electrical connector further comprising a shield member within the conductive housing, the shield member being electrically and mechanically engaged with the conductive housing; 4. The electrical connector of claim 1, wherein the second insulating member separates the shield member from the second portion of the electrical conductor.

12. 12. The electrical connector of claim 11, wherein the shield includes a protrusion that biases the second insulating member toward the first insulating member.

13. the chamber having an opening at a mating interface of the electrical connector; The electrical connector of claim 11 , wherein the projections of the shield member are configured to apply pressure to the terminal assemblies.

14. the chamber having an opening at a mating interface of the electrical connector; The electrical connector of claim 11 , wherein pressure on the terminal assembly urges the terminal assembly toward the mating interface.

15. 12. The electrical connector of claim 11, wherein the second portion of the electrical conductor is parallel to the contact tail.

16. the second insulating member includes a channel; 10. The electrical connector of claim 1, 3, 7 or 9, wherein at least a portion of the second portion of the electrical conductor is disposed within the channel.

17. the electrical connector includes a mating interface, the mating contact portion of the electrical conductor is disposed at the mating interface; 17. The electrical connector of claim 16, wherein the electrical connector comprises a mounting interface, and the contact tails of the electrical conductors are disposed in the mounting interface.

18. the channel has a first end adjacent the mounting interface and a second end opposite the first end; 18. The electrical connector of claim 17, wherein the channel is open at the first end and closed at the second end.

19. 20. The electrical connector of claim 18, wherein the first insulating member includes an opening therethrough, the first portion of the electrical conductor being disposed within the opening.

20. the channel has a first end adjacent the mounting interface and a second end opposite the first end; the channel is configured at the first end to slidably receive the second portion of the electrical conductor; 18. The electrical connector of claim 17, wherein the channel is configured at the second end to prevent the second portion of the electrical conductor from sliding out of the channel.

21. the channel has a first end adjacent the mounting interface and a second end opposite the first end; 18. The electrical connector of claim 17, wherein the electrical conductor further comprises a shoulder portion at the first end engaged within the channel.

22. 10. The electrical connector of claim 1, 3, 7 or 9, wherein the contact tails are press-fit tails.

23. the first insulating member and the second insulating member include a connecting mechanism; The electrical connector of claim 12 , wherein the second insulating member includes a channel configured to slideably receive the protrusion.

24. the first insulating member has a hole penetrating the first insulating member; the first portion of the electrical conductor is disposed within the bore; 10. The electrical connector of claim 1, 3, 7 or 9, wherein the mating contact portion of the electrical conductor extends from the first insulating member.

25. The first portion of the electrical conductor a first width for at least more than 50% of its length within the aperture; a barb having a second width greater than the first width and adapted to engage the first insulating member; 25. The electrical connector of claim 24, having a third width proximal to the barb that is narrower than the first width.

26. the conductive housing having a wall within the chamber; 9. The electrical connector of claim 4 or 8, wherein the shield member includes a retention barb that engages the wall portion, thereby positioning the shield member within the chamber of the conductive housing.

27. the electrical connector comprises a mounting interface; The conductive housing further comprises: a shelf adjacent to the mounting interface; 10. The electrical connector of claim 1, 3, 7 or 9, further comprising a hole extending through the shelf.

28. 28. The electrical connector of claim 27, wherein the electrical connector further comprises a hold-down, the hold-down extending through the hole in the shelf and configured to hold the electrical connector to a printed circuit board (PCB).

29. the shelf has a first surface and a second surface at the mounting interface opposite the first surface; The hold down a first end extending through the first surface of the shelf; 30. The electrical connector of claim 28, comprising one or more barbs that engage the first surface of the shelf.

30. 30. The electrical connector of claim 29, wherein the hold-down includes a second end opposite the first end, the second end configured to be press-fit into a hole in the PCB.

31. 30. The electrical connector of claim 29, wherein the hold-down comprises a first flexible arm and a second flexible arm separated by an opening through the hold-down, whereby the first arm and / or the second arm can flex toward the opening to compress the hold-down for insertion through the hole in the shelf.

32. 10. The electrical connector of claim 1, further comprising a second housing configured to be pressed against the conductive housing in a mating direction.

33. the first insulating member includes a first segment and a second segment orthogonal to the first segment; 10. The electrical connector of claim 1, 3, 7 or 9, wherein the second insulating member is engaged with the second segment of the first insulating member.

34. the first insulating member has an opening extending therethrough; the first portion of the electrical conductor is disposed within the opening; the second insulating member has a surface facing the second segment of the first insulating member; the second insulating member includes a recessed channel in the surface; 34. The electrical connector of claim 33, wherein the second portion of the electrical conductor is disposed within the channel.

35. the electrical conductor is a first electrical conductor; 10. The electrical connector of claim 1, 3, 7 or 9, wherein the terminal assembly includes a second electrical conductor parallel to the first electrical conductor.

36. the terminal assembly is a first terminal assembly; 36. The electrical connector of claim 35, wherein the electrical connector comprises a second terminal assembly.

37. 1. An electrical connector comprising: a conductive housing having a chamber; a terminal assembly disposed within the chamber; The terminal assembly includes: an insulating housing; an electrical conductor having a mating contact portion extending from the insulating housing and a contact tail extending from the insulating housing, the electrical conductor having an intermediate portion connecting the mating contact portion and the contact tail; a hold-down having a first end engaged with the conductive housing and a second end extending from the insulating housing, the first end comprising a first flexible arm and a second flexible arm separated by an opening; Electrical connector.

38. The hold-down further comprises: a first barb extending from the first flexible arm; 38. The electrical connector of claim 37, comprising: a second barb extending from the second flexible arm.

39. the electrical connector comprises a mounting interface; The conductive housing further comprises: a shelf adjacent to the mounting interface; a hole through the shelf; 39. The electrical connector of claim 38, wherein the first end of the hold-down extends through the hole through the shelf.

40. 40. The electrical connector of claim 39, wherein the hold-down is configured to be compressed for insertion through the hole in the shelf by deflection of the first flexible arm and / or the second flexible arm toward the opening between the first flexible arm and the second flexible arm.

41. the shelf has a first surface and a second surface at the mounting interface opposite the first surface; the first end of the hold-down extends through the first surface of the shelf; 41. The electrical connector of claim 40, wherein the first barb and the second barb engage the first surface of the shelf.

Images