High-speed, durable, miniature cable connectors

Abstract

A miniature connector, which may be a right-angle connector, economically provides high signal integrity in harsh environments such as automotive. The connector may include a contact carrier position assurance component (CCPA) that ensures that the contact carrier is latched and remains latched in its designed position, thereby improving signal integrity. The CCPA can hold the mating interface portion or contact carrier in a desired position relative to the mating direction, but is narrow enough to fit within a narrow slot perpendicular to the mating direction of the connector so as to allow the connector to extend a short distance in the mating direction beyond the mating face of the mating connector. Such a connector may also have a connector position assurance device that facilitates reliable operation of the connector.

Description

[Technical Field]

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

[0002] Electrical connectors are used in many electronic systems. It is generally easier and more cost-effective to manufacture systems as separate electronic assemblies that can be joined together with electrical connectors. Connectors can be used to interconnect assemblies so that they can work together as part of a system. For example, connectors may be mounted on printed circuit boards in two assemblies that are connected by mating connectors. In other systems, it may be impractical to join two printed circuit boards by directly mating connectors on the printed circuit boards. For example, when the system is assembled, the printed circuit boards may be too far apart to directly connect the connectors mounted on the printed circuit boards.

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

[0005] Automobiles present a harsh environment for electrical connectors. Vehicles can vibrate, which can cause connectors to unmate and fail completely. Even if the vibrations do not completely prevent the connector from operating, they can cause electrical noise, which can interfere with the operation of electronic devices joined through interconnects that include the connector. For example, noise can result from the relative motion of components within a connector, which can change the electrical properties of the connector. Variations in electrical properties cause variations in signals passing through the interconnect, which is a form of noise that interferes with the processing of the underlying signal.

[0006] In an automotive environment, electrical noise can also come from automotive components that generate electromagnetic radiation. That radiation can couple to the conductive structures of connectors and create noise on any signals passing through those conductive structures. In an automobile, several components, such as spark plugs, alternators, or power switches, can all generate electromagnetic radiation. The noise can be particularly destructive to high-speed signals, such as those used to communicate data over an automotive network. Summary of the Invention

[0007] The concepts disclosed herein may be embodied in an electrical connector comprising: (i) a housing (120) having a chamber and a first opening (128); (ii) a contact carrier having a mating portion extending in a first direction and a cable attachment portion extending in a second direction perpendicular to the first direction; (iii) the housing and contact carrier, wherein (a) the mating portion is positioned within the chamber of the housing and engaged with the housing; and (b) the mating portion has a tab (146); and (c) a position assurance component (130) configured to latch in a closed position within the first opening of the housing, wherein in the closed position the position assurance component engages with the tab (146) of the contact carrier such that the position assurance component engages with the contact carrier between the tab (146) and the cable attachment portion to retain the contact carrier within the chamber of the housing.

[0008] Optionally, the first opening may comprise a channel extending in a second direction. Optionally, the position assurance component may be configured to slide within the channel between open and closed positions and latch to the housing in the open position. Optionally, the second direction is approximately perpendicular to the first direction. That is, the electrical connector may be a right-angle connector. Optionally, the position assurance component (130) may comprise a tab (136) configured to abut against a tab (146) of the contact carrier when the position assurance component is in the closed position. Optionally, the position assurance component may comprise (i) a base (652) and (ii) a first arm (650A) and (iii) a second arm (650B) extending from the base and configured to latch to the housing, with the tab (136) extending from the base. Optionally, the tab (136) of the position assurance component is thinner than the first and second arms.

[0009] In another aspect, an electrical connector comprises: (i) a housing (120) having a chamber, a first opening (128), and a latch (122); (ii) a contact carrier having a mating portion extending in a first direction and a cable attachment portion extending in a second direction perpendicular to the first direction; (iii) the housing and contact carrier, wherein (a) the mating portion is within the chamber of the housing; (b) the contact carrier has a protrusion; and (c) the latch (122) engages with the protrusion to latch the contact carrier within the chamber of the housing; and (iv) a position assurance component (130) positioned within the first opening of the housing and configured to slide to a closed position to prevent withdrawal of the contact carrier from the chamber of the housing.

[0010] Optionally, the housing may comprise an insulating housing (160), and the latch may comprise an arm integrally molded with the insulating housing. Optionally, the electrical connector may further comprise (i) a conductive housing (150), and (ii) the contact carrier comprises (a) an insulating housing comprising a channel and a contact disposed in the channel, and (b) the conductive housing comprises a contact carrier protrusion. Optionally, the conductive housing is a die-cast member, and the conductive housing comprises an integrally formed portion of the die-cast member.

[0011] In yet another aspect, a cable assembly comprises: (i) a cable having a conductor; and (ii) an electrical connector (100) comprising: (a) an outer housing (120) having a chamber; (b) a conductive housing (150) having a portion having the chamber positioned at least partially within the chamber of the outer housing; (c) an insulating housing having a channel disposed within the chamber of the conductive housing; and (d) a contact having a mating portion disposed within the channel of the insulating housing and a tail portion attached to the conductor of the cable, wherein the conductive housing further comprises a tail portion (152) configured to support the cable.

[0012] Optionally, the cable assembly may further include (i) a one-piece seat having a first portion at least partially surrounding the tail portion and the cable. Optionally, the one-piece seat includes an outer ferrule, and the electrical connector further includes an inner ferrule disposed over the cable, with the first portion of the one-piece seat at least partially surrounding the tail portion, the cable, and the inner ferrule. Optionally, the cable includes a jacket and a shield, with the cable shield extending beyond the jacket and disposed between the inner ferrule and the outer ferrule. Optionally, the tail portion includes a stepped portion extending toward the cable, with one end of the cable shield being between and in contact with the stepped portion and the cable jacket. Optionally, the inner ferrule includes a first portion having a circular cross-section and a second portion having an elliptical cross-section, with the first portion of the one-piece seat at least partially surrounding the tail portion, the cable, and the first portion of the inner ferrule such that the shield is between and in contact with the inner ferrule and the outer ferrule around substantially the entire circumference of the first portion of the inner ferrule. Optionally, the unitary sheet comprises a second portion, the second portion at least partially surrounding the cable at a location offset from the tail.

[0013] Optionally, the chamber of the conductive housing includes an entrance, and the monolithic sheet includes a third portion covering the entrance. Optionally, the conductive housing includes at least one embossment that holds the third portion to the conductive housing. Optionally, the third portion includes a planar portion and an embossed area offset from the planar portion. Optionally, the mating portion of the contact is elongated in a first direction, the tail extends in a second direction perpendicular to the first direction, and the conductor of the cable includes a distal portion extending in the second direction within the conductive housing, the distal portion of the conductor adjacent the embossed area of ​​the third portion. Optionally, the embossed area extends into the chamber of the conductive housing, and the inner ferrule is outside the chamber of the conductive housing.

[0014] In yet another aspect, a housing subassembly for an electrical connector comprises: (i) an insulating housing (120) comprising a latch and a channel; and (ii) a connector position assurance device (CPA) (110) disposed within the channel; (iii) (a) the CPA comprising: (1) a compliant arm having a protrusion (112) extending therefrom; and (2) a distal portion; (b) the insulating housing further comprising: a stop (729) disposed within the channel and configured to engage a cam surface on the protrusion to bias the protrusion into a predetermined position; and (c) the housing subassembly configured such that a portion of the insulating housing prevents movement of the CPA beyond a predetermined position within the channel.

[0015] Optionally, the compliant arm is a first compliant arm, and the CPA further comprises a second compliant arm parallel to the first compliant arm. Optionally, the CPA further comprises (i) a first cross member connecting a first end of the first compliant arm to a first end of the second compliant arm, and (ii) a second cross member connecting a second end of the first compliant arm opposite the first end to a second end of the second compliant arm opposite the first end. Optionally, the stop may be a first stop, the protrusion is a first protrusion, the CPA comprises a second protrusion on the compliant arm, and the insulative housing comprises a second stop disposed in the channel and configured to engage the second protrusion to prevent movement of the CPA in the first direction within the channel when the CPA is in the unlocked position where the CPA is disengaged from the latch. [Brief explanation of the drawings]

[0016] The accompanying drawings are not to scale. For clarity, components may not be labeled in the drawings. [Figure 1]1 is a perspective view of an exemplary interconnection system including a board connector 100 and a cable connector 200' mated to the board connector. [Figure 2A] 2 is an exploded perspective view of an exemplary right-angle cable connector 200 that can mate with the board connector 100 of FIG. 1. FIG. [Figure 2B] 2B is a series of schematic diagrams illustrating exemplary steps of a method 200 for terminating a cable 300 with an exemplary cable connector 200 as shown in FIG. 2A to produce a cable assembly. [Figure 2C] 2C is a side view of a cable connector 200 formed by the manufacturing process of FIG. 2B. [Figure 3A] 2C is an enlarged view of the cable with ferrules and braid during the manufacturing process step of FIG. 2B. [Figure 3B] 3B is a cross-sectional view of the exemplary cable of FIG. 3A taken along line AA. [Figure 3C] 3B is a cross-sectional view of the exemplary cable of FIG. 3A along line BB. [Figure 3D] 2B is a cross-sectional view of a portion of the example cable connector 200 of FIG. 2A showing a portion of a cable termination. [Figure 4A] 2 is a perspective view of an exemplary insulating housing of an exemplary cable connector 200 showing the housing and electrical contacts of a right-angle contact carrier. FIG. [Figure 4B] 4B is a top cross-sectional view of the exemplary housing and electrical contacts of FIG. 4A. [Figure 4C] 4B is a cross-sectional view of the exemplary housing and electrical contacts of FIG. 4A with TPA 170 attached. [Figure 5A] 5B are perspective views of an exemplary right-angle contact carrier at successive steps in the manufacturing process, showing a conductive housing, an insulating housing inserted therein with contacts terminating cables within the insulating housing, and a cross-sectional view of the contact carrier taken along line CC in FIG. [Figure 5B]5B are perspective views of an exemplary right-angle contact carrier at successive steps in the manufacturing process, showing a conductive housing, an insulating housing inserted therein with contacts terminating cables within the insulating housing, and a cross-sectional view of the contact carrier taken along line CC in FIG. [Figure 5C] 5B are perspective views of an exemplary right-angle contact carrier at successive steps in the manufacturing process, showing a conductive housing, an insulating housing inserted therein with contacts terminating cables within the insulating housing, and a cross-sectional view of the contact carrier taken along line CC in FIG. [Figure 5D] FIG. 5D is a cross-sectional view of the exemplary right angle contact carrier of FIG. 5C. [Figure 6A] FIG. 5D is a side perspective view of the example contact carrier of FIG. 5C being inserted into a housing subassembly. [Figure 6B] FIG. 1 is a perspective view of a portion of an exemplary contact carrier. [Figure 6C] 1 is a cross-sectional view of an exemplary cable connector 200 with a contact carrier locked in place by a contact carrier position assurance component (CCPA) 130. FIG. [Figure 6D] FIG. 1 is a perspective view of an exemplary CCPA. [Figure 6E] FIG. 2 is a perspective view of an exemplary cable connector 200 showing the latch and CCPA. [Figure 7A] 2 is an enlarged side view of a portion of an exemplary housing subassembly of a cable connector 200 having a connector position assurance component (CPA). [Figure 7B] 7A is a perspective view of an exemplary connector position assurance (CPA) component of FIG. [Figure 7C] 7C is a cross-sectional view of the exemplary cable connector housing subassembly of FIG. 7A taken along line 7C-7C with the exemplary CPA in a first, unlocked position. [Figure 7D]7C is a cross-sectional view of the exemplary cable connector housing subassembly of FIG. 7A taken along line 7C-7C with the exemplary CPA in a second, locked position. [Figure 7E] 7B is a top perspective view of the exemplary housing subassembly of FIG. 7A with the CPA in a second, locked position. DETAILED DESCRIPTION OF THE INVENTION

[0017] The present inventors have recognized and appreciated techniques for creating connectors for providing high data rate transmission that can be manufactured economically and yet operate reliably in the harsh environments presented by automobiles. Such connectors are suitable, for example, for interconnecting assemblies within an automobile network. These techniques can be applied to modular connector systems in which sets of components can be combined to form connectors in any of a number of configurations. Costs associated with manufacturing connectors of the type described herein can be reduced by modularly designing the parts of the connector.

[0018] 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 can result from controlling the electrical properties of the signal path through the connector and / or configuring the connector to operate effectively despite the harsh automotive environment in which the connector is used. The techniques disclosed herein can provide mechanical and / or electrical stability of the conductors within the connector. These techniques can be used to produce a robust, compact right-angle cable connector with high SI.

[0019] For example, one connector configuration may be formed from an insulative outer housing that establishes at least the mating interface of the connector. The insulative outer housing may provide latching features. A component set may include insulative outer housings of complementary configurations that can be used to form two connector configurations that mate and latch together. The insulative housing may include a chamber and a channel.

[0020] A cable connector may be assembled by inserting one or more contact carriers, each terminating one or more cables within a chamber of the insulative housing. The contact carriers may have tabs that align with channels in the connector housing. Latching features on the insulative housing can engage with the contact carriers to retain them within the housing. Alternatively or additionally, a contact carrier position assurance component (CCPA) may ensure that the connector's contact carriers are properly positioned within the connector and remain properly positioned during use of the connector, despite shock and vibration that might otherwise tend to displace the contact carriers from their intended positions. Ensuring that the contact carriers are securely held in their designed positions reduces impedance discontinuities in the mated connector pair and reduces vibration-induced noise.

[0021] The CCPA can have a design that facilitates simple and reliable manufacturing of the connector. The CCPA can be latched to the insulative housing in one of multiple positions. The multiple positions can be, for example, an open position and a closed position. The CCPA can allow contact carriers to be inserted into the insulative housing while the CCPA is in the open position. These multiple contact carriers can be locked in place by moving the CCPA to the closed position.

[0022] For example, one connector configuration may be embodied as a right-angle connector to be compact and fit within a constrained space. Such a connector may include a housing having a chamber and a first opening, a contact carrier having a mating portion extending in a first direction and a cable attachment portion extending in a second direction orthogonal to the first direction, the mating portion positioned within and engaged with the chamber of the housing. The mating portion includes a tab, and a position assurance component configured to latch in a closed position within the first opening of the housing, the position assurance component engaging the tab of the contact carrier such that the position assurance component engages the contact carrier between the tab and the cable attachment portion to retain the contact carrier within the chamber of the housing.

[0023] Another connector configuration may include a housing having a chamber, a first opening, and a latch; a contact carrier having a mating portion extending in a first direction and a cable attachment portion extending in a second direction perpendicular to the first direction, the mating portion being within the chamber of the housing; and the contact carrier having a protrusion, the latch engaging the protrusion to latch the contact carrier within the chamber of the housing; and a position assurance component positioned within the first opening of the housing, the position assurance component configured to slide to a closed position preventing withdrawal of the contact carrier from the chamber of the housing.

[0024] The cable assembly may include a cable having a conductor; and an electrical connector comprising: an outer housing having a chamber; a conductive housing having a portion having the chamber positioned at least partially within the chamber of the outer housing; an insulating housing having a channel disposed within the chamber of the conductive housing; a contact having a mating portion disposed within the channel of the insulating housing; and a tail attached to the conductor of the cable, the conductive housing further comprising the tail configured to support the cable.

[0025] Additionally, a subassembly for an electrical connector may include an insulating housing having a latch and a channel; and a connector position assurance device (CPA) disposed in the channel, the CPA comprising a compliant arm having a protrusion extending therefrom and a distal portion, the insulating housing further including a stop disposed in the channel and configured to engage the protrusion to prevent movement of the CPA in the channel in a first direction when the CPA is in a locked position that prevents movement of the latch, and the housing subassembly is configured such that a portion of the insulating housing prevents movement of the CPA in the channel in a second direction opposite the first direction when the CPA is in the locked position.

[0026] The techniques described herein may be used alone or in combination and are illustrated below in the context of an interconnection system that may be used, for example, to make physical connections between assemblies in an automobile.

[0027] FIG. 1 is a perspective view of an exemplary interconnection system including a board connector 100 and a cable connector 200′ mated to the board connector. The interconnection system can be used to connect two electronic devices to each other. In some embodiments, the interconnection system 100 is used in high-data-rate transmission applications (e.g., applications involving an automotive ECU). In this example, the interconnection system comprises the board connector 100 and a cable connector 200′. In this example, the cable connector 200′ has an elongated orientation in which the cable 300 exits the housing of the connector 200′ from the rear, in a direction opposite to the direction in which the cable connector 200′ is inserted into the board connector 100 for attachment. A cable connector having the configuration shown in FIG. 1 can only be used in systems in which a clearance space 101′ exists in the front connector or board connector 100 that exceeds the length of the cable connector 200′ by a distance sufficient to accommodate the cable 300 when bent at its minimum bend radius.

[0028] However, in some scenarios, the clearance space may be insufficient to accommodate the cable connector 200′ and the cable 300 without bending the cable 300 to a radius smaller than its minimum bend radius. For example, the board connector 100 may be mounted to an ECU panel adjacent to the wall of an automobile, where clearance space 101′ is constrained. In such a scenario, a miniature right-angle cable connector 200 ( FIG. 2 ) may be used. Such a miniature connector may nevertheless have a mating interface similar to that of the cable connector 200′ so as to allow mating with the same board connector. Similarly, the miniature cable connector may have a durability and SI comparable to that of the connector 200′ so that the use of the miniature connector does not degrade system performance.

[0029] Figure 2A is an exploded perspective view of an exemplary right-angle cable connector 200 that can mate with the board connector 100 of Figure 1. The right-angle cable connector 200 can include a plug housing 120 that can be manufactured, such as by injection molding, from an insulating material such as plastic or nylon. The cable connector 200 can also include a connector position assurance (CPA) component 110 that engages with the plug housing 120.

[0030] Cable connector 200 may also include a conductive housing 150. Conductive housing 150 may be, for example, a die-cast component. In this example, conductive housing 150 has a forward portion 152 that extends into an opening in plug housing 120 when conductive housing 150 is inserted into plug housing 120.

[0031] Cable connector 200 may also include one or more additional shielding members, shown here as front shield 140. Front shield 140 may be fitted over front portion 152 of conductive housing 150 such that both front portion 152 of conductive housing 150 and front shield 140 extend into the opening in plug housing 120 to further enclose conductors 180. Shield 140 is electrically and mechanically coupled to conductive housing 150 such that shield 140 may also be grounded.

[0032] The front shield 140 may be fitted over the front portion 152 of the conductive housing 150 such that both the front portion 152 of the conductive housing 150 and the front shield 140 extend into the opening of the plug housing 120. The front shield 140 may be formed from a sheet of metal to provide shielding and may include one or more features to provide one or more functions. For example, one or more features stamped into the sheet of metal forming the front shield 140 may hold the front shield 140 to the conductive housing 150, mate the front shield 140 with corresponding conductive structure on the board connector 100, or provide one or more tabs that engage with the CCPA 130.

[0033] Some of the components of cable connector 200 may be assembled into a contact carrier that may include electrical conductors 180 that may function as signal conductors. In this example, the contact carrier is assembled with components that hold and shield electrical conductors 180 and provide a controlled impedance environment for electrical conductors 180. In this example, conductive housing 150 forms part of the contact carrier.

[0034] In this example, a pair of electrical conductors 180 is shown such that the contact carrier is 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. In this example, the mating contact portions of the electrical conductors are formed as receptacles that can receive and mate with mating contact portions of conductors (not shown) formed as pins in the board connector 100. In other examples, the mating contact portions of the electrical conductors in the cable connector 200 may be shaped as pins, blades, or have other shapes.

[0035] In this example, the tail of conductor 180 is configured to be attached to a conductor within cable 300. The conductor within cable 300 may, for example, be soldered to the tail of conductor 180. In the example of Figure 2A, the mating contact portion and the tail of conductor 180 are joined by a middle portion that bends at a right angle. As a result, cable 300 terminated to conductor 180 extends from connector 200 perpendicular to the mating direction in which connector 200 is inserted into board connector 100 for mating.

[0036] A ferrule 190 may also be included in the contact carrier to facilitate termination of the cable 300 to the contact carrier. In FIG. 2A , the ferrule 190 is shown exploded relative to its design position. The ferrule 190 may be, for example, annular, with the conductor of the cable 300 passing through an opening in the ferrule 190. The cable's shield may be folded back over the ferrule 190 and captured between the ferrule 192 and the outer ferrule 192 when the ferrule 190 is installed.

[0037] The contact carrier may also include an insulative inner housing 160 that holds mating contact portions of the conductors 180. The insulator may be shaped and sized to receive the mating contacts. For example, the contacts 180 may pass through openings in the insulative inner housing 160. The insulative housing 160 may be inserted into cavities within the conductive housing 150. In this manner, the conductive housing 150 at least partially surrounds the insulative inner housing 160, including the conductors 180 therein.

[0038] The contact carrier may also include a terminal position assurance (TPA) component 170 that may be inserted into the insulative inner housing 160 to secure the electrical contacts 180 within the insulative inner housing 160 .

[0039] The contact carrier may further include a mechanism for connecting the conductive housing 150 to ground. In this example, the outer ferrule 192 (shown unformed in FIG. 2A ) may connect the shield of the cable 300 to the conductive housing 150. By grounding the conductive housing 150, the conductive housing may act as a shield for the contact carrier that contains the pair of conductors 180 therein.

[0040] The cable connector 200 may also include a contact carrier position assurance component (CCPA) 130 that provides accurate and stable positioning of conductors such as contacts 180. The CCPA 130 ensures that the contact carrier is latched and remains latched in its designed position. The contact carrier position assurance component can be slid to a closed position to lock the contact carrier in its designed position.

[0041] FIG. 2B is a series of schematic diagrams illustrating exemplary steps of a method 200 for terminating a cable 300 with an exemplary cable connector 200, such as that shown in FIG. 2A, to produce a cable assembly. In the example of FIG. 2B, the cable is first prepared for termination. The cable may include, for example, one or more insulated conductors. In the example shown, cable 300 includes two insulated conductors 250A and 250B that are ultimately attached to contacts 180. These conductors may be surrounded by one or more layers that provide the cable with desired electrical and / or mechanical properties. Some or all of these layers may be removed and / or exposed at one end of the cable, thereby allowing electrical and / or mechanical connection to structures within the cable connector.

[0042] The insulated conductors may be wrapped in, for example, foil, which may be a thin metal foil backed with a polymer such as Mylar. The foil may mechanically hold the insulated conductors together and / or provide electrical shielding for the insulated conductors and / or provide a conductive ground path through the cable.

[0043] Instead of, or in addition to, foil, the cable may include a layer formed from a wire braid. The wire braid can provide mechanical integrity to the cable and shield the insulated conductors and ground paths. In this example, a foil and braid are used, with the foil forming the inner layer and the braid forming the outer layer.

[0044] The cable may include an outer layer that forms a jacket of the cable, which may be an insulating polymer that provides mechanical protection to the cable.

[0045] In step 202, the jacket of the cable 300 is stripped, in this example exposing the braid 304 and the foil underneath the braid.

[0046] In step 204, the inner ferrule 190 is threaded onto the cable and crimped into place. In the example of Figure 2B, the ferrule 190 has two connection sections. The larger diameter section 190A is crimped onto a portion of the cable with the jacket still in place. The smaller diameter section 190B is crimped onto the portion of the cable with the braid 304 exposed.

[0047] In step 206, the braid 304 of the portion of the cable extending beyond the smaller diameter portion 190B is folded back over the ferrule 190. In this state, the outermost layer of the portion of the cable between the ferrule 190 and the end is foil.

[0048] In step 208, the foil on the portion of the cable that extends beyond ferrule 190 is trimmed away to expose insulated conductors 250A and 250B. Portions 306 of the insulation at the ends of insulators 250A and 250B may also be removed to expose the ends of the cable conductors.

[0049] In step 210, contact 180 may be crimped onto the exposed end of the cable conductor. Contact 180 may be bent so that a mating portion of the contact extends in a first direction and a tail of the contact to which the cable conductor is attached extends in a second direction perpendicular to the first direction.

[0050] In step 212, contacts 180 are inserted into inner housing 160. In step 214, TPA 170 is inserted into inner housing 160 to secure contacts 180 within inner housing 160.

[0051] In step 216, the conductive housing 150 is assembled onto the insulating housing 160. The conductive housing 150 includes a tail portion 152 that is aligned with the portion of the cable 300 that includes the inner ferrule 190. Thus, the portion of the braid 304 that is folded over the ferrule 190 contacts the conductive housing 150 at the tail portion 152.

[0052] In step 218, the metal sheet that forms the outer ferrule 192 is wrapped around the tail 152 and inner ferrule 190. The sheet is crimped in place to provide a mechanical connection of the cable to the conductive housing 150. Alternatively or additionally, the braid 304 may be electrically connected to the conductive housing 150 by this crimping operation.

[0053] As part of the assembly process, the opening in the conductive housing 150 through which the insulative housing 160 is inserted can be covered. In the example of FIG. 2B , the metal sheet forming the outer ferrule 192 has a portion that aligns with and covers the opening. In step 220, embossments 154 are formed on each side of the conductive housing 150, as shown. The embossments 154 may be formed, for example, by a pounding operation, which can hold the portion of the metal sheet forming the outer ferrule 192 to the conductive housing 150.

[0054] In step 220, the front shield 140 is positioned over the front portion 152 of the conductive housing 150. Tabs or other features on the front shield 140 may engage recesses or other complementary features on the conductive housing 150.

[0055] The cable connectors described herein may be assembled from a housing subassembly, which may be assembled as part of the cable termination process or may be assembled at a different time and / or location. A connector manufacturer may, for example, provide the housing subassembly as part of a kit that includes some or all of the connector components shown in FIG. 2A . Step 224 illustrates assembly of the subassembly. In step 224, the CCPA 130 is slid into the plug housing 120, latching the CCPA 130 to the plug housing 120 in a first position. As shown, the CCPA 130 is latched in a first, open position that does not impede movement of the contact carrier into the housing 120. The CPA 110 also slides into the plug housing 120 and latches in the open position. In the open position, the CPA 110 is held away from a latching member that can latch the cable connector to a mating connector. In the open position, the latching member is movable to allow the cable connector to be latched and / or unlatched to a mating connector.

[0056] In step 226, the assembled contact carrier, including the front shield 140, conductive housing 150, inner housing 160, TPA 170, and contacts 180, is positioned within the right-angle plug housing 120. Latching members 122 on the plug housing 120 can engage the contact carrier assembly to retain it within the housing. A CCPA can be used to provide additional durability to prevent withdrawal of the contact carrier from the housing and to provide an indication that the contact carrier is positioned in its intended location within the housing 120. In step 228, the CCPA 130 is slid from its open position to a second, closed position within the plug housing 120. If the contact carrier is not fully seated in its designed position, portions of the contact carrier may impede the movement of the CCPA 130 as it slides toward the closed position. Therefore, if the contact carrier is misaligned, a force greater than a threshold may be required to slide the CCPA 130 to the closed position, and this large force can provide feedback to the user that the contact carrier is not properly positioned within the housing subassembly. Conversely, when the CCPA 130 is slid into the closed position, it interferes with tabs or other structure on the contact carrier, thereby securing the contact carrier within the plug housing 120 .

[0057] Figure 2C shows the resulting cable assembly formed by performing the steps of method 200 of Figure 2B. Figure 2C shows one end of the cable assembly. The opposite end of the cable assembly may be terminated in other ways, such as with another connector or by directly connecting the conductors in cable 300 to other electronic components.

[0058] Further details of the structure and operation of these components of the cable assembly are shown in the following figures. Figure 3A shows a cable having a first portion and a second portion with an inner ferrule 190 and a braid 304. The braid 304 is folded back as described with respect to step 206 of method 200 shown in Figure 2B. Figure 3B is a cross-sectional view of the first portion of the exemplary cable of Figure 3A along line AA. Figure 3C is a cross-sectional view of the second portion of the exemplary cable of Figure 3A along line BB.

[0059] As shown in Figure 3B, the exemplary cable includes insulated conductors 250A and 250B surrounded by a first portion 190B of inner ferrule 190 having an oval cross-section. As shown in Figure 3C, the second portion of the exemplary cable includes insulated conductors 250A and 250B surrounded by a second portion 190A of inner ferrule 190 having a circular cross-section.

[0060] FIG. 3D is a cross-sectional view of a cable attachment to an exemplary cable connector. As shown in FIG. 3D, the conductive housing 150 includes a tail 152 that extends parallel to the axis of the cable 300. The tail 152 includes a step 153. In this example, the step 153 is on the portion of the tail 152 that extends beyond the inner ferrule 190. In the illustrated state, the braid 304 is folded back over the ferrule 190 and can extend beyond the inner ferrule 190, thereby ensuring that the conductive housing 150 presses the braid 304 against its free end. In this example, the step 153 captures the braid 304 between the tail 152 and the jacket of the cable 300.

[0061] Additional structure of the outer ferrule 192 can also be seen in FIG. 3D. In this example, the outer ferrule 192 has multiple sections integrally formed from a single sheet of metal. Section 192A contacts and is crimped around the cable 300. Section 192A can, for example, press against the jacket of the cable 300. Section 192A can provide a mechanical connection between the connector and the cable.

[0062] The second portion 192B surrounds a portion of the cable, including the inner ferrule 190 and the conductive housing tail 152. In this example, portion 192B presses against the tail 152 over a portion of its circumference. Over the remainder of its circumference, it presses against the braid 304, which is folded back over the inner ferrule 190. The portion 192B can attach the cable to the tail 152 and press the conductive housing tail 152 against the braid 304, thereby forming an electrical connection, thereby providing both a mechanical and electrical connection between the cable and the connector.

[0063] The third portion 192C may extend over an opening in the conductive housing 150 and form a cover for the conductive housing 150.

[0064] 4A is a perspective view of an exemplary insulative inner housing 160 with electrical contacts 180 inserted therein. In this example, insulative inner housing 160 is L-shaped with two orthogonal channels to receive electrical contacts 180 after bending them, as described above in connection with step 210.

[0065] Figure 4A shows electrical contact 180 partially inserted into inner housing 160. Figure 4B is a top cross-sectional view showing electrical contact 180 fully inserted into inner housing 160. As can be seen, electrical contact 180 has features that engage with an inner wall 410 of inner housing 160. Inner wall 410 has a hole through which contact 180 is inserted. Contact 180 includes features that engage on either side of wall 410 and lock the contact axially relative to wall 410.

[0066] In this example, these features include spring fingers 412 cut out of contact 180. Spring fingers 412 can be pressed into the body of contact 180 to insert contact 180 through a hole in wall 410 and can spring outward on a second side of the wall to prevent contact 180 from being pulled through the hole from its designed position. Alternatively or additionally, contact 180 can have a dimple 182. The dimple fits within slot 162 on the first side of the wall. The interference between the dimple and the first side of the wall prevents contact 180 from being inserted beyond its designed position.

[0067] Figure 4C is a cross-sectional view of the exemplary insulating housing of Figure 4A. As shown in these figures, dimple 182 is disposed within slot 162. The engagement between the dimple and the slot also prevents rotation of contact 180 from its designed orientation.

[0068] In this example, electrical contact 180 has a mating portion elongated in a first direction and a tail portion extending in a second direction perpendicular to the first direction, as shown in FIG. 4A. The mating portion of electrical contact 180 slides through a channel in inner housing 160 such that dimple 182 of electrical contact 180 is disposed within slot 162. Optionally, the contact carrier may include a terminal position assurance component (TPA) 170 positioned to prevent withdrawal of dimple 182 from slot 162, as shown in FIGS. 4B and 4C. In this example, TPA 170 includes two compliant arms that latch under a ledge in the inner insulating housing.

[0069] 5A-5D show further details of the assembly of the insulating housing with the contacts 180 secured thereto to the conductive housing 150. FIGS. 5A, 5B, and 5C are perspective views of an exemplary right-angle contact carrier. As shown in these figures, the conductive housing 150 can have a chamber 510 that receives the insulating housing. The conductive housing 150 can be open at the rear, providing an entrance to the chamber 510 through which the insulating housing can be inserted. The one-piece sheet forming the outer ferrule 192 can have a third portion 192C that covers the entrance after the insulating housing is inserted. Optionally, the conductive housing 150 can include at least one embossment 154 that extends into the entrance to the conductive housing 150 and prevents removal of portion 192C. The embossment 154 can be formed, for example, by pounding, which deforms the conductive housing 150 after portion 192C is in place to cover the entrance. Alternatively, conductive housing 150 may have embossments 154 formed therein, such as by die casting, before portion 192C is positioned over the inlet. In this latter scenario, portion 192C may be slid into position beneath embossments 154. Optionally, as also shown in FIG. 5C , embossments 154 may be positioned on opposite sides of conductive housing 150.

[0070] The third portion of the monolithic sheet may include a planar portion 155 and an offset region 142, as shown in FIG. 5C. In this example, region 142 may be formed by embossing the metal sheet. The embossed region 142 can improve signal integrity at the electrical contact 180. As shown in FIG. 5D, a cross-sectional view of an exemplary right-angle contact carrier, the embossed region 142 varies the spacing between the contact 180 and portion 192C. When the outer ferrule 192 is grounded, the embossed region 142 varies the signal-to-ground spacing in a limited area of ​​the contact 180. Such a configuration can compensate for impedance changes resulting from crimping the contact 180 to the cable conductors or other features that, without compensation, result in impedance changes that degrade signal integrity.

[0071] Optionally, electrical contact 180 of cable 300 includes a distal portion that extends into conductive housing 150, the distal portion adjacent embossed area 142 of the third portion of the monolithic sheet, as shown in Figures 5B and 5C. Optionally, embossed area 142 extends into chamber 510 of conductive housing 150, and inner ferrule 170 is outside the chamber of the conductive housing.

[0072] Based on the foregoing description, it can be understood that optionally, the one-piece sheet includes a first portion that at least partially surrounds the tail of the electrical contact 180 and the cable 300. Optionally, the one-piece sheet includes an outer ferrule 192. Optionally, the inner ferrule 190 is disposed over the cable 300. Preferably, the first portion of the one-piece sheet at least partially surrounds the tail of the electrical contact 180, the cable 300, and the inner ferrule 192. Optionally, the cable 300 includes a jacket 302 and a shield that may extend beyond the jacket and may be disposed between the inner ferrule 190 and the outer ferrule 192. Optionally, the tail of the electrical contact 180 includes a stepped portion extending toward the cable 300, and one end of the cable shield is between and in contact with the stepped portion and the cable jacket 302.

[0073] Optionally, a first portion of the one-piece seat at least partially surrounds the tails of the electrical contacts 180, the cable 300, and the first portion of the inner ferrule 190 such that the shield is between and in contact with the inner ferrule 190 and the outer ferrule 192 around substantially the entire circumference of the first portion of the inner ferrule 190. Optionally, the one-piece seat includes a second portion that at least partially surrounds the cable 300 at a location offset from the tails of the electrical contacts 180.

[0074] Figure 6A is a side perspective view of the exemplary contact carrier of Figure 5C being inserted into a housing subassembly 600. As shown in this figure, the contact carrier is an assembly having a front shield 140, a conductive housing 150, and electrical contacts 180 shielded by an outer ferrule 192 and terminated to a cable 300. This subassembly is inserted through the rear of the right-angle plug housing 120 to position the front shield 140, which surrounds the mating contact portions of the contacts 180, at the mating interface of the connector. As further shown in Figure 6A, the contact carrier includes a mating portion 610 extending in a first direction and a cable-mounting portion 612 extending in a second direction orthogonal to the first direction, such that the mating portion is positioned within a chamber of the right-angle plug housing 120 and engaged with the plug housing 120 via the latch 122.

[0075] Housing subassembly 600 can include contact carrier position assurance component (CCPA) 130. In the example of Figure 6A, the CCPA is latched at a first position within housing subassembly 600 where a portion of the CCPA extends from housing 120. This first position is an open position where the portion of CCPA 130 that can block movement of the contact carrier into or out of housing subassembly 600 is pulled out a sufficient distance so as not to interfere with movement of the contact carrier.

[0076] Figure 6B is a perspective view of a portion of the example contact carrier of Figure 6A. Figure 6B shows front shield 140 held to the insulating housing with tab 644 bent into recess 544 (Figure 5A) in conductive housing 150. Tab 644 may be formed, for example, by cutting out a metal sheet formed on front shield 140. Although only one such tab is shown, the contact carrier may have two or more such features to hold front shield 140 to conductive housing 150.

[0077] The contact carrier may include one or more other features that position and / or secure the contact carrier in its designed position. For example, FIG. 6B shows that the contact carrier includes tab 146. Tab 146 can engage with CCPA 130 when mating portion 610 is inserted into its designed position within housing subassembly 600 and CCPA 130 is pressed into the closed position. Tab 146 is formed as part of conductive housing 150 in this example. The conductive housing may be formed, for example, by die casting, and tab 146 may be formed as part of that operation. Alternatively, the tab may be formed from the metal sheet used to form front shield 140.

[0078] FIG. 6C is a cross-sectional view of an example cable connector 200 with a contact carrier locked in place by CCPA 130. As seen in this example, CCPA 130 is inserted into a channel in housing 120. In the state shown in FIG. 6C, CCPA 130 has been pushed further into the channel and is in a closed position. In this state, tab 136 of CCPA 130 is aligned with tab 146 in the direction in which the contact carrier is inserted into or removed from housing 120. When the CCPA is pushed into this second, closed position after the contact carrier has been inserted into housing 120 to its designed position, tab 136 interferes with tab 146, preventing the contact carrier from being moved out of its position within housing 120.

[0079] FIG. 6D is a perspective view of an exemplary contact carrier position assurance (CCPA) component.

[0080] FIG. 6E is a perspective view of the exemplary cable connector 200 showing the latch and CCPA.

[0081] As shown in FIGS. 6A-6E , the mating portion 610 of the contact carrier may optionally include a tab 146, and the position assurance component 130 may be configured to latch in a closed position within the first opening 128 of the plug housing 120, with the position assurance component 130 engaging the tab 146 of the contact carrier in the closed position to retain the contact carrier within the chamber of the housing 120. As shown in FIGS. 6C and 6D , the position assurance component 130 may engage the contact carrier between the tab 146 and the cable attachment portion of the contact carrier. The first opening 128 may include a channel for access to the position assurance component 130, and the position assurance component 130 may be configured to slide within the channel between an open position and a closed position. The position assurance component 130 may be configured to latch to the plug housing 120 in the open and / or closed positions. The channel provided by the first opening 128 in the plug housing 120 for access to the position assurance component 130 may extend in a direction approximately perpendicular to the direction of another channel 670 in the plug housing 120 configured to receive the mating portion 610 of the contact carrier.

[0082] As shown in FIG. 6D , the position assurance component 130 may include a tab 136 configured to abut against a tab 146 on the contact carrier front shield 140 when the position assurance component 130 is in the closed position. As further shown in FIG. 6D , the position assurance component 130 may include a base 652 and first and second arms 650A and 650B extending from the base 652 and configured to latch onto the housing. In the example shown in FIGS. 6C and 6D , the tab 136 of the position assurance component 130 is thinner than the first and second arms 650A and 650B of the position assurance component 130. Such a configuration can result in a more compact connector. As further shown in FIG. 6D , the CCPA 130 has a first side and a second side opposite the first side. The CCPA 130 may be inserted into the insulative housing 120 with the first side facing the cable attachment portion 612 of the contact carrier, such that the tabs 136 of the CCPA 130 are adjacent the first side and offset from the second side. The tabs 136 of the CCPA 130 may be configured to engage the contact carrier and retain it within the chamber of the plug housing 120.

[0083] Optionally, as shown in FIGS. 7A and 7E , the insulative housing 120 may include a latch 700 configured to latch the cable connector 200 to a mating connector, such as the board connector 100 ( FIG. 1 ). The cable connector 200 may include a connector position assurance component (CPA) 110 that, while compact, ensures a secure and reliable connection between the cable connector 200 and the board connector. The CPA 110 may be configured to slide between an open state and a closed state. In the closed state, the CPA 110 may be configured to prevent deflection of the latch 700 in a direction that would unlatch the cable connector 200 from the board connector 100. When the CPA 110 is in the open position, the CPA does not interfere with the movement of the latch 700, allowing the latch 700 to latch or unlatch.

[0084] 7A is an enlarged side view of a portion of the housing subassembly of the exemplary cable connector 200, showing the latch 700 and the CPA 110. As shown, the CPA 110 is in an open position. The top surface 712 of the CPA 110 is offset from the distal end 710 of the latch 700. Thus, the latch 700 is not prevented by the CPA 110 from flexing so that it can engage and disengage complementary latch features in the mating connector.

[0085] 7A , CPA 110 can be held in an open state by engaging one or more features of CPA 110 with complementary engagement features on connector housing 120. For example, in the open state, member 730 fits within notch 702 in housing 120. In this example, the walls of notch 702 are generally perpendicular to direction 704 in which CPA 110 can slide between the unlocked and locked states within the channel of housing 120, such that a relatively large force is required to slide CPA 110 in direction 704 without first removing member 730 from notch 702. In this example, member 730 is at the distal end of arms 732 and 734 and can bend when a downward force 706 is applied thereto. Thus, these engagement features can be disengaged by a user pushing member 730 in direction 706.

[0086] FIG. 7A also shows other engagement features that may be used instead of or in addition to member 730 and notch 702. Alternatively or additionally, protrusion 112 may be included. Protrusion 112 is on compliant arm 111. In the open state shown in FIG. 7A , the front surface of protrusion 112 abuts stop 729 on housing 120. The front surface is cammed so that if CPA 110 is pushed forward with sufficient force, its cam surface generates a lateral force that deflects arm 111 until protrusion 112 clears stop 729. CPA 110 can then slide forward until member 730 abuts wall 703 ( FIG. 6C ) of housing 120. In this position, protrusion 112 clears stop 729, allowing arm 111 to relax from its deflected state, with protrusion 112 on the opposite side of stop 729 (as shown in FIG. 7D ). The protrusion 112 and the stop 729 can be configured such that when the protrusion 112 is opposite the stop 729, the CPA 110 is in its closed position, as shown in FIG. 7E, in which the surface 712 of the CPA 110 prevents movement of the distal end 710 in a direction that latches or unlatches it from the mating connector.

[0087] Arm 111 may be dimensioned such that the force on CPA 110 in sliding direction 704 required to generate sufficient cam force at the interface between protrusion 112 and one side of stop 729 to deflect arm 111 exceeds a threshold, but is not low enough as a force that could be generated by a human user attempting to slide CPA 110 (if these engagement features are present) into a locked state while holding member 730 to disengage from notch 702.

[0088] Alternatively or additionally, protrusion 114 may be included on CPA 110. For example, when CPA 110 is in the open (i.e., unlocked) position shown in FIG. 7A , protrusion 714 is shown abutting stop 728. As seen in FIG. 7B , protrusion 114 may have a surface facing stop 728 that is perpendicular to sliding direction 704. Unlike protrusion 112, such a surface generates little or no camming force in response to a force on CPA 110 that urges protrusion 114 toward stop 728. In this example, protrusion 114 and stop 728 are positioned to contact when CPA 110 is in its open position. Because little or no camming force is generated at that interface, little force is generated to move protrusion 114 in a direction that allows it to pass through stop 728. Thus, protrusion 114 and stop 728 interact to block CPA 110 from moving rearward in sliding direction 704 enough to be removed from housing 720. Rather, to remove CPA 110, a user can insert a tool into the opening between stops 728 and 729 and push directly on arm 111 to flex the arm sufficiently so that protrusion 114 passes through stop 728.

[0089] Optionally, the CPAs described herein can be actuated with a bistable latching mechanism that tends to position the CPA in either an open (e.g., unlocked) or closed (e.g., locked) position. Such a bistable latching mechanism can bias the CPA 110 out of a position that is neither open nor closed. Preventing the CPA from being in such a position can reduce actuation errors that can result from improperly securing the connector to a mating connector. For example, because both sides of the protrusion 112 are cammed, a force exerted by the arm 111 to bias the protrusion 112 toward the stop 729 can generate a force that biases the protrusion 112 to one side or the other of the stop 729. Because the one-side or the other-side positions correspond to the open and closed positions of the CPA, this force is generated when the CPA is between the open and closed positions, biasing the CPA to either the open or closed position. Other features can prevent the CPA from being pushed further into the housing than its designed closed position and / or from being pulled out of the housing beyond its designed open position. For example, protrusion 114 interacting with stop 728 can limit withdrawal of CPA 110 beyond the open position. Alternatively or additionally, protrusion 112 and wall 727 bounding the channel through which CPA 110 slides may cooperate to generate a camming force that biases CPA 110 back into its designed locked position if over-inserted.

[0090] Alternatively or additionally, the above-described structure may be used to provide audible feedback to the user. As described above, when CPA 110 is between the open and closed positions, the force generated by the cam surface of protrusion 112 interacting with stop 729 deflects arm 111. When CPA 110 slides to the closed or open position, the force stops and arm 111 can return to its undeflected state with enough force to produce a clock-like sound, which can serve as audible feedback to the user that the CPA is in a predetermined position, such as the open or closed position.

[0091] FIG. 7B is a perspective view of the example CPA 110 of FIG. 7A. FIG. 7B illustrates that the CPA 110 can be symmetrical, such that the features described above in connection with FIG. 7A can be present on both sides of the connector housing. FIG. 7C is a cross-sectional view of the example cable connector housing subassembly of FIG. 7A along line 7C-7C, with the example CPA 110 in a first, unlocked position. A second arm 113, symmetrical to arm 111, is visible in this view. FIG. 7D is a cross-sectional view of the example cable connector housing subassembly of FIG. 7A along line 7C-7C, with the example CPA 110 in a second, locked position. FIG. 7E is a top perspective view of the example cable connector housing subassembly of FIG. 7A, with the CPA in a second, locked position.

[0092] 7B and 7C , connector position assurance device (CPA) 110 may include a first compliant arm 111 having a first protrusion 112 and a second protrusion 114 extending therefrom, which may be disposed within a channel in insulative housing 120. CPA 110 may also include a second compliant arm 113 parallel to first compliant arm 111 and also including first and second protrusions. CPA 110 may also include a first cross member 115 connecting a first end of first compliant arm 111 to a first end of second compliant arm 113, and a second cross member 117 connecting a second end of first compliant arm 111 (opposite the first end) to a second end of second compliant arm 113 (opposite the first end).

[0093] Optionally, as shown in FIGS. 7A , 7C , 7D, and 7E , insulative housing 120 may include a first stop 729 disposed within the channel and configured to engage a first protrusion 112 on compliant arm 111 of CPA 110. When CPA 110 is in the locked position, movement of CPA 110 in a second direction opposite the first direction may be prevented within the channel of insulative housing 120. Optionally, insulative housing 120 may also include a second stop disposed within the channel and configured to engage a second protrusion 114 on compliant arm 111 of CPA 110 to prevent movement of the CPA in the first direction within the channel when the CPA is in the unlocked position where the CPA is disengaged from the latch.

[0094] Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art.

[0095] For example, the contact carrier position assurance component 130 may include other types of latching features for engaging the connector housing in the open and / or closed positions.

[0096] As another example, the techniques described herein may be used with connectors having configurations other than those described above.

[0097] Such alternative connector configurations may be used with all of the features described herein, or with any suitable subset of the features. Further, 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.

[0098] 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, while advantages of the present invention may be noted, it should be understood that not all embodiments of the present invention include all described advantages. Some embodiments may not implement every feature described herein and in some instances as advantageous. Accordingly, the foregoing description and drawings are by way of example only.

[0099] Various aspects of the invention may be used alone, in combination, or in various arrangements not specifically described in the foregoing embodiments, and are therefore not limited in application to the details and arrangements of components set forth in the foregoing description or shown in the drawings. For example, aspects described in one embodiment can be combined in any manner with aspects described in other embodiments.

[0100] The use of ordinal numbers such as "first," "second," and "third" in the claims to modify claim elements does not, in and of itself, imply that one claim element has a priority, precedence, or order relative to another claim element, or a chronological order in which method operations 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 (absent the use of ordinal terms) to distinguish claim elements.

[0101] 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.

[0102] 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."

[0103] As used in this specification and claims, the phrase "at least one" referring to a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, and does not necessarily include at least one of each of every element specifically listed in the list of elements, nor does it exclude any combinations 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, to optionally be present, whether or not related to those elements specifically identified.

[0104] The phrase "and / or," as used in the specification and claims, should be understood to mean "either or both" of the elements so conjoined, i.e., elements that may be present conjunctively or disjunctively. Multiple elements listed with "and / or" should be construed in the same manner, i.e., "one or more" of the elements so conjoined. Other elements other than the elements specifically identified by the "and / or" clause may optionally be present, whether or not they are related to those elements specifically identified. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," may refer in one embodiment to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements), etc.

[0105] As used herein and in the claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be interpreted as inclusive, i.e., including at least one, but also including more than one, of a number of elements or list of elements, and optionally including 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," refer to the inclusion of exactly one element of a number of elements or list of elements. Generally, the term "or" as used herein should be interpreted as indicating exclusive alternatives (i.e., "one or the other but not both") only when preceded by terms of exclusivity, such as "either," "one of," "only one of," or "exactly one of." As used in the claims, "consisting essentially of" shall have its ordinary meaning as used in the field of patent law.

[0106] Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," "having," "containing," "involving," and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items.

Claims

1. a cable having a conductor; an electrical connector; The electrical connector comprises: an outer housing having a chamber; a conductive housing having a portion with a chamber positioned at least partially within the chamber of the outer housing; an insulating housing including a channel disposed within the chamber of the conductive housing; a contact comprising a mating portion disposed within the channel of the insulating housing and a tail attached to the conductor of the cable; The conductive housing further comprises a tail configured to support the cable.

2. The cable assembly of claim 1 , further comprising a unitary sheet comprising a first portion at least partially surrounding the tail and the cable.

3. the unitary seat comprises an outer ferrule; the electrical connector further comprising an inner ferrule disposed over the cable; The cable assembly of claim 2 , wherein the first portion of the unitary sheet at least partially surrounds the tail, the cable, and the inner ferrule.

4. The cable comprises a jacket and a shield; 4. The cable assembly of claim 3, wherein the shield of the cable extends beyond the jacket and is disposed between the inner ferrule and the outer ferrule.

5. the tail includes a stepped portion extending toward the cable; one end of the shield of the cable is located between and in contact with the stepped portion and the jacket of the cable; The cable assembly of claim 4 .

6. the inner ferrule comprising a first portion having a circular cross section and a second portion having an elliptical cross section; 5. The cable assembly of claim 4, wherein the first portion of the monolithic sheet at least partially surrounds the tail, the cable, and the first portion of the inner ferrule such that the shield is between and in contact with the inner and outer ferrules around substantially the entire circumference of the first portion of the inner ferrule.

7. the unitary sheet comprises a second portion; The cable assembly of claim 2 , wherein the second portion at least partially surrounds the cable at a location offset from the tail.

8. the chamber of the conductive housing includes an inlet; The cable assembly of claim 7 , wherein the unitary sheet includes a third portion covering the inlet.

9. The cable assembly of claim 8 , wherein the conductive housing includes at least one embossment that retains the third portion to the conductive housing.

10. The cable assembly of claim 8 , wherein the third portion comprises a planar portion and an embossed area offset from the planar portion.

11. the mating portion of the contact is elongated in a first direction and the tail extends in a second direction perpendicular to the first direction; the conductor of the cable includes a distal portion extending in the second direction within the conductive housing; The cable assembly of claim 10 , wherein the distal portion of the conductor is adjacent the embossed area of ​​the third portion.

12. an embossed area extending into the chamber of the conductive housing; The cable assembly of claim 11 , wherein an inner ferrule is outside the chamber of the conductive housing.

13. a housing having a chamber, a first opening, and a latch; a contact carrier including a mating portion extending in a first direction and a cable attachment portion extending in a second direction perpendicular to the first direction; a position assurance component; the mating portion is within the chamber of the housing; the contact carrier includes a protrusion; the latch engages the protrusion to latch the contact carrier within the chamber of the housing; The position assurance component is positioned within the first opening of the housing and configured to slide to a closed position that prevents withdrawal of the contact carrier from the chamber of the housing.

14. 14. The electrical connector of claim 13, wherein the housing comprises a dielectric housing and the latch comprises an arm integrally molded with the dielectric housing.

15. Further comprising a conductive housing; the contact carrier comprises an insulating housing having a channel and a contact disposed within the channel; The electrical connector of claim 14 , wherein the conductive housing comprises the protrusions of the contact carrier.

16. the conductive housing is a die-cast member; 16. The electrical connector of claim 15, wherein said conductive housing comprises an integrally formed portion of said die-cast member.

17. 14. The electrical connector of claim 13, wherein the first opening comprises a channel extending in the second direction.

18. the position assurance component is configured to slide within the channel between an open position and the closed position; 18. The electrical connector of claim 17, wherein the position assurance component is configured to latch onto the housing in the open position.

19. 14. The electrical connector of claim 13, wherein the second direction is substantially perpendicular to the first direction.

20. 14. The electrical connector of claim 13, wherein the position assurance component includes a tab configured to abut the tab of the contact carrier when the position assurance component is in the closed position.

21. The position assurance component comprises: A base and a first arm and a second arm extending from the base and configured to latch to the housing; 21. The electrical connector of claim 20, wherein the tab extends from the base.

22. 22. The electrical connector of claim 21, wherein the tab of the position assurance component is thinner than the first arm and the second arm.

23. the position assurance component has a first side and a second side opposite the first side; the position assurance component is positioned such that the first side faces the cable attachment portion; 23. The electrical connector of claim 22, wherein the tab is adjacent the first side and offset from the second side.

24. the contact carrier includes a shield, the shield includes a tab; 14. The electrical connector of claim 13, wherein the position assurance component comprises a tab configured to engage the tab to retain the contact carrier within the chamber of the housing.

25. the contact carrier comprises at least one electrical contact; 25. The electrical connector of claim 24, wherein the electrical connector is in combination with a cable, the cable including a jacket surrounding the at least one electrical contact, the jacket having an oval cross section.

26. a die-cast member having at least one step positioned within the chamber of the housing; a shield; and 26. The electrical connector of claim 25, wherein the cable includes a braid, and the step ensures that the die-cast member presses against the braid.

27. the contact carrier includes an inner housing with a slot; the electrical contacts include dimples; 27. The electrical connector of claim 26, wherein the dimple is disposed within the slot.

28. 28. The electrical connector of claim 27, wherein the contact carrier further comprises a terminal position assurance component positioned to prevent withdrawal of the dimple from the slot.

29. a second position assurance component having a first protrusion; the housing further comprising a shelf having a first side and a second side; 14. The electrical connector of claim 13, wherein the first protrusion is positioned against the first side of the ledge of the second position assurance component to secure the second position assurance component within the housing.

30. the second position assurance component includes a second protrusion; 30. The electrical connector of claim 29, wherein the second protrusion is positioned against the second side of the ledge of the second position assurance component to further secure the second position assurance component within the housing.

31. a housing having a chamber and a first opening; a contact carrier including a mating portion extending in a first direction and a cable attachment portion extending in a second direction perpendicular to the first direction; a position assurance component; the mating portion is positioned within the chamber of the housing and engaged with the housing; The mating portion includes a tab. the position assurance component is configured to latch in a closed position within the first opening of the housing; In the closed position, the position assurance component engages the tab of the contact carrier to retain the contact carrier within the chamber of the housing such that the position assurance component engages the contact carrier between the tab and the cable attachment portion.

32. 32. The electrical connector of claim 31, wherein the first opening comprises a channel extending in the second direction.

33. the position assurance component is configured to slide within the channel between an open position and the closed position; 33. The electrical connector of claim 32, wherein the position assurance component is configured to latch onto the housing in the open position.

34. 32. The electrical connector of claim 31, wherein the second direction is substantially perpendicular to the first direction.

35. 32. The electrical connector of claim 31, wherein the position assurance component includes a tab configured to abut the tab of the contact carrier when the position assurance component is in the closed position.

36. The position assurance component comprises: A base and a first arm and a second arm extending from the base and configured to latch to the housing; 36. The electrical connector of claim 35, wherein the tab extends from the base.

37. 37. The electrical connector of claim 36, wherein the tab of the position assurance component is thinner than the first arm and the second arm.

38. the position assurance component has a first side and a second side opposite the first side; the position assurance component is positioned such that the first side faces the cable attachment portion; 38. The electrical connector of claim 37, wherein the tab is adjacent the first side and offset from the second side.

39. the contact carrier includes a shield, the shield includes the tab; 32. The electrical connector of claim 31, wherein the position assurance component comprises a tab configured to engage the tab to retain the contact carrier within the chamber of the housing.

40. the contact carrier comprises at least one electrical contact; 34. The electrical connector of claim 33, wherein the electrical connector is in combination with a cable, the cable comprising a jacket surrounding at least one conductor and a shielding layer between the jacket and the at least one conductor.

41. a die-cast member having a tail portion; 41. The electrical connector of claim 40, wherein the die-cast member is attached to the cable with the tails pressing against the exposed portions of the shielding layer.

42. the contact carrier includes an inner housing with a slot; the electrical contacts include dimples; 41. The electrical connector of claim 40, wherein the dimple is disposed within the slot.

43. 43. The electrical connector of claim 42, wherein said contact carrier further comprises a terminal position assurance component positioned to prevent withdrawal of said dimple from said slot.

44. a second position assurance component having a first protrusion; the housing further comprising a shelf having a first side and a second side; 32. The electrical connector of claim 31, wherein the first protrusion is positioned against the first side of the ledge of the second position assurance component to secure the second position assurance component within the housing.

45. the second position assurance component includes a second protrusion; 45. The electrical connector of claim 44, wherein the second protrusion is positioned against the second side of the ledge of the second position assurance component to further secure the second position assurance component within the housing.

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