High-speed, durable connectors

Abstract

A modular connector is provided that economically provides high signal integrity in harsh environments, such as automotive. The connector may include structures that provide accurate and stable positioning of conductors, such as contacts. These structures may include a contact carrier position assurance component (CCPA) that ensures that contact carriers are latched and remain latched in their designed positions. The contact carrier position assurance component may slide to a closed position to simultaneously lock multiple contact carriers in their designed positions. In an unsealed connector, the CCPA may slide into the connector housing transverse to the direction in which the contact carriers are inserted into the housing. In a sealed connector, the CCPA may slide to a closed position in the same direction as the contact carriers are inserted, facilitating sealing 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 a system as separate electronic subassemblies that can be joined together with electrical connectors. Connectors can be used to interconnect assemblies so that they can operate together as part of a system. For example, connectors can be mounted on printed circuit boards in two assemblies that are connected by mating connectors. In other systems, it can be impractical to join two printed circuit boards by directly mating mating connectors on the printed circuit boards. For example, when the system is assembled, the printed circuit boards may be separated by a distance that is too great for a direct connection between 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 vehicle includes electronic control units (ECUs) for controlling various vehicle systems, such as the engine, transmission (TCU), 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 with cables routed between these assemblies. To simplify automobile manufacturing, the assemblies may be formed separately and then connected via cables that terminate in connectors that terminate other cables or allow connection to mating connectors mounted on printed circuit boards within the assemblies.

[0005] Automobiles create a harsh environment for electrical connectors. Automobiles can vibrate, potentially causing connectors to unmate and shut down completely. Even if the vibrations don't completely prevent the connector from operating, they can create electrical noise, which can interfere with the operation of electronic devices joined through interconnections that include the connector. For example, noise can result from relative movement of components within a connector, which can change the electrical characteristics of the connector. Variations in electrical characteristics cause variations in signals passing through the interconnection, which is a form of noise that interferes with the processing of the underlying signals.

[0006] In an automotive environment, electrical noise can also originate 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. Any of several components in an automobile, such as spark plugs, alternators, or power switches, can generate electromagnetic radiation. The noise can be particularly destructive to high-speed signals, such as those used to communicate data over automotive networks. Summary of the Invention

[0007] The concepts disclosed herein may be embodied as an electrical connector comprising: (i) an insulating housing having a chamber and a channel; (ii) a position assurance component having an opening with a channel and a surface adjacent to the channel; and (iii) a contact carrier having a tab, wherein the position assurance component is slidably mounted within the insulating housing and configured to slide between an open position in which the channel of the insulating housing, the channel of the position assurance component, and the tab on the contact carrier are aligned, and a closed position in which the surface of the position assurance component is aligned with the channel of the insulating housing.

[0008] In another aspect, an electrical connector may include (i) an insulating housing having a chamber; (ii) a position assurance component having an opening and a surface; and (iii) a contact carrier having a tab (1611) positioned within the chamber, the contact carrier extending through the opening in the position assurance component, the position assurance component positioned such that the surface interferes with the tab on the contact carrier to prevent the contact carrier from being pulled out of the chamber in the insulating housing and the opening in the position assurance component.

[0009] In yet another aspect, the electrical connector subassembly may include (i) an insulating housing (1609) having a chamber (1622) with a channel (1628), and a position assurance component (1630) having a channel (1626) and an opening (1631) having a surface adjacent to the channel, the position assurance component being slidably mounted within the insulating housing to slide between an open position in which the channel (1628) of the insulating housing (1609) and the channel (1626) of the position assurance component are aligned, and a closed position in which a surface of the position assurance component is aligned with the channel (1628) on the insulating housing (1609), and the position assurance component (1630) includes a latch configured to engage with a complementary structure within the insulating housing when the position assurance component is in the open position.

[0010] In yet another aspect, a method of operating an electrical connector comprising an insulating housing (1603) having a chamber (1612) and a latch (1654) protruding into the chamber, and a position assurance component (1650) having a body with an opening (1652) therethrough and a protruding member, the method including: i) sliding a contact carrier through the opening in the body of the position assurance component into the chamber of the housing until a tab on the contact carrier engages with the latch on the insulating housing; and ii) sliding the position assurance component into the chamber until the protruding member is adjacent the latch such that disengagement of the latch and the tab is restrained by the protruding member.

[0011] In yet another aspect, an electrical connector may include: (i) an insulating housing (1603) having a chamber (1612) and a latch (1654) adjacent the chamber; (ii) a position assurance component (1650) having a body with an opening (1652) therethrough, a protruding member, and a slot separating the protruding member from the body; and a contact carrier (1606) having a tab (1611) extending through the opening in the position assurance component and disposed within the chamber of the insulating housing, wherein the latch (1654) of the housing engages with the tab (1611) of the contact carrier (1606) to hold the contact carrier (1606) in position within the chamber, and the position assurance component (1650) is positioned such that the latch is disposed within the slot such that movement of the latch is restricted.

[0012] In yet another aspect, a method of operating an electrical connector comprising an insulating housing (1603) having a chamber (1612) and a latch (1654) adjacent the chamber, and a position assurance component (1650) having a body with an opening (1652) therethrough, a protruding member, and a slot separating the protruding member from the body, the method including: (i) sliding the contact carrier into the chamber of the insulating housing until a tab on the contact carrier engages with the latch on the housing; and (ii) sliding the position assurance component into the insulating housing until the latch on the insulating housing is disposed in a slot on the position assurance component. [Brief explanation of the drawings]

[0013] The accompanying drawings are not limited to the scale shown, and for clarity, not every component may be labeled in every drawing. [Figure 1] FIG. 1 is a perspective view of an illustrative interconnection system, according to some embodiments. [Figure 2] 2 is an exploded perspective view of the illustrative board connector 100 of FIG. 1. [Figure 3A] 2 is a cross-sectional view of the illustrative board connector 100 of FIG. 1. [Figure 3B] 3B is a rear view of the illustrative board connector of FIG. 3A. [Figure 4A] 1 is a perspective view of an illustrative multi-port board connector; [Figure 4B] 4B is a cross-sectional view of the illustrative multi-port board connector of FIG. 4A. [Figure 5] FIG. 2 is a perspective view of the cable connector 200 of FIG. [Figure 6] FIG. 6 is an exploded perspective view of the illustrative cable connector of FIG. 5. [Figure 7] 6 is a cross-sectional view of the illustrative cable connector of FIG. 5. [Figure 8] 1 is an exploded perspective view of an illustrative unsealed multi-port cable connector terminating a cable assembly; [Figure 9] 16 is a perspective view of an illustrative contact carrier position assurance component 1630. FIG. [Figure 10] FIG. 9 is a perspective view of the housing components of the illustrative unsealed multi-port cable connector of FIG. 8 assembled into a housing subassembly for an electrical connector, with the contact carrier position assurance component inserted and engaged in the open position and no contact carrier inserted into the subassembly. [Figure 11] FIG. 10 is a perspective view of the illustrative contact carrier position assurance component of FIG. 9, with an enlarged view of the latch shown with callouts. [Figure 12] 11 is a side view of the illustrative electrical connector subassembly of FIG. 10, including a close-up view of a latch engaged with the housing to maintain the contact carrier position assurance component in an open position within the housing. [Figure 13] 1 is a cross-sectional view of an illustrative electrical connector subassembly with the contact carrier position assurance component latched in an open position. [Figure 14] 9 is a perspective view of the illustrative unsealed multi-port cable connector of FIG. 8 with the contact carrier inserted into the housing with the contact carrier position assurance component in an open position. [Figure 15] 15 is a cross-sectional view of an illustrative unsealed multi-port cable connector in the state illustrated in FIG. 14. [Figure 16] 9 is a perspective view of the illustrative unsealed multi-port cable connector of FIG. 8 with the contact carrier position assurance component slid into a closed position. [Figure 17A] 10 is a perspective view of the illustrative contact carrier position assurance component and contact carrier of FIG. 9, with the carrier position assurance component in an open position. [Figure 17B] 10 is a perspective view of the illustrative contact carrier position assurance component and contact carrier of FIG. 9, with the contact carrier position assurance component in a closed position. [Figure 17C] 1 is a top cross-sectional view of an illustrative unsealed multi-port cable connector with a contact carrier and contact carrier position assurance component inserted into a housing and in a closed position; [Figure 18] 9 is a cross-sectional view of the illustrative multi-port cable connector of FIG. 8 with the contact carrier and contact carrier position assurance component inserted into the housing and the contact carrier position assurance component in a closed position. [Figure 19] FIG. 9 is a side cross-sectional view of the illustrative multi-port cable connector of FIG. 8, showing that the walls of the contact carrier position assurance component in the closed position retain the contact carrier within the housing by blocking tabs on the contact carrier, with enlarged views of the tabs shown with callouts. [Figure 20] 9 is a side view of the illustrative unsealed multi-port cable connector of FIG. 8, showing the contact carrier position assurance component latched in a closed position within the housing. [Figure 21] 1 is an exploded perspective view of an illustrative sealed multi-port cable connector. FIG. [Figure 22] 22 is a cross-sectional perspective view of a housing component of the illustrative sealed multi-port cable connector of FIG. 21 assembled into a connector subassembly. [Figure 23]22 is a perspective view of two illustrative contact carrier position assurance components of the illustrative sealed multi-port cable connector of FIG. 21, with a contact carrier inserted into one of the contact carrier position assurance components. [Figure 24A] 22 is a cross-sectional view of the illustrative sealed multi-port cable connector of FIG. 21, with the contact carrier retained within the housing by a primary latch, with an enlarged view of the latch shown with callouts. [Figure 24B] FIG. 22 is a cross-sectional view of the illustrative sealed multi-port cable connector of FIG. 21 showing the contact carrier position assurance component slid into a position blocking the primary latch. [Figure 24C] 22 is a rear perspective view of the illustrative sealed multi-port cable connector of FIG. 21, with the cover holding the contact carrier position assurance component in a position blocking the primary latch. [Figure 25] 22 is a cross-sectional view of the illustrative sealed multi-port cable connector of FIG. 21 showing the seal and cover blocking the contact carrier position assurance component. DETAILED DESCRIPTION OF THE INVENTION

[0014] The present inventors have recognized and appreciated techniques for creating connectors for providing high data rate transmission that can be manufactured economically and that can operate reliably in the harsh environments created by automobiles. Such connectors are suitable for interconnecting assemblies within automobile networks, for example. 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.

[0015] The inventors have recognized and appreciated various techniques that can be applied to components of a connector system to provide connections with high signal integrity (SI). Improved SI can result from controlling the electrical characteristics 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 electrical conductors within the connector.

[0016] For example, one connector configuration may be formed from an insulating outer housing that establishes at least the mating interface of the connector. The insulating outer housing may provide a latching mechanism. A set of components may include insulating outer housings of complementary configurations that can be used to form two connector configurations that mate and latch together. The insulating housing may include a chamber and a channel.

[0017] A cable connector can be assembled by inserting one or more contact carriers, each terminating one or more cables within a chamber of an insulating housing. The contact carriers can have tabs that align with channels in the connector housing. A contact carrier position assurance component can 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 move the contact carriers from their intended positions. Ensuring that the contact carriers are securely held in their designed positions reduces impedance discontinuities and vibration-induced noise in the mated connector pair.

[0018] The contact carrier position assurance component may have a design that facilitates easy and reliable manufacturing of the connector by engaging multiple contact carriers while in an open position, and locking the multiple contact carriers in place by moving the position assurance component to a closed position.

[0019] The connectors may include a position assurance component having, for example, an opening, a channel, and a surface adjacent the channel. Each connector may also include a contact carrier having a tab. The position assurance component may be slidably mounted within the insulating housing and configured to slide between (i) an open position in which the channel in the insulating housing, the channel in the position assurance component, and the tab on the contact carrier are aligned, and (ii) a closed position in which the surface of the position assurance component is aligned with the channel in the insulating housing.

[0020] The position assurance component may have a wall bounding its channel, with a surface included on one side of the wall such that the surface interferes with withdrawal of the tab of the contact carrier through the channel when the position assurance component is in the closed position.

[0021] Alternatively or additionally, the electrical conductor may comprise an insulating housing having a chamber, a position assurance component having an opening and a surface, and a contact carrier having a tab and positioned within the chamber, the contact carrier may extend through the opening in the position assurance component, and the position assurance component may be positioned such that its surface interferes with the tab on the contact carrier to prevent the contact carrier from being withdrawn from the chamber in the insulating housing and the opening in the position assurance component.

[0022] The position assurance component may also include a protrusion, and the insulating housing may also include a first groove, the protrusion of the position assurance component being seated in the first groove of the insulating housing to maintain the position assurance component in a first position within the insulating housing. The insulating housing may also include a second groove, the protrusion of the position assurance component being seated in the second groove of the insulating housing to maintain the position assurance component in a second position within the insulating housing. For example, the first position may correspond to an open position, and the second position may correspond to a closed position.

[0023] Use of the techniques as described herein may be facilitated by providing a housing subassembly for an electrical connector. The subassembly may include, for example, an insulating housing with a contact carrier position assurance component held within the insulating housing. The contact carrier position assurance component may be latched in an open position, for example. Such a subassembly may include an insulating housing with a chamber and a channel, and a position assurance component with an opening, a channel, and a surface adjacent to the channel, the position assurance component slidably mounted within the insulating housing to slide between (i) an open position in which the channel of the insulating housing and the channel of the position assurance component are aligned, and (ii) a closed position in which a surface of the position assurance component is aligned with the channel of the insulating housing, the position assurance component including a latch configured to engage a complementary structure within the insulating housing when the position assurance component is in the open position.

[0024] Alternatively or additionally, the contact carrier may latch the housing, and the position assurance component may slide over one or more contact carriers into a closed position where the latch is restrained from unlatching. The electrical connector may, for example, include: (i) an insulating housing including a chamber and a latch adjacent the chamber; (ii) a position assurance component including a body having an opening therethrough, a protruding member, and a slot separating the protruding member from the body; and (iii) a contact carrier having a tab extending through the opening in the position assurance component and disposed within the chamber of the insulating housing, the housing latch engaging the tab on the contact carrier to hold the contact carrier in position within the chamber, and the position assurance component positioned such that the latch is disposed within the slot such that movement of the latch is restrained. Alternatively or additionally, sliding the position assurance component into the insulating housing may be positioned until the protruding member on the position assurance component is positioned to block movement of the insulating housing latch to unlatch from the tab.

[0025] These techniques may be used alone or in combination and are illustrated below with respect to an interconnection system that may be used, for example, to make physical connections between assemblies in an automobile.

[0026] 1 is a perspective view of an illustrative interconnection system, according to some embodiments. The interconnection system may 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 ECUs in automotive vehicles). In this example, the interconnection system includes a board connector 100 and a cable connector 200.

[0027] 2 is an exploded perspective view of the illustrative board connector 100 of FIG. 1 when not mated to a cable connector 200, according to some embodiments. The board connector 100 includes an opening 158 in the housing 150, which may be arranged to allow mating contacts to pass therethrough. The mating interface of the board connector 100 may be disposed within the opening 158.

[0028] The board connector 100 also includes a conductive housing 140. The conductive housing 140 may be, for example, a die-cast component. 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.

[0029] 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 conductors maintained by the insulator 120. As shown, the board connector 100 includes conductors that may function as signal conductors. In this example, a pair of conductors is shown so that the illustrated terminal assembly is configured to pass differential signals. In addition to transmitting one or more signals through the connector, the conductors may have a mating contact portion at one end, a tail at the opposite end, and an intermediate portion therebetween. Thus, the conductors may function as contacts of the connector.

[0030] In the example of FIG. 2, the mating contact portions of the conductors are shaped as pins so that the board connector 100 is configured as a header. In other embodiments, the mating contact portions of the conductors in the header connector may be shaped as blades or have other shapes. Alternatively or additionally, in some embodiments, the board connector may have conductors with mating contact portions shaped as receptacles. In the example of FIG. 2, the tails of the conductors are shaped as posts. For example, the posts may be attached to a printed circuit board using plated through holes or pins with paste soldering techniques.

[0031] 2 illustrates a plurality of mating contacts, including contacts 110A and 110B (also referred to herein as "terminals"). Mating contact portions of the 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 embodiments, board 160 may be a printed circuit board (PCB).

[0032] 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.

[0033] One or more mating contacts may be maintained within insulator 120 to form a terminal assembly. The insulator may be shaped and sized to receive the mating contacts. For example, contacts 110A and 110B may pass through openings in insulator 120. Insulator 120 may be inserted into cavities within conductive housing 140. In this manner, the conductive housing partially surrounds the terminal assembly and the conductors within the terminal assembly.

[0034] The conductive housing 140 may further include mounting posts 140 configured to electrically and mechanically connect the conductive housing 140 to the substrate 160. For example, the mounting posts may extend into holes 161, which may be ground vias. By grounding the conductive housing 140, it may act as a shield for the terminal assembly and the pair of conductors within the terminal assembly.

[0035] The board connector 100 may include one or more additional shielding members, illustrated here as a shield 130. The shield 130 is also inserted into the cavity of the conductive housing 140 to further surround the terminal assembly. The shield 130 is electrically and mechanically coupled to the conductive housing 140 so that the shield 130 may also be grounded. The shield 130, together with a spacer on the insulator 120, may function to position the terminal assembly within the cavity, thereby establishing a signal-to-ground spacing for the conductors within the terminal assembly. Such a configuration may provide a desired and stable impedance.

[0036] 3A is a cross-sectional view of the illustrative board connector 100 of FIGS. 1 and 2 taken along line 3A-3A in 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 arranged to establish a designed separation 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.

[0037] As described herein, the insulator 120 and the shield 130 may be engaged within a conductive housing 140. The conductive housing 140 may include a retention feature 141 to prevent movement of the insulator 120 and absorb forces of the insulator 120. 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.

[0038] 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 features 142 and 143 for retaining the shield 130.

[0039] Each of contacts 110A and 110B may include one or more retention features configured to prevent movement of the contact within insulator 120 of connector 100. For example, contact 110A includes a barb configured to provide retention of the contact within the insulator. For example, insulator 120 may include a channel that receives each of contacts 110A and 110B. The barbs bite into the insulator at the sides of the channel to securely hold the contact. The channel is narrower adjacent to the barb and wider away from the barb.

[0040] 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 portion proximate the retention feature. In this example, the impedance compensation portion is formed by a narrowed portion 111.

[0041] In the illustrated embodiment, contact 110A or 110B has the same shape. Therefore, they may have the same retention features and the same impedance compensation portion. 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 compensation portion 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.

[0042] FIG. 4A is a perspective view of an illustrative multi-port board connector 400, according to some embodiments. For example, FIG. 4A shows a 2x2 connector 400 including four ports arranged in two rows of two ports. A conductive housing is shown with ports 470A-470D, each shaped and sized to receive a mating element therein. Each of the ports may have the same configuration as mating portion 146 of board connector 100, so that the same mating element can mate with either connector. Similar to board connector 100, conductive housing 440 is configured to mount to board 460. Insulating housing 450 serves the same function as insulating housing 150 of the larger connector and is attached to conductive housing 440.

[0043] FIG. 4B illustrates a portion of a cross-sectional view taken along line 4B-4B of FIG. 4A, according to some embodiments. In the example of FIG. 4B, contacts in two of the ports are visible. Similar to connector 100, connector 400 has a pair of contacts in each port. In this example, the contacts for each port are maintained within a separate insulator, forming a terminal assembly for each of the ports. The insulators may have the same function as described above for connector 100. For example, mating contact 410A is disposed within insulator 420A, which includes rib 421A. Mating contact 410B is disposed within insulator 420B, which includes rib 421B. Ribs 421A and 421B each position the respective terminal assembly relative to respective shields 430A and 430B. Each of the shields and insulators is engaged within conductive housing 440, which is further disposed within insulator housing 450.

[0044] 5 is a perspective view of a cable connector 200, according to some embodiments. The cable connector 200 may have similar components as 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 within the shield. However, the outer insulating housing may have a mating interface and latching mechanism complementary to that of the board connector 100, such that the cable connector 200 may 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 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.

[0045] Figure 6 is an exploded perspective view of an illustrative cable connector 200, according to some embodiments. As illustrated in Figures 5 and 6, the illustrative cable connector 200 is configured to terminate a cable 210. The cable connector 200 includes a mating end 520 and a cable termination 522 opposite the mating end. A cavity is open at the mating end 520. The connector terminates the cable at the cable termination 522, and the cable has been manipulated to facilitate termination.

[0046] The bulk of the cable 210 may include one or more insulated conductors. In the example provided, the cable includes a pair of insulated conductors surrounded by a cable shield, which is then covered by an insulating jacket. The cable shield may be, for example, a braided shield or a conductive foil. For termination, the jacket may be removed, exposing the cable shield. The insulated conductors may be separated, and at the distal end, the insulation may be removed. For cables in which the insulated conductors are twisted together within the bulk cable, separating the insulated conductors may also include untwisting the conductors. This manipulation of the cable allows the conductors of the insulated conductors to be attached to the terminals of the connector. The cable shield may also be attached to the connector shield.

[0047] 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. Terminals 240 may be crimped onto the conductors of the cable. The terminals may be part of a terminal assembly having an insulator, illustrated here as contact carrier housing 250. The conductive inner housing of the cable connector may be formed from a rear shield 260 and a front shield 270 that may be electrically and mechanically coupled. Front shield 270 may include a mating interface, and rear 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.

[0048] Components 220, 230, 240, 250, 260, and 270 illustrated in Figure 6 that terminate the cable provide contact carriers. In this example, the contact carriers are shielded. The position of the contact carriers within the housing can be secured using contact carrier position assurance (CCPA) component 280.

[0049] FIG. 7 is a cross-sectional view of the illustrative cable connector of FIG. 6 , according to some embodiments. An impedance adapter 230 is located in a separated and / or untwisted region 231 of the cable termination. The region 231 where the cable is manipulated provides space for the process of crimping contacts to the cable's conductors. However, this manipulation of the cable changes the impedance of the conductors. Metal is placed in close proximity to the cable to provide a compensating change in impedance in the opposite direction. 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, establishing a signal-to-ground spacing for the cable's conductors, thereby establishing a desired impedance that matches the impedance of the bulk cable. As used herein, impedances do not have to be identical to be matched. Rather, the impedances can be close enough so as not to provide impedance discontinuities that hinder performance. For example, the matched impedance can be within + / - 5% or + / - 3 ohms in some embodiments.

[0050] To terminate cable 210, the cable end may be prepared for termination and inserted through 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 be engaged with rear shield 260 and latched in place. These components may form a terminated cable assembly that is inserted into housing 290. Housing 290 may include an opening 292 for receiving the terminated cable assembly.

[0051] A terminated cable assembly may be latched to the housing 290, for example, by latching a beam within the housing to a tab extending from one of the connector shields. The housing 290 may include, for example, a beam 294 with a cantilevered end 291 and a latch 293 that extends into an opening 292 at the cantilevered end 291. The latch 293 may have a camming surface 295, and the tab on the terminated cable assembly may have a tapered forward edge. When the terminated cable assembly is inserted into the housing 290, the tapered surface of the tab may engage a camming surface on the latch 293, pushing the latch 293 upward until the rear edge of the tab clears the camming surface. In that position, the spring force of the deflected beam 294 pushes the beam downward, latching the tab in place.

[0052] Figure 7 illustrates a connector having one contact carrier maintained within an insulating housing. Such a connector may be configured to mate with a single-port board connector such as illustrated in Figure 1. A plug connector may be configured to mate with a multi-port connector such as illustrated in Figure 4A by incorporating multiple contact carriers within the insulating housing.

[0053] Figure 8 is a perspective exploded view of an illustrative unsealed multi-port cable connector, here configured as a plug, that may mate with a board connector such as that shown in Figure 4A or other connectors having a similar mating interface. The illustrative unsealed cable connector 1620 shown in Figure 8 includes an insulating housing 1609 that includes four chambers 1622 arranged in a 2x2 matrix, each chamber receiving a contact carrier 806. Each contact carrier 806 may have a configuration as described above in connection with Figure 6.

[0054] The unsealed contact carrier connector 1620 may include a contact carrier position assurance component 1630. In this example, the contact carrier position assurance component 1630 allows for easy and reliable assembly of a cable connector having multiple contact carriers. For example, it may latch to the insulating housing 1609 in an open position, where multiple contact carriers may be inserted into the housing 1609. When the contact carriers are properly seated within the insulating housing 1609, the contact carrier position assurance component 1630 may be slid to the closed position by applying a force to overcome the latch. A latching mechanism on the contact carrier position assurance component 1630 may snap into place when the contact carrier position assurance component 1630 reaches the closed position and may provide audible and / or tactile feedback to the user that the contact carriers are properly seated within the insulating housing 1609. Conversely, if one or more of the contact carriers are out of position, the contact carrier position assurance component 1630 may not slide or may require the application of a large amount of force above a threshold that is noticeable by the user to slide. In this way, a user (who may be a human or an assembly machine) can quickly secure multiple contact carriers within the housing or determine that one or more are not properly seated.

[0055] Figure 9 is a perspective view of an illustrative contact carrier position assurance component 1630. In this example, the contact carrier position assurance component 1630 is configured to simultaneously secure four contact carriers. The contact carrier position assurance component 1630 of Figure 9 may include four openings 1631 arranged in a 2x2 matrix, each opening receiving a contact carrier 806 when the contact carrier position assurance component 1630 is inserted into the insulative housing 1609.

[0056] Figure 10 is a perspective view of a housing subassembly of the illustrative unsealed multi-port cable connector 1620 of Figure 8, in which a contact carrier position assurance component 1630 is inserted into an insulative housing 1609. Either or both of the insulative housing 1609 and the contact carrier position assurance component 1630 may include one or more latching mechanisms and / or one or more complementary latching mechanisms such that the contact carrier position assurance component 1630 is latched relative to the housing.

[0057] In some examples, the contact carrier position assurance component 1630 may include a latching mechanism, and the insulating housing 1609 may have two complementary latching mechanisms, such that the contact carrier position assurance component 1630 may be latched in two positions relative to the insulating housing 1609. Figure 10 shows the contact carrier position assurance component 1630 latched in a first such position. In the illustrated state, the contact carrier position assurance component 1630 is in an open state such that a contact carrier may be inserted into the chamber 1622 through the opening 1631.

[0058] One or more additional components may optionally be integrated into the connector housing subassembly. A connector position assurance component 1610 may be attached to the housing 1609, for example.

[0059] FIG. 11 is a perspective view of the illustrative contact carrier position assurance component 1630 of FIG. 9 , showing a latch 1632 configured to engage a complementary latching feature of the insulating housing 1609 when the position assurance component 1630 is in one or more predetermined positions within the insulating housing 1609. The contact carrier position assurance component 1630 of FIG. 9 may include a body 1663. The latch 1632 of the contact carrier position assurance component 1630 may include a member 1665 separated from the body 1663 by a slit 1633. The latch 1632 of the contact carrier position assurance component 1630 may further include a protrusion 1635 on the member 1665. The member 1665 may be elongated in a direction between a first end and a second end, and the member 1665 may be attached to the body 1663 at the first end and the second end. The member 1665 may include a central portion between the first and second ends, and the protrusion 1635 may extend from the central portion. The contact carrier position assurance component 1630 may be molded from plastic such that the member 1665 is integral with the body 1663.

[0060] The member 1665 may be compliant. When the protrusion 1635 presses against the surface of the housing 1609, a central portion of the member 1665 may be forced into the slot 1663 so that the protrusion 1635 does not interfere with the contact carrier position assurance component 1630 sliding relative to the housing. However, when the protrusion 1635 aligns with a groove in the surface of the housing, the member 1665 may spring back from the body 1663, forcing the protrusion 1635 into the groove. This action may provide tactile and / or audible feedback to the user indicating that the contact carrier position assurance component 1630 is in the position established by the relative positions of the protrusion and groove. Additionally, the engagement of the protrusion 1635 with the groove may restrict movement of the contact carrier position assurance component 1630 relative to the housing 1609 until sufficient force is applied to the contact carrier position assurance component 1630 to overcome the constraint caused by deflecting the member 1665 into the slot 1633.

[0061] 12 is a side view of the illustrative unsealed multiport cable connector of FIG. 8 showing the contact carrier position assurance component 1630 in an open position within the housing 1609. The complementary latching mechanism of the insulating housing 1609 includes a first groove 1625 configured to engage a protrusion 1635 on a member 1665 of the contact carrier position assurance component 1630 to maintain the contact carrier position assurance component 1630 in an open position within the insulating housing 1609.

[0062] As shown in FIG. 12, the insulating housing 1609 may also include a second groove 1627 configured to engage with a protrusion 1635 on a member 1665 of the contact carrier position assurance component 1630 to maintain the contact carrier position assurance component 1630 in a closed position within the insulating housing 1609.

[0063] FIG. 13 is a cross-sectional view of an illustrative housing subassembly. In the illustrated state, the contact carrier position assurance component 1630 is latched in an open position. As shown in FIG. 13, the contact carrier position assurance component 1630 may include one or more openings 1631. In this example, the contact carrier position assurance component 1630 has four openings 1631 arranged in a 2×2 matrix. As also shown in FIG. 13, the insulating housing 1609 may include one or more chambers 1622. The openings 1631 in the contact carrier position assurance component 1630 may align with each of the chambers 1622. In this example, the four chambers 1622 in the insulating housing 1609 are arranged in a 2×2 matrix. Optionally, the four chambers 1622 in the insulating housing 1609 correspond to four respective openings 1631 in the contact carrier position assurance component 1630.

[0064] The contact carrier position assurance component 1630 and housing 1609 may be collectively configured such that a contact carrier can be inserted through the opening 1631 into the chamber 1622 when the contact carrier position assurance component 1630 is in the open position, but cannot be withdrawn when the contact carrier position assurance component 1630 is slid to the closed position. In the illustrated example, the contact carrier may have an ejection feature that allows it to pass through the channel of the contact carrier position assurance component 1630 when the contact carrier position assurance component 1630 is in the open position, but is blocked from being withdrawn from the opening when the contact carrier position assurance component 1630 is slid to the closed position.

[0065] 13 , the contact carrier position assurance component has a channel 1626 and a wall 1634 that bounds the channel 1626. Optionally, the insulating housing 1609 includes a channel 1628. When the contact carrier position assurance component 1630 is in the open position, the channel 1628 of the insulating housing 1609 may align with the channel 1626 of the contact carrier position assurance component 1630. In this state, the contact carrier 1606 with the tabs 1611 may slide through the opening 1631 in the contact carrier position assurance component 1630 and into the chamber 1622 of the insulating housing 1609, as described in more detail below.

[0066] Figure 14 is a perspective view of the illustrative unsealed multi-port cable connector of Figure 8, with the contact carrier 1606 and contact carrier position assurance component 1630 inserted into the housing subassembly of Figure 10. In Figure 14, the contact carrier position assurance component 1630 is in an open position. In this example, it can be seen that the exterior surface of the contact carrier position assurance component 1630 extends beyond the surface of the housing 1609.

[0067] Figure 15 is a cross-sectional view of the illustrative unsealed multi-port cable connector of Figure 14. Figure 15 shows a contact carrier position assurance component 1630 inserted into an insulating housing 1609 such that an opening 1631 in the contact carrier position assurance component 1630 aligns with a chamber 1622 in the insulating housing 1609. Figure 15 also shows a contact carrier 1606 inserted through the opening 1631 in the contact carrier position assurance component 1630 and into the chamber 1622 in the insulating housing 1609. Tabs 1611 on the contact carrier 1606, channels 1628 on the insulating housing 1609, and channels 1626 on the contact carrier position assurance component 1630 align to allow tabs 1611 on the contact carrier 1606 to pass through channels 1628 on the insulating housing 1609 and channels 1626 in the contact carrier position assurance component 1630. In this condition, the contact carrier 1606 can be inserted into the chamber 1622 of the insulating housing 1609 through the opening 1631 in the contact carrier position assurance component 1630. As shown, when the contact carrier is inserted deep enough into the chamber, as in the design position, the rear edge of the tab 1611 extends beyond the forward surface of the wall 1634.

[0068] 16 is a perspective view of the illustrative unsealed multi-port cable connector of FIG. 14 , showing contact carriers 1606 inserted into respective chambers 1622 of insulating housing 1609 and contact carrier position assurance component 1630 slid into a closed position within insulating housing 1609. In this example, it can be seen that the exterior surface of contact carrier position assurance component 1630 is substantially flush with the surface of housing 1609, in contrast to the position of FIG. 14 .

[0069] Figure 17A is a rear view of the illustrative contact carrier position assurance component 1630 of Figure 9 and the contact carrier 1606 in an open position within the electrical connector 1620. Arrow 1700 illustrates the direction of sliding the contact carrier position assurance component 1630 from the open position to the closed position. In this example, the sliding direction 1700 is perpendicular to the direction of insertion of the contact carrier into the housing 1609. Figure 17B is a rear view of the illustrative contact carrier position assurance component 1630 and contact carrier 1606 of Figure 17B with the contact carrier position assurance component 1630 slid to a closed position within the electrical connector 1620.

[0070] In this example, opening 1631 is wider in the sliding direction than the portion of contact carrier 1606 within opening 1631. This additional width allows contact carrier position assurance component 1630 to slide within housing 1609 with the contact carrier inserted in opening 1631.

[0071] 17A, tab 1611 (see FIG. 15) extends beyond wall 1634 but is aligned with channel 1626. With contact carrier position assurance component 1630 slid to the closed position shown in FIG. 17B, tab 1611 is aligned with the forward surface of wall 1634, and wall 1634 blocks withdrawal of the contact carrier from chamber 1622.

[0072] 17C is a top cross-sectional view of an illustrative unsealed multi-port cable connector with a contact carrier 1606 and a contact carrier position assurance component 1630 inserted into an insulating housing 1609 of an electrical connector 1620. Figures 17A, 17B, and 17C illustrate a method of operating the electrical connector while the contact carrier 1606 passes through an opening in the contact carrier position assurance component 1630 into the insulating housing 1609 of the electrical connector 1620, with the contact carrier position assurance component 1630 first in an open position and then in a closed position.

[0073] In the exemplary method, the contact carrier position assurance component 1630 is placed at least partially within the insulating housing 1609 in an open position such that the chambers 1622 of the insulating housing 1609 are aligned with respective openings 1631 in the contact carrier position assurance component 1630. In this open position, the channels 1628 of the insulating housing 1609 also align with the channels 1626 of the contact carrier position assurance component 1630. The contact carrier 1606 is inserted into the chambers 1622 of the insulating housing 1609 through the openings 1631 of the contact carrier position assurance component 1630 by aligning the tabs 1611 of the contact carrier 1606 with the channels 1628 of the insulating housing 1609 and the channels 1626 of the contact carrier position assurance component 1630. The contact carrier position assurance component 1630 is then slid relative to the insulating housing 1609 such that the channels 1628 of the insulating housing 1609 are blocked by the contact carrier position assurance component.

[0074] Optionally, the contact carrier position assurance component 1630 may be slid relative to the insulating housing 1609 by pushing the contact carrier position assurance component 1630 until its protrusion 1635 engages the first groove 1625 of the insulating housing 1609 to securely maintain the contact carrier position assurance component 1630 in the open position. The housing and contact carrier position assurance component 1630 in this state may form a housing subassembly. After the contact carrier 1606 is inserted through the opening 1631 in the contact carrier position assurance component 1630 and into the chamber 1622 of the insulating housing 1609 (e.g., by aligning the tab 1611 of the contact carrier 1606 with the channel 1628 in the insulating housing 1609 and the channel 1626 in the contact carrier position assurance component 1630, as described above), the contact carrier position assurance component 1630 can be slid further relative to the insulating housing 1609 by further pushing the contact carrier position assurance component 1630 until its protrusion 1635 engages the second groove 1627 in the insulating housing 1609. In this second position, the contact carrier position assurance component can be in a closed position within the insulating housing 1609.

[0075] When the contact carrier is fully inserted into the insulating housing, the tab 1611 is in front of the wall 1634 and the contact carrier position assurance component 1630 can slide relatively easily from the open position to the closed position. A first force above a first threshold may be required to overcome the retention of the latch of the contact carrier position assurance component 1630 in the first groove. However, this first force may be less than the second force required to move the contact carrier position assurance component 1630 to the closed position if the contact carrier is not positioned where it was designed. If the contact carrier is not fully inserted, the tab 1611 may interfere with the wall 1634, blocking the contact carrier position assurance component 1630 from easily sliding to the closed position. In some scenarios, the amount of force required to slide the contact carrier position assurance component 1630 may exceed a force that can be easily generated by a person or may otherwise be so high that a user may perceive one or more contact carriers as misaligned.

[0076] 18 is a cross-sectional front view of the illustrative multi-port cable connector 1620 of FIG. 14 with the contact carrier 1606 in the design position and the contact carrier position assurance component 1630 secured in the closed position. In the closed position, the rear edges of the tabs 1611 of the contact carrier 1606 face the surface of the wall 1634 of the contact carrier position assurance component 1630, such that this surface interferes with the withdrawal of the tabs 1611 of the contact carrier 1606 through the channels in the insulating housing 1609.

[0077] Figure 19 is a cross-sectional view of the illustrative multi-port cable connector 1620 of Figure 16, showing the positioning of the contact carrier 1606 within the insulating housing 1609 by the tabs 1611 on the contact carrier 1606 when the contact carrier position assurance component 1630 is in the closed position. Figure 19 also shows that the surfaces of the walls 1634 of the contact carrier position assurance component 1630 block the withdrawal of the tabs 1611 of the contact carrier 1606 through the channels in the insulating housing 1609.

[0078] 20 is a side view of the illustrative unsealed multiport cable connector 1620 of FIG. 16 , showing the contact carrier position assurance component 1630 in an open position within the insulating housing 1609. A protrusion 1635 on a member 1665 of the body 1663 of the contact carrier position assurance component 1630 engages with a second groove 1627 in the insulating housing 1609 to secure the contact carrier position assurance component 1640 in a final position within the insulating housing 1609.

[0079] In other embodiments, the contact carrier position assurance component may slide from an open position to a closed position in a direction parallel to the insertion direction of the contact carrier into the connector housing. Such a configuration may allow one or more seals to be integrated into the connector. Furthermore, a sliding direction parallel to the insertion direction of the contact carrier allows the contact carrier position assurance component to be inserted into the connector housing through the same connector housing opening as the contact carrier, reducing the number of openings that must be sealed to provide a sealed connector.

[0080] 21 is an exploded perspective view of an illustrative sealed multi-port cable connector 1600. In this example, the cable connector is assembled from one or more contact carriers 1606, as described above. The mating interface of the sealed connector may be the same as that of an unsealed cable connector, for example, as shown in FIG.

[0081] 21 includes a two-piece insulating housing including a main housing 1603 and a front housing 2103. Such a configuration facilitates installation of a ring seal 2110 around the mating interface within the main housing 1603. The ring seal 2110 can be positioned to engage the mating connector and seal the interface between the cable connector and the mating connector.

[0082] The insulating housing in this example includes four chambers 1612 arranged in a 2x2 matrix, with each chamber receiving a contact carrier 1606. The sealed contact carrier connector 1600 may also include one or more contact carrier position assurance components. In this example, two contact carrier position assurance components 1650A and 1650B may together form the contact carrier position assurance component 1650. Forming the contact carrier position assurance component 1650 as multiple pieces may strengthen the walls or ribs between the separate pieces within the connector housing. On the other hand, forming the contact carrier position assurance component 1650 with multiple openings per piece may simplify assembly and facilitate proper seating of each piece within the connector housing. Thus, one piece per row or column of contact carriers in the connector may provide both enhanced manufacturability and durability of the finished connector. In this example, the contact carrier position assurance component is formed in two pieces, one for each column of the 2x2 connector. Such a configuration can contribute to the modularity of the connector system, as the same contact carrier position assurance components used in the 2x2 connector can be used to build a 1x2 connector. Similarly, the same components can be used for other sized connectors, such as a 4x4 connector.

[0083] 21 , the contact carrier position assurance component 1650 may be inserted into the housing 1603 when the cable connector is assembled. Optionally, the insulative housing 1603 may be pre-assembled into a housing subassembly, with the contact carrier position assurance component 1650 inserted into the insulative housing 1609. In such a configuration, the contact carrier position assurance component 1650 may be latched to the insulative housing 1603, such as by using a latching mechanism and a complementary latching mechanism, as described above.

[0084] The illustrative sealed contact carrier connector 1600 may also include a cable seal 1607 having one or more openings 1609. The openings 1609 in the seal 1607 may be aligned with chambers 1612 in the insulating housing 1603. The illustrative sealed contact carrier connector 1600 may include a cover 1608. When installed, the cover 1608 may engage with the main housing 1603, such as through a latching mechanism or other engagement mechanism. The cover 1608 may cover the cable seal 1607, retaining the cable seal within the main housing 1603 and / or protecting it from physical damage, etc. Optionally, the cover 1608 may be configured to press the seal 1607 against the contact carrier position assurance component 1650. In some embodiments, when the contact carrier is positioned in its designed location within the connector housing, the cover 1608 may press onto the housing with a force below a threshold. In contrast, if the contact carrier is not positioned where it was designed, the contact carrier position assurance component 1650 cannot easily slide into its closed position and a greater force above a second threshold is required to press the cover 1608 into place, providing feedback to the installer, whether human or machine, that the components within the connector housing are not positioned where they were designed.

[0085] The illustrative sealed cable connector 1600 may also include a connector position assurance component 1604 .

[0086] The illustrative contact carrier position assurance component 1650 of FIG. 21 has four openings 1652 arranged in a 2×2 matrix, each opening receiving a contact carrier 1606 when the contact carrier position assurance component 1650 is inserted into the insulating housing 1603.

[0087] 22 is a cross-sectional view of a portion of the illustrative unsealed multi-port contact carrier connector 1600 of FIG. 21 showing the insulating housing 1603. The insulating housing may include a latch 1654 adjacent each chamber 1612.

[0088] Figure 23 is a perspective view of the illustrative sealed multi-port cable connector 1600 of Figure 21 with a contact carrier 1606, shown in phantom, inserted into an insulating housing 1603. The contact carrier position assurance component 1650 may include a body having one or more openings therethrough and a protruding member 2310 adjacent each opening. Optionally, the contact carrier position assurance component 1650 may have a slot 2410 (Figure 24B) separating the protruding member from the body. Figure 23 illustrates the relative positions of the contact carrier position assurance component 1650 and the contact carrier 1606 with the contact carrier position assurance component 1650 in the open position.

[0089] 24A is a cross-sectional view of the illustrative sealed multi-port cable connector 1600 of FIG. 21 showing the positioning of a contact carrier 1606 within an insulating housing 1603 by a primary latch 1654. In the illustrated state, the primary latch 1654 of the insulating housing 1603 engages a tab 1611 on the contact carrier 1606 to hold the contact carrier 1606 in position within a chamber 1612 of the insulating housing 1603. In the illustrated example, the latch 1654 includes a flexible beam with a hook-like end that engages a rear edge of the tab 1611. When the latch 1654 engages the tab 1611, the latch 1654 blocks movement of the tab 1611 in a direction that would withdraw the contact carrier from the housing.

[0090] 24A, the contact carrier position assurance component 1650 is in an open position and is not visible in FIG. Optionally, the contact carrier position assurance component 1650 is slidably disposed with the insulating housing 1603 so that it may slide to a closed position. For example, installing the cover 11608 may apply a force to the contact carrier position assurance component 1650, forcing it to slide into the illustrated position.

[0091] FIG. 24B is a cross-sectional view of the illustrative sealed multiport cable connector 1600 of FIG. 21 showing the contact carrier position assurance component 1650 in the closed position. In this position, the protrusion 2310 blocks the primary latch 1654. Optionally, the contact carrier position assurance component 1650 may include a slot 2410 whereby the primary latch 1654 is disposed within the slot 2410 of the contact carrier position assurance component 1650 to constrain movement of the primary latch 1654 when the contact carrier position assurance component 1650 is in the closed position. The primary latch 1654 is constrained to a position engaging the tab 1611. As illustrated, the protrusion 2310 blocks movement of the primary latch 1654 away from the tab 1611. FIG. 24C is a perspective view of the illustrative sealed multiport cable connector 1600 of FIG. 21 with the cover 1608 installed. The sealed multi-port cable connector 1600 is configured to mate with a mating connector in an insertion direction, and the contact carrier position assurance component 1650 is configured to slide into the housing in the insertion direction. In the assembled state, a cable connected to the contact carrier 1606 extends through an opening 1609 in the seal 1607 and an opening in the cover 1608.

[0092] Figure 25 is a cross-sectional view of the illustrative sealed multi-port cable connector 1600 of Figure 24C, showing the seal 1607 and cover 1608 blocking the contact carrier position assurance component 1650. The configurations illustrated in the figures of the sealed multi-port cable connector (e.g., Figures 21-25) result from methods of constructing the connector. In an exemplary method, the cover 1608 and seal 1607 can be threaded onto a cable terminated by the contact carrier 1606. The contact carrier can then be installed.

[0093] The contact carrier 1606 may then be inserted into an opening in the contact carrier position assurance component 1650 and slid into the chamber 1612 of the insulating housing 1603 until the tabs 1611 on the contact carrier 1606 engage with respective primary latches 1654 on the insulating housing 1603. The contact carrier position assurance component 1650 may then be slid forward within the insulating housing 1603 until a portion of the contact carrier position assurance component 1650 is adjacent each of the latches 1654 on the insulating housing, blocking movement of the latch in a direction to disengage the latch from the contact carrier. Optionally, a distal end of each of the latches may be disposed within a slot in the contact carrier position assurance component 1650.

[0094] The force that slides the contact carrier position assurance component 1650 into the closed position may be generated by pushing the cover 1608 toward the insulating housing 1603. Such pushing action may urge the seal 1607 against the contact carrier position assurance component 1650. Optionally, misalignment of the contact carrier 1606 may be detected when the magnitude of the force pushing the cover 1608 toward the insulating housing 1603 exceeds a threshold, but the cover 1608 does not engage the insulating housing 1603.

[0095] 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.

[0096] For example, the contact carrier position assurance component 1650 may include a latching mechanism that engages the connector housing in the open and / or closed positions.

[0097] As another example, the techniques described herein may be used in connectors having configurations other than those described above. For example, the techniques described herein may be used in, for example, board connectors or right-angle cable connectors. Furthermore, features of position assurance components described in connection with sealed connectors may be used in unsealed connectors instead of, or in addition to, features described in connection with unsealed connectors. Similarly, features of position assurance components described in connection with unsealed connectors may be used in sealed connectors instead of, or in addition to, features described in connection with sealed connectors.

[0098] Such alternative connector configurations may be used with all of the features described herein, or 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.

[0099] 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 illustrated, 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.

[0100] Various aspects of the present invention may be used alone, in combination, or in various configurations not specifically discussed in the foregoing embodiments, and therefore the application is not limited to the details and arrangements of components set forth in the foregoing specification or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments.

[0101] The use of ordinal terms such as "first," "second," "third," etc. in the claims to modify claim elements does not, in itself, imply any priority, precedence, or ordering of one claim element relative to another, or the chronological order in which method actions are performed, but is merely used as a marker to distinguish one claim element having a particular name from another element having the same name (absent the use of ordinal terms) to distinguish between claim elements.

[0102] 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.

[0103] 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."

[0104] As used in this specification and claims, the phrase "at least one" in connection with 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 every element specifically listed within the list of elements, and does not 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, whether related or unrelated to those specifically identified elements, may optionally be present.

[0105] 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 in some cases and disjunctively in other cases. 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, whether related or unrelated to those elements specifically identified, 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," 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.

[0106] As used in this specification and the claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" shall be interpreted as being inclusive, i.e., including at least one, but also including more than one, of several elements or lists 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," shall refer to the inclusion of exactly one element of several elements or lists of elements. Generally, as used herein, the term "or" shall 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.

[0107] 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. 1. An electrical connector comprising: an insulating housing having a chamber and a channel; a position assurance component comprising an opening (1631) having a channel and a surface adjacent to said channel; a contact carrier having tabs; Equipped with the position assurance component is slidably mounted within the insulating housing and configured to slide between an open position in which the channel in the insulating housing, the channel in the position assurance component, and the tab on the contact carrier are aligned, and a closed position in which the surface of the position assurance component is aligned with the channel in the insulating housing.

2. the position assurance component has a wall bounding the channel; the surface comprises one end of the wall; 2. The electrical connector of claim 1, wherein the position assurance component is in the closed position such that the surface interferes with withdrawal of the tab of the contact carrier through the channel.

3. the position assurance component includes a latch mechanism with a slit; 2. The electrical connector of claim 1, wherein the insulating housing includes a complementary latching mechanism that is complementary to the latching mechanism of the position assurance component and configured to engage the latching mechanism when the position assurance component is in place within the insulating housing.

4. the position assurance component comprises a body; the latch mechanism comprises a member; the slit separating the member from the body; The electrical connector of claim 3 , wherein the latching mechanism comprises a protrusion on the member.

5. the member is elongated in a direction between a first end and a second end; 5. The electrical connector of claim 4, wherein the member is attached to the body at the first end and the second end.

6. the member having a central portion between a first end and a second end; The electrical connector of claim 4 , wherein the protrusion extends from the central portion.

7. 4. The electrical connector of claim 3, wherein the complementary latching mechanism comprises a groove configured to engage at least a portion of the latching mechanism of the position assurance component to maintain the position assurance component in the predetermined position within the insulating housing.

8. the groove is a first groove, the predetermined position is a first predetermined position, the insulating housing includes a second groove; 8. The electrical connector of claim 7, wherein the second groove is configured to engage the latch mechanism when the position assurance component is in a second predetermined position within the insulating housing.

9. Equipped with multiple contact carriers, the insulating housing includes a plurality of chambers; The electrical connector of claim 1 , wherein the position assurance component comprises a plurality of openings.

10. Equipped with four contact carriers, The insulating housing includes four chambers; The electrical connector of claim 1 , wherein the position assurance component comprises four openings.

11. 1. An electrical connector comprising: an insulating housing having a chamber; a position assurance component having an opening and a surface; a contact carrier having a tab and positioned within the chamber; Equipped with the contact carrier extends through the opening in the position assurance component; the position assurance component is positioned such that the surface interferes with the tab of the contact carrier to prevent the contact carrier from being pulled out of the chamber of the insulating housing and the opening in the position assurance component.

12. the position assurance component includes a protrusion; 12. The electrical connector of claim 11, wherein the insulating housing includes a first groove, and the tab of the position assurance component is seated within the first groove of the insulating housing to maintain the position assurance component in a first position with the insulating housing.

13. 13. The electrical connector of claim 12, wherein the insulating housing includes a second groove, and the protrusion of the position assurance component is seated within the second groove of the insulating housing to maintain the position assurance component in a second position with the insulating housing.

14. further comprising a plurality of contact carriers including the contact carrier; the insulating housing includes a plurality of chambers, including the chamber; The electrical connector of claim 11 , wherein the position assurance component comprises a plurality of openings, including the opening.

15. Equipped with four contact carriers, The insulating housing includes four chambers; The electrical connector of claim 11 , wherein the position assurance component comprises four openings.

16. 16. The electrical connector of claim 15, wherein the four openings in the position assurance component are arranged in a 2x2 matrix.

17. 1. A housing subassembly for an electrical connector, comprising: an insulating housing including a chamber having a channel; a position assurance component comprising a channel and an opening having a surface adjacent the channel; the position assurance component is slidably mounted within the insulating housing so as to slide between an open position in which the channel of the insulating housing and the channel of the position assurance component are aligned and a closed position in which the surface of the position assurance component is aligned with the channel on the insulating housing; a housing subassembly, the position assurance component including a latch configured to engage complementary structure within the insulating housing when the position assurance component is in the open position;

18. the position assurance component comprises a body and a slit; the latch comprises a member; the slit separating the member from the body; The housing subassembly of claim 17 , wherein the latch comprises a protrusion on the member.

19. the member is elongated in a direction between a first end and a second end; 20. The housing subassembly of claim 18, wherein the member is attached to the body at the first end and the second end.

20. the member having a central portion between a first end and a second end; 20. The housing subassembly of claim 19, wherein the protrusion extends from the central portion.

21. 21. The housing subassembly of claim 20, wherein a complementary latching mechanism comprises a groove configured to engage at least a portion of a latching mechanism of the position assurance component to maintain the position assurance component in place within the insulating housing.

22. the groove is a first groove, the predetermined position is a first predetermined position, the insulating housing includes a second groove; 22. The housing subassembly of claim 21, wherein the second groove is configured to engage the latch mechanism when the position assurance component is in a second predetermined position within the insulating housing.

23. further comprising four contact carriers; The insulating housing includes four chambers; The housing subassembly of claim 17 , wherein the position assurance component comprises four openings.

24. 24. The housing subassembly of claim 23, wherein the four openings in the position assurance component are arranged in a 2x2 matrix.

25. 1. A method of operating an electrical connector comprising: an insulating housing comprising a chamber and a channel; a position assurance component comprising an opening having a channel and a surface adjacent said channel; and a contact carrier comprising a tab, the method comprising: With the position assurance component at least partially disposed within the insulating housing in a first position such that the channel of the insulating housing is aligned with the channel of the position assurance component, inserting the contact carrier through the opening in the position assurance component and into the chamber of the insulating housing by aligning the tabs of the contact carrier with the channels of the insulating housing and the position assurance component; and sliding the position assurance component relative to the insulating housing such that the channel of the insulating housing is blocked by the position assurance component.

26. The position assurance component further comprises a protrusion, the insulating housing comprises a first groove, and the method further comprises:

26. The method of operating an electrical connector of claim 25, further comprising pressing the position assurance component until the protrusion engages the first groove of the insulating housing to secure the position assurance component in an open position within the insulating housing, thereby maintaining the position assurance component in the first position.

27. the insulating housing includes a second groove; 27. The method of operating an electrical connector of claim 26, wherein sliding the position assurance component relative to the insulating housing includes pushing the position assurance component until the protrusion engages the second groove to secure the position assurance component in a final position within the insulating housing.

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