Spring-Loaded Electrical Connector

Abstract

The electrical connector and assembly may include a housing and contact members therein. The contact members include electrical contacts. A contact barrier is connected to the housing and movable between a closed state and an open state. In the open state, the contact members are exposed, and in the closed state, the contact members are protected by the contact barrier. The contact barrier is biased to the closed state. The electrical connector and assembly may include a housing with a core assembly having at least one electrical contact. The rotatable coupling member is rotatably mounted to an end of the housing and includes the coupling housing, at least one latch element coupled to an inner surface of the coupling housing, and at least one central biasing element configured to bias and self-center the rotatable coupling member relative to the housing in a connection-ready orientation.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Patent Application No. 18 / 166,857, filed February 9, 2023, which is incorporated herein by reference in its entirety. [Background technology]

[0002] Conventional high-density electrical connectors often suffer from contact intermittency and mating reliability issues at the mating interface due to the narrow pitch and density required to achieve small package sizes that result in connection failures related to tolerance stackup. In addition, conventional high-density connectors are expensive to manufacture and bulky due to the increased number of signals. Summary of the Invention

[0003] The present disclosure describes an electrical connector that can provide a high density of contacts without increasing the size of the connector, and that provides stability and consistent signal integrity to the connector system when mated with another connector in the connector system. Accordingly, the present disclosure may provide an electrical connector including a housing having a mating interface end section, an opposing cable termination end section, and an inner support member. A core is slidably coupled to the inner support member of the housing and includes a receiving end and a spring engagement end. The spring member is received within the housing and is behind the core for abutment with the spring engagement end of the core. An interposer is received in the receiving end of the core and may be separated from the spring member. The core is axially slidable relative to the inner support member along a longitudinal axis of the housing between an unmated position in which the spring member pushes the core outward from the cable termination end of the housing and a mated position in which the core presses inward against the spring member.

[0004] In one embodiment, the electrical connector includes contact members coupled to the core, the contact members having one end adjacent the interposer and another end near or at the cable termination end section of the housing. The contact members may be flexible printed circuit boards having an end face and an opposite end. The interposer may include at least one contact side for electrically connecting with the contact members. The interposer may be supported within the receiving end of the core by an inner support member of the housing.

[0005] In other embodiments, the at least one contact side includes a plurality of individual contacts that electrically connect with contact elements coupled to the core, the interposer includes a second contact side opposite the at least one contact side for electrically connecting with a mating connector, and one or more alignment pins may be provided that extend through the interposer and into the core to align the interposer with the contact elements. These alignment pins may be fine alignment features that extend all the way to the mating connector to ensure sufficiently fine alignment between the connectors so that all contacts align with mating pads on the flex circuit. In another embodiment, the housing's inner support member is a longitudinally extending central post having a distal free end that extends beyond the mating interface end section of the housing and through the interposer. In one embodiment, the spring member is one or more wave springs.

[0006] The present disclosure may also include an electrical connector including a housing having a mating interface end section, an opposing cable termination end section, and an inner support member, wherein a core is slidably coupled to the inner support member of the housing and includes a receiving end and a spring engagement end. A spring member is received within the housing and behind the core for abutment with the spring engagement end of the core. A first contact member is coupled to the core. A double-sided contact interposer is received in the receiving end of the core and may be spaced from the spring member and includes opposing first and second contact sides, the first contact side configured to electrically connect with the first contact member and the second contact side configured to electrically connect with the mating connector. The core is axially slidable relative to the inner support member along a longitudinal axis of the housing between an unmated position in which the spring member pushes the core outward from the cable termination end of the housing and a mated position in which the core pushes inward against the spring member.

[0007] In one embodiment, the first contact element coupled to the core is a flexible printed circuit board having an end face that contacts the first contact side of the double-sided contact interposer and an end that is located at or near the cable termination end section of the housing. In another embodiment, the contact element can be a conventional rigid printed circuit board. The first and second contact sides of the double-sided contact interposer can include a plurality of individual contacts. In another embodiment, the double-sided contact interposer has a wafer body that supports a plurality of individual contacts, each individual contact being a C-clip. The inner support element of the housing can be a longitudinally extending central post having a distal free end that extends beyond the mating interface end section of the housing and through the double-sided contact interposer.

[0008] In one embodiment, the mating connector is coupled to the housing when the core is in the mating position, such that the second contact member of the mating connector is received in the core and electrically connects with the second side of the double-sided contact interposer, and the first contact member electrically connects with the first side of the double-sided contact interposer. The second contact member can be a flexible printed circuit board having an end face that abuts the second contact side of the double-sided contact interposer. In yet another embodiment, an outer coupling member is received on the mating interface end section of the housing to couple the mating connector to the housing. In other embodiments, the housing's inner support member is a longitudinally extending central post, where the post has a distal free end that extends through the double-sided contact interposer, beyond the mating interface end section of the housing, and engages with a corresponding post on the mating connector, one or more alignment pins may extend through the first contact member, the double-sided contact interposer, and the second contact member for alignment thereof, and the spring member is one or more wave springs. In another embodiment, a keyway may be provided on the connector and the mating connector that serves as an overall alignment feature for proper alignment of the connectors.

[0009] The present disclosure may further provide an electrical connector including a housing having a mating interface end section and an opposing cable termination end section, the housing having an inner support member, a contact carrier slidably coupled to the housing, the contact carrier including a receiving end and a spring-engagement end, the contact carrier supporting at least one contact member, at least one spring member received within the housing and adjacent the contact carrier for abutment with the spring-engagement end of the contact carrier, and an interposer received in the receiving end of the contact carrier and spaced from the spring member, the contact carrier being slidable relative to the housing along a mating axis between an unmated position and a mated position.

[0010] In certain embodiments, the interposer includes at least one contact side for electrically connecting with the contact members, the at least one contact side including a plurality of individual contacts for electrically connecting with the contact members coupled to the contact carrier, and / or the interposer includes a second contact side opposite the at least one contact side for electrically connecting with the mating connector. In other embodiments, one or more alignment pins extend through the interposer and into the contact carrier to align the interposer with the contact members and / or coupling members associated with the housing for coupling the mating connector to the housing.

[0011] The present disclosure may still further provide an electrical connector comprising: a housing having a mating interface end section and an opposing cable termination end section; a contact carrier slidably coupled to the housing, the contact carrier including a receiving end and a spring-engagement end, the contact carrier supporting at least one contact member, at least one spring member received inside the housing and adjacent the contact carrier for abutting the spring-engagement end of the contact carrier, an interposer received in the receiving end of the contact carrier and spaced from the spring member, and a coupling member associated with the housing. The contact carrier is slidable relative to the housing along a mating axis between an unmated position and a mated position.

[0012] In some embodiments, the contact member is a flexible printed circuit board, the interposer has a wafer body supporting a plurality of individual contacts, each individual contact being a C-clip, and / or one or more alignment pins extend through the first contact member, the interposer, and the second contact member for alignment thereof.

[0013] The present disclosure may also provide an electrical connector including a housing having a receiving area and a mating interface, and a contact carrier received within the housing. The contact carrier may include a receiving portion and a spring-engaging portion and supports contact members. An interposer is mounted on the receiving portion of the contact carrier with the contact members therebetween. One or more spring members are provided operably associated with the spring-engaging portion of the contact carrier. The contact carrier is movable relative to the housing between an unmated electrical position and a mated electrical position along an axis perpendicular or substantially perpendicular to the longitudinal mating axis.

[0014] In certain embodiments, the contact elements are flexible circuit boards, the interposer includes at least one contact side for electrically connecting with the contact elements, the at least one contact side including a plurality of individual contacts for electrically connecting with the contact elements coupled to the contact carrier, and / or the interposer includes a second contact side opposite the at least one contact side for electrically connecting with the mating connector. In one embodiment, the electrical connector may further include one or more alignment pins extending through the contact carrier and into or through the interposer to align the interposer with the contact elements of the mating connector.

[0015] The present disclosure may further provide an electrical connector assembly including a receptacle including: a housing having a receiving area; a contact carrier received within the housing, the contact carrier including a receiving portion and a spring-engagement portion and supporting a first contact member; an interposer mounted on the receiving portion of the contact carrier having a contact member between the receiving portion and the spring-engagement portion; and one or more spring members operably associated with the spring-engagement portion of the contact carrier. The contact carrier is movable relative to the housing between an unmated electrical position and a mated electrical position. The assembly may also include a plug including a housing having a mating interface configured for insertion into the receiving area of ​​the housing and having a second contact member configured to engage the interposer of the housing on a side opposite the first contact member.

[0016] In one embodiment, the contact carrier of the assembly moves between an unmated electrical position and a mated electrical position along an axis that is perpendicular or substantially perpendicular to the longitudinal mating axis of the receptacle and plug. In another embodiment, one or more alignment pins extend through the first contact member, the interposer, and the second contact member for alignment thereof.

[0017] In another embodiment, the assembly further includes a latch mechanism for securing the contact carrier in the mated electrical position, the latch mechanism being a cam member configured to rotate between a deactivated position and an activated position to move the contact elements of the plug, which in turn move the contact carrier or contact system of the receptacle, respectively, between the unmated electrical position and the mated electrical position. The cam member may rotate a selected or predetermined number of degrees, such as about 45 degrees, about 90 degrees, about 135 degrees, about 180 degrees, or about 225 degrees (or any other suitable angle) from the deactivated position to the activated position. The cam member includes a stem having a width and a thickness, the width being greater than the thickness. The cam member has an end coupled to the coupling nut of the plug. The latch mechanism is a sliding latch member configured to slide between a deactivated position and an activated position to move the contact elements of the plug, which in turn move the contact carrier or contact system of the receptacle, respectively, between the unmated electrical position and the mated electrical position. and / or the plug includes an elevator support associated with the second contact member, the elevator support configured to move between a first position and a second position in response to an inactivated position and an activated position of the sliding latch member, respectively; and / or the latch mechanism includes a latch actuation release at a mating interface of the plug configured to depress when the plug is mated with the receptacle.

[0018] In another embodiment, the latch mechanism may include a latch actuation / release system that will allow actuation of the latch / mating mechanism only when the system is engaged (i.e., fully mated) within the mating receptacle. The latch actuation / release system may include a spring probe system in the nose of the plug that is depressed when mated with the receptacle, subsequently allowing engagement of the coupling mechanism and therefore latch actuation.

[0019] The present disclosure may also provide an electrical connector including a housing having a receiving area and a mating interface, a contact carrier received within the housing, the contact carrier including a receiving portion and a spring-engagement portion, the contact carrier supporting contact elements, a contact system mounted on a face of the contact elements, one or more spring members operably associated with the spring-engagement portion of the contact carrier, and the contact carrier movable relative to the housing between an unmated electrical position and a mated electrical position.

[0020] In some embodiments, the contact element is a flexible circuit board, the contact system includes at least one contact side for electrically connecting with a surface of the contact element, the contact system includes a plurality of individual contacts electrically connecting with the surface of the contact element, the electrical connector is a receptacle, the contact carrier moves relative to the housing between an unmated electrical position and a mated electrical position along an axis that is perpendicular or substantially perpendicular to the longitudinal mating axis, and / or the electrical connector further includes one or more alignment pins extending through the contact carrier and the contact element.

[0021] The present disclosure may also further provide an electrical connector assembly, the electrical connector assembly comprising a first connector including a housing having a mating interface, a contact carrier having a receiving portion and a spring-engagement portion, the contact carrier supporting first contact members, the contact carrier being movable relative to the housing between an unmated electrical position and a mated electrical position. A contact system is mounted on the first contact members. One or more spring members are operably associated with the spring-engagement portion of the contact carrier. The assembly includes a second connector including a housing having a mating interface configured to mate with the mating interface of the housing of the first connector. The second connector has a second contact member. The contact system exists between the first contact member and the second contact member when the first connector and the second connector are electrically mated.

[0022] In certain embodiments, the first connector is a receptacle and the second connector is a plug, each of the first and second contact members is a flexible printed circuit board, and / or the contact carrier moves between an unmated electrical position and a mated electrical position along an axis that is perpendicular or substantially perpendicular to the longitudinal mating axis of the first connector and the second connector.

[0023] The present disclosure may further provide an electrical connector assembly including a first connector including a housing having a mating interface, a contact carrier having a receiving portion and a spring-engagement portion, the contact carrier supporting first contact members, the contact carrier being movable relative to the housing between an unmated electrical position and a mated electrical position. An interposer is mounted on the receiving portion of the contact carrier with the contact members therebetween. One or more spring members are operably associated with the spring-engagement portion of the contact carrier. The assembly includes a second connector including a housing having a mating interface configured to mate with the mating interface of the housing of the first connector, the second connector having second contact members configured to engage with the interposer. The interposer resides between the first and second contact members when the first and second connectors are electrically mated.

[0024] In some embodiments, the first connector is a receptacle and the second connector is a plug, each of the first contact member and the second contact member is a flexible printed circuit board, and / or the contact carrier moves between an unmated electrical position and a mated electrical position along an axis that is perpendicular or substantially perpendicular to the longitudinal mating axis of the first connector and the second connector.

[0025] In other embodiments, the electrical connector assembly may further include a latch mechanism for securing the connector assembly in the mated electrical position, the latch mechanism being a cam member configured to rotate between an unactuated position and an actuated position to move a second contact member that moves the contact carrier between the unmated electrical position and the mated electrical position, respectively; the second connector including an elevator support associated with the second contact member, the elevator support configured to move between a first position and a second position in response to the unactuated and actuated positions of the cam member, respectively; a sliding latch member configured to slide between an actuated position to move the second contact member that moves the contact carrier between an unmated position and a mated position, respectively, the second connector including an elevator support associated with the second contact member, the elevator support configured to move between a first position and a second position in response to the unactuated and actuated positions of the sliding latch member, respectively, and / or the latch mechanism includes a latch actuation release at a mating interface of the second connector configured to depress when the first connector and the second connector are mated.

[0026] A more complete understanding of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings. [Brief explanation of the drawings]

[0027] [Figure 1] 1 is a front perspective view of an electrical connector according to an exemplary embodiment of the present disclosure; [Figure 2] FIG. 2 is an exploded perspective view of the electrical connector shown in FIG. 1. [Figure 3] 2 is a cross-sectional view of the electrical connector shown in FIG. 1, showing the core or contact carrier of the electrical connector in an unmated position. [Figure 4]2 is a cross-sectional view of the electrical connector shown in FIG. 1, showing the electrical connector mated to a mating connector and showing its core or contact carrier in a mated position. [Figure 5A] 2 is a perspective view of one side of an interposer of the electrical connector shown in FIG. 1. [Figure 5B] FIG. 5B is an enlarged view of an individual contact of the interposer shown in FIG. 5A. [Figure 6] 2 is an exploded view of a mating connector that mates with the electrical connector shown in FIG. 1. FIG. [Figure 7A] FIG. 10 is a perspective view of a pair of mated electrical connectors according to an alternative exemplary embodiment of the present disclosure, showing the electrical connectors assembled; [Figure 7B] 10 is an exploded view of a mated pair of electrical connectors according to an alternative exemplary embodiment of the present disclosure, showing the electrical connectors assembled; [Figure 8] FIG. 7C is an exploded view of one of the electrical connectors shown in FIGS. 7A and 7B. [Figure 9A] FIG. 7C is an exploded view of another electrical connector shown in FIGS. 7A and 7B. [Figure 9B] FIG. 7C is another perspective view of the electrical connector shown in FIGS. 7A and 7B. [Figure 10A] 7B is a cross-sectional view of the assembly of the electrical connector of FIG. 7A showing the unmated electrical position. [Figure 10B] 7B is a cross-sectional view of the assembly of the electrical connector of FIG. 7A showing the mated electrical position. [Figure 11] FIG. 10 is a cross-sectional view of an assembled electrical connector assembly according to yet another exemplary embodiment of the present disclosure. [Figure 12A] 1 is a schematic diagram of a portion of a connector assembly according to one embodiment of the present disclosure, showing a contact barrier in a closed state. [Figure 12B] FIG. 12B is a schematic diagram of the connector assembly of FIG. 12A showing the contact barrier in an open state. [Figure 13A]1 is a schematic diagram of a portion of a connector assembly according to one embodiment of the present disclosure, illustrating a closed state of the contact barrier during assembly of the connector assembly. [Figure 13B] 13B is a schematic diagram of the connector assembly of FIG. 13A, showing the open state of the contact barrier when the connector assembly is assembled; [Figure 14] 1 is a schematic diagram of a connector assembly having a contact barrier according to one embodiment of the present disclosure. [Figure 15] 1 is a schematic diagram of a connector assembly having a contact barrier according to one embodiment of the present disclosure. [Figure 16] 1 is a schematic diagram of a connector assembly having a contact barrier according to one embodiment of the present disclosure. [Figure 17A] FIG. 1 is a schematic diagram of a first connector of a connector assembly according to one embodiment of the present disclosure. [Figure 17B] 17B is a schematic diagram of the second connector of the connector assembly of FIG. 17A connecting to the first connector. [Figure 18A] 1 is a schematic diagram of a connector according to one embodiment of the present disclosure. [Figure 18B] 18B is an exploded schematic view of the components of the connector of FIG. 18A shown in an exploded state. [Figure 18C] FIG. 18B is a schematic diagram of a plug core assembly of the connector of FIG. 18A. [Figure 18D] 18B is a schematic diagram of a coupling member of the connector of FIG. 18A. [Figure 19A] 1 is a schematic diagram of a connector according to one embodiment of the present disclosure. [Figure 19B] 19B is an exploded schematic view of the components of the connector of FIG. 19A shown in an exploded state. [Figure 20A] FIG. 1 is a schematic diagram of a connector assembly according to one embodiment of the present disclosure. [Figure 20B] FIG. 20B is an enlarged schematic view of a portion of the connector assembly of FIG. 20A. [Figure 21A] 10A-10C are schematic diagrams of steps for joining connector assemblies together according to one embodiment of the present disclosure. [Figure 21B] 21B is a schematic diagram of another step in joining the connector assemblies of FIG. 21A together. [Figure 21C] 21B is a schematic diagram of another step in joining the connector assemblies of FIG. 21A together. [Figure 21D] 21B is a schematic diagram of another step in joining the connector assemblies of FIG. 21A together. DETAILED DESCRIPTION OF THE INVENTION

[0028] 1-6 , the present disclosure generally relates to an electrical connector 100, such as a high-density electrical connector, that incorporates a spring-loaded core or contact carrier 110 (generally referred to as a “contact carrier 110”) designed to provide positive electrical contact with a mating connector 200, thereby ensuring consistent signal integrity throughout the connector system without interruptions before or during use of the system. The contact carrier 110 is designed to allow overtravel to overcome tolerance stacking of the mating connectors, ensuring each of the contacts is fully engaged. Furthermore, the contact carrier 110 is configured to maintain an electrical connection between the connectors even when their respective mating faces are not planar with one another during mating. In one embodiment, the contact carrier 110 of the electrical connector 100 is configured to cooperate with a double-sided contact interposer 112 to provide a consistent electrical connection between the connectors 100, 200. Another advantage of the connector system of the present disclosure is that it can have an increased density, such as a 1 mm pitch, and can be mated / unmated up to 5,000 times. Additionally, the connector system of the present disclosure can provide increased signal contact density at a relatively low cost, which is reliable for up to 5,000 cycles. The connector design of the present disclosure allows users to increase signal count while maintaining the same size connector and raw cable.

[0029] Generally, the electrical connector 100 includes a housing 102 that slidably supports a contact carrier 110, a spring member 114 received within the housing 102 behind the contact carrier 110, an interposer 112 received within the contact carrier 110, and contact members 116. The contact carrier 110 is configured to slide axially along a longitudinal axis of the housing 102 between an unmated position ( FIG. 3 ) in which the contact carrier 110 is biased outward and ready to mate with a mating connector 200, and a mated position ( FIG. 4 ) in which the contact carrier 110 is pushed inward to compress the spring member 114 and electrically engage the mating connector 200. The spring member 114 may be any biasing member, such as one or more wave springs.

[0030] The housing 102 generally includes a mating interface end section 104 for interfacing with the mating end 202 of the mating connector 200, a cable termination end section 106 configured to receive a prepared end of the cable C, an inner support member 108 that slidably supports the contact carrier 110, and an inner receiving area 109 that receives at least a portion of the contact carrier 110 and surrounds the inner support member 108 for receiving a spring member 114 within the housing 102. The cable termination end section 106 may also be configured to receive a potting member 10 and a strain relief member 12, such as a boot, for the prepared end of the cable C. The inner support member 108 may be a longitudinally extending central post or barrel, as seen in FIGS. 3-4 . 4 , the inner support member 108 can extend outwardly beyond the mating interface end section 104 such that its distal free end can engage a corresponding component 204 of the mating connector 200 to provide stability to the connector system when the connectors 100, 200 are mated. In one embodiment, the inner support member 108 is hollow at its distal end to receive a corresponding component 204 of the mating connector 200, which may be a post sized to be insertable into the distal end of the inner support member 108.

[0031] The contact carrier 110 is mounted on and slides along the inner support member 108 of the housing 102 between the unmated and mated positions. The contact carrier 110 may also be slidably attached to the housing 102, such as by snaps and the like. The contact carrier 110 generally includes a spring-engagement end 120 that abuts the spring member 114 when the contact carrier 110 is compressed inwardly in the mated position, and a receiving end 122 that is sized and shaped to receive the interposer 112. The contact members 116 are mounted within the spring-engagement end of the contact carrier 110 such that one end is adjacent the interposer 112 and the other end is near or at the cable termination end section 106 of the housing 102. The contact members 116 may be, for example, flexible printed circuit boards having end faces 126 that are received in the contact carrier 110 configured to electrically engage the interposer 112 and end faces 128 that connect to the cable C. The end faces 128 of the flexible printed circuit board are designed to allow for bucking due to spring-loaded movement of the contact carrier 110 along the inner support member 108 between the unmated and mated positions.

[0032] The interposer 112 includes at least one contact side 130, such as at its end face 126, for electrically contacting the contact members 116. In one embodiment, the interposer 112 is a double-sided contact interposer having a second contact side 132 opposite the first contact side 130 and configured to electrically contact the contact members 216 of the mating connector 200. The contact members 216 of the mating connector 200, like the contact members 116, may also be flexible printed circuit boards (“PCBs”) having end faces 226 and terminal ends 228, as seen in FIG. 6 . The end faces 226 of the contact members 216 are configured to abut the second contact side 132 of the interposer 112. According to embodiments of the present disclosure, the contact members may be flexible or flex PCBs, rigid PCBs, or rigid-flex or rigid-flex PCBs. A rigid-flex PCB incorporates flexible materials in conjunction with rigid materials by laminating a flexible circuit board inside of a rigid circuit board material, thus combining the versatility of flexible circuits with the stability, strength, and circuit routing density of a rigid PCB.

[0033] In one embodiment, the interposer 112 has a wafer body 136 that can include a central opening 138 sized to receive the inner support member 108 of the housing 102. Each of the contact sides 130, 132 of the interposer 112 can include a plurality of individual contacts 140, as seen in FIG. 5A, for electrical contact with the contact members 116, 216, respectively. The individual contacts 140 can be, for example, conductive C-clips, as seen in FIG. 5B. The biasing force of the spring members 114 can be higher than the mating force of each individual C-clip 140 loaded onto the interposer 112 to provide overtravel of the contact carrier 110 beyond full mating compression of the C-clip for consistent contact with the spring members 114. Such action ensures full compression of the end faces 126 of the contact members 116 on the individual contacts 140, resulting in a connector system, i.e., a mated connector, with a consistent mating force, as determined by the spring members 114. The mating force of the connector system can be adjusted through the use of different spring members. For example, the number of individual contacts 140 on the interposer 112 may be increased or decreased to increase or decrease their biasing force, respectively, in which case the biasing force of the spring members 114 can compensate for this increase or decrease in the biasing force of the contacts 140 to provide overtravel of the contact carrier 110. In this manner, the connector system can be configured to have the lowest maximum insertion force achievable for a given number of contacts.

[0034] Once the connectors 100 and 200 are mated, a coupling member 150, such as a coupling nut, can be used to latch the connectors together. The coupling nut 150 can be designed, for example, to be spring-loaded so that the coupling nut 150 self-rotates and latches into place during installation. Although the coupling nut 150 is preferably used to latch the connectors 100, 200, any known latching mechanism and / or friction fit can be used to latch or secure the connectors 100, 200 together.

[0035] In one embodiment, the inner support member 108 and corresponding component 204 of the mating connector 200 generally provide coarse alignment of the connector system, while one or more alignment members 160, such as alignment pins, generally provide fine alignment of the connector system. The one or more alignment pins 160 may extend through the contact end face 226, the interposer 112, the contact end face 126, and into the contact carrier 110 to align the interposer 112, and particularly the individual contacts 140, with the end faces 126, 226 of each of the contact members 116, 216 of the connectors 100, 200, respectively. The alignment pins 160 may also extend through to the mating connector to ensure sufficiently fine alignment between the connectors so that all contacts line up with mating pads on the flex circuit.

[0036] 7A-11 illustrate an alternative exemplary embodiment of the present disclosure. Specifically, FIGS. 7A-11 illustrate a connector 100′ according to one embodiment of the present disclosure. The connector 100′ has a similar back spring overtravel design as described above. The connector 100′ and each mating connector 200′ each have similar interconnection features as described above, except that the engagement between the two connectors 100′, 200′ is in a direction generally perpendicular to the mating or longitudinal axis of the connector assembly. The design of the connector 100′ advantageously provides a reduced outer diameter of the connector 100′ while allowing for an extended length of the connector 100′ for a higher density of contacts. This can be particularly beneficial for handheld applications, such as catheter handles, where a smaller outer diameter is preferred for the user to handle and manipulate the connector (e.g., generally to fit more comfortably in the user's hand).

[0037] Similar to the connector 100 described above with respect to Figures 1-6, the connector 100' of Figures 7A-11 generally includes a housing 102' that movably supports a contact carrier 110', a spring member 114' received within the housing 102' in association with the contact carrier 110', an interposer 112', and a contact member 116' supported by the contact carrier 110', as seen in Figure 8. The connector 100' is designed so that the contact carrier 110' can move within the housing 102' in a direction perpendicular or substantially perpendicular to the longitudinal mating axis L of the connector assembly, which functions as an overtravel buffer, between an unmated position (FIG. 10A) in which the contact carrier 110' is biased toward and ready to electrically mate with the mating connector 200', and a mated position (FIG. 10B) in which the contact carrier 110' is compressed against the spring members 114' and electrically engages the contact members 216' of the mating connector 200'. The spring members 114' may be any biasing member, such as one or more wave springs, compression springs, resilient materials, or the like.

[0038] The housing 102' generally includes a mating interface end section 104' for interfacing with the mating end 202' of the mating connector 200' and an inner receiving area 109' for receiving the contact carrier 110', interposer 112', and spring members 114' inside the housing 102'. The contact carrier 110' is mounted within the housing 102' and is movable between an unmated electrical position and a mated electrical position, as seen in FIGS. 10A-10B. The contact carrier 110' generally includes a spring engagement portion 120' configured to mate with the spring members 114' when the contact carrier 110' is compressed into the mated position by the mating connector 200', and a receiving portion 122' configured to support the contact members 116' and interposer 112'. The contact member 116' may be, for example, a flexible printed circuit board having one surface 126' that mounts on the receiving portion 122' of the contact carrier 110' and an opposite surface 128' configured to electrically engage the interposer 112'.

[0039] The interposer 112' is similar to the interposer 112 described in the embodiment of Figures 1-6. The interposer 112' includes a first contact side 130' for electrically contacting a contact member 116', e.g., a surface 126' of the contact member 116', and a second contact side 132' opposite the first contact side 130' and configured to electrically connect with a contact member 216' of a mating connector 200'. Like the interposer 112 of the embodiment of Figures 1-6, the interposer 112' of this embodiment may have a wafer body 136', and each of the contact sides 130', 132' may include a plurality of individual contacts, such as conductive C-clips. The biasing force of the spring members 114' can be higher than the mating force of each individual contact loaded on the interposer 112' to provide overtravel of the contact carrier 110' beyond full mating compression of the individual contacts for consistent contact with the contact members 216'. This ensures full compression of the contact members on the individual contacts of the interposer 112', so that the mated connector system or assembly has a consistent mating force.

[0040] As seen in FIGS. 9A-9B, the mating connector 200′ may have a housing 202′ having an interface end 204′ and an opposing coupling nut 150′. The housing 202′ includes an inner elevator support 208′ that houses a second contact member 216′. The elevator support 208′ is configured to move between a first position ( FIG. 10A ) and a second position ( FIG. 10B ) corresponding to the unmated and mated electrical positions of the contact carrier 110′, respectively. The elevator support 208′ may be spring-loaded in the unmated position by an elevator biasing spring 208 a′ to prevent “bumping” during coarse-aligned axial engagement with the mating connector 100′, for example, prior to electrical connection. The contact member 216′ of the mating connector 200′ may also be a flexible printed circuit board having a contact surface 226′ similar to that of the contact member 116′.

[0041] The connector 100' may be, for example, a receptacle, and the mating connector 200' may be, for example, a plug that inserts into the receptacle. When the connectors 100', 200' are axially assembled, i.e., when the interface end 204' of the connector 200' (e.g., a plug) is received in the housing 102' of the connector 100' (e.g., a receptacle), a latching mechanism can be activated to complete and secure the electrical connection between the receptacle and the plug. The latching mechanism is designed to move the contact members 216' of the plug toward the receptacle interposer 112' in a direction substantially perpendicular to the axis of mating between the plug and receptacle.

[0042] In one embodiment, the latch mechanism may include a cam member 300 supported by the plug and rotatable between an inactivated position and an activated position. The cam member 300 may include an elongated stem 302 having one end 304 connected to the plug's coupling nut 150′ and an opposite locking end 306. The elongated stem 302 may be generally flat, i.e., when the cam member 300 is rotated a predetermined number of degrees, e.g., 90 degrees or approximately 90 degrees, from the inactivated position ( FIG. 10A ) to the activated position ( FIG. 10B ), the stem 302 pushes the plug's elevator support 208′, which supports the plug's contact members 216′, from a first position toward the receptacle's interposer 112′ (e.g., downward on the page of FIGS. 10A-10B ), to a second position. That is, as the coupling nut 150' rotates, the cam member 300 operates via the elevator support 208' to move the contact member 216' from a non-mated electrical position toward the mating receptacle contact system to a mated electrical position, thereby electrically connecting the plug and receptacle. In that position, the locking end 306 locks or abuts against the plug housing 202'.

[0043] The latch mechanism may alternatively be a sliding latch member 400, as seen in FIG. 11 . The sliding latch member 400 is configured to slide between an inactivated position and an activated position. That is, when the sliding latch member moves from the inactivated position to the activated position, the plug's elevator support 208' is pushed from a first position toward the receptacle's interposer 112' to a second position, thereby moving the contact carrier 110' from a non-mated electrical position to a mated electrical position and electrically connecting the plug's contact members 216' with the receptacle's interposer 112'. The sliding latch member 400 may have a feature 402, such as a snap feature, configured to prevent premature mating of the components prior to plug / receptacle assembly. In this embodiment, the receptacle 100' may push the feature 402 out of the way of interference within the plug 200', thereby allowing the sliding latch member 400 to be engaged.

[0044] In yet another embodiment, latching of the plug to the receptacle when fully seated may be provided by a friction fit, a spring clip latch, or a locking latch mechanism, etc. The latch mechanism may incorporate a latch actuation release system configured to prevent the contact system coupling nut from being actuated without engagement of the plug and receptacle. Such a configuration ensures that the plug and receptacle are seated without damaging the plug contact system. A spring-loaded mechanism, such as a spring probe, may be included at the plug's interface end 204', which can prevent the cam member 300 from being actuated / rotated by the user due to interference with the cam member 300's interface end 204' (which also acts as a locking feature to the receptacle upon engagement and actuation). Once the interface end 204' of the plug is fully inserted into the bottom of the receptacle, the spring-loaded mechanism can be depressed away from the cam member 300, thereby allowing the user to rotate the coupling nut 150', which engages the plug contact system with the receptacle contact system and further latches the plug to the receptacle so that it cannot be disengaged unless the user manually disconnects it by rotating the coupling nut 150' back to its unactuated state and engaging it.

[0045] In one embodiment, the coupling nut 150' may be spring-loaded in a locked position or state. The coupling nut 150' may have a mating orientation feature, such as a protrusion, configured to engage a corresponding receptacle mating feature, such as a protrusion, that rotates the coupling nut 150' to an unlocked position or state during mating. The coupling nut 150' may include an orientation feature that overcomes the receptacle orientation feature and latches into place when the receptacle and plug are assembled together. In this manner, latching via the latching mechanism and electrical engagement between the components are simultaneous or near simultaneous.

[0046] In another embodiment, coupling nut 150' is configured to utilize mating orientation features corresponding to mating orientation features on the receptacle, as described above, but latching and electrical engagement may not occur simultaneously. After initial assembly of the receptacle and plug, coupling nut 150' can be rotated toward a locking orientation that cams the plug's contact system (e.g., elevator support 208' and contact members 216') onto the mating receptacle contact system (e.g., interposer 112'), thereby fully engaging electrical engagement and over-travel spring 114'. This allows a user to overcome high axial mating forces by utilizing a latching mechanism, such as cam member 300, for mechanical advantage.

[0047] One or more alignment pins 160, 160' may be provided in the receptacle housing 102' to facilitate alignment of the plug with the connector system when a latching mechanism, such as cam member 300, is actuated to complete the electrical coupling of the receptacle and plug. The pins 160, 160' may extend through the contact carrier 110', the contact members 116', and into the interposer 112', as seen in FIG. 10A, leaving their ends 162, 162' ready to engage with the plug's contact members 216'. The plug contact members 216' may include holes 218' corresponding to the receptacle alignment pins 160, 160' such that when the latch mechanism is actuated, the plug holes 218' receive the ends 162, 162' of the alignment pins 160, 160' for proper fine alignment and contact alignment of the receptacle interposer 112 with the plug contact members 216'. Alternatively, alignment pins may be provided in the plug 200' that engage with corresponding holes in the receptacle 100'.

[0048] While particular embodiments have been selected to illustrate the present disclosure, those skilled in the art will recognize that various changes and modifications can be made therein without departing from the scope of the present disclosure, as defined by the appended claims. A method can be incorporated to prevent the contact system coupling mechanism from being actuated without engagement of the plug and receptacle. This ensures that the plug and receptacle can be seated without damaging the contact system or the interposer. A spring-loaded mechanism, such as a spring probe 209', can be included within the plug's interface end 204' to prevent the cam member 300 from being actuated / rotated by the user due to interference with the cam member's interface end 204' (which also acts as a locking feature to the receptacle upon engagement and actuation). Once the interface end 204' of the plug is fully embedded in the bottom of the receptacle, the spring-loaded mechanism may be pushed down by a mating feature in the receptacle, away from the cam member 300, thereby allowing the user to rotate the coupling nut 150', which engages the plug contact system with the receptacle contact system and further latches the plug to the receptacle, so that the plug cannot be disengaged from the receptacle unless the user manually disconnects it by rotating the coupling nut 150' back to its unactuated state.

[0049] During installation and / or mating and separation of two components, contacts (e.g., contact members 216, 216′) may be exposed. Thus, a user may inadvertently make contact when the connectors (e.g., connectors 100, 200, or 100′, 200′) are separated from one another. Specifically, in the configurations of FIGS. 7A-11 , contact member 216′ may be exposed and may come into contact with contact member 216′. To prevent such contact by a person (e.g., a finger, etc.), according to some embodiments of the present disclosure, a contact barrier is provided to automatically protect the contact member(s) when the connectors are separated from one another.

[0050] For example, referring now to FIGS. 12A-12B , a schematic diagram of a connector assembly according to one embodiment of the present disclosure is shown. The connector assembly includes a connector 500 (e.g., similar to mating connector 200′) configured to removably engage with a mating connector (e.g., similar to connector 100′). Connector 500 includes a boot 502, a coupling nut 504, and a housing 506 assembled to form connector 500. Boot 502 is configured to connect to or provide connection and protection to a cable or the like (e.g., as shown in FIGS. 1-4 ). Coupling nut 504 is arranged to be manually operated as described above (e.g., as described with respect to FIGS. 7A-11 ). Coupling nut 504 is configured to operate in response to locking end 508, as described above. Coupling nut 504 may be rotatable between a locked position or state ( FIG. 12B ) and an unlocked position or state ( FIG. 12A ).

[0051] The housing 506 supports and houses contact members 510 including one or more electrical contacts 512 thereon. The electrical contacts 512 may be pins or the like and may be sensitive to liquids, oils, or unintentional mechanical or physical contact that could damage or otherwise affect the functionality of the connector 500. To prevent unintentional mechanical or physical contact with the electrical contacts 512, the connector 500 includes a protective cover or the like, such as, but not limited to, a contact barrier 514, as shown in FIGS. 12A-12B. FIG. 12A shows the contact barrier 514 in a closed (protective) state, while FIG. 12B shows the contact barrier 514 in an open (exposed) state. The closed state is the default or normal position of the contact barrier 514, such as when the connector 500 is not connected to or engaged with another mating connector. However, when the connector 500 is inserted into and engaged with a mating connector, the contact barrier 514 transitions to an open state, exposing the electrical contacts 512 and allowing an electrical connection between and through the mating connectors. That is, the contact barrier 514 is movable (eg, releasable, slidable, transitionable, actuatable, etc.) from a closed state to an open state during mating of the connector.

[0052] As shown in the embodiment of FIGS. 12A-12B, contact barrier 514 includes first panel 516 and second panel 518. In this embodiment, panels 516, 518 are biased and rotatable about hinges to open and close (see, e.g., hinge 517 on first panel 516 and hinge 519 on second panel 518). For example, as shown, first panel 516 includes a respective first biasing member 520 that biases first panel 516 toward a closed position (FIG. 12A). Similarly, second panel 518 includes a respective second biasing member 522 that biases second panel 518 toward a closed position (FIG. 12A). As such, the default or normal configuration of panels 516, 518 is the closed position (FIG. 12A). To open the panels 516, 518, an external force (e.g., an actuation action) must be provided to urge the panels open and expose the electrical contacts 512 of the contact members 510 (e.g., as shown in FIG. 12B).

[0053] 13A-13B, a schematic diagram of a connector assembly 600 according to one embodiment of the present disclosure is shown. The connector assembly 600 includes a first connector 602 (e.g., similar to the mating connectors 200′, 500) that releasably engages with a second connector 604 (e.g., similar to the connector 100′). The first connector 602 includes a boot, a coupling nut, and a housing assembled to form the first connector 602, similar to those shown and described above. In this exemplary embodiment, the first connector 602 releasably engages and connects with the second connector 604 to provide an electrical connection through the connector assembly 600. The first connector 602 includes contact members 606 that are selectively protected by a contact barrier 608. In this embodiment, the contact barrier 608 is a two-panel configuration similar to that shown and described with respect to FIGS. 12A-12B. The contact barrier 608 is normally biased to a closed position (FIG. 13A) and can be urged to an open position (FIG. 13B) during insertion of the portion of the first connector 602 seated within the second connector 604.

[0054] To cause the opening of a panel of the contact barrier 608, the contact barrier 608 may include one or more first engagement features 610. The first engagement feature 610 is a structure, surface, etc. that assists in the transition of the contact barrier 608 from a closed state to an open state. The second connector 604 includes one or more second engagement features 612 that interact with the first engagement feature 610 to cause the opening of the contact barrier 608 when the first connector 602 is inserted into the second connector 604. In this exemplary embodiment, the first engagement feature 610 of the contact barrier 608 is an angled or chamfered surface on the contact barrier 608 at an end that is present at the front or engagement end of the first connector 602. When the first connector 602 is inserted into the second connector 604, the first engagement feature 610 engages and interacts (e.g., contacts) with the second engagement feature 612 of the second connector 604, thus urging the contact barrier 608 from a closed state to an open state.

[0055] In this exemplary embodiment, the first engagement feature 610 is an angled surface on the edge of each panel of the contact barrier 608. The contact barrier 608 has two panels in this configuration, and therefore the second connector 604 includes two second engagement features 612, one for each panel of the contact barrier 608. In other embodiments, the two separate second engagement features may be arranged as a single structure, such as a wedge, that simultaneously interacts with both panels of the contact barrier 608. Because the second engagement feature 612 will open the contact barrier 608 only when the connectors 602, 604 are connected and the contact barriers are biased in a normally closed position, the electrical contact of the contact members 606 may be protected when the first connector 602 is not positioned in connection with the second connector 604.

[0056] While the second engagement feature 612 is illustratively shown as a static structural element (e.g., a protrusion or rib) of the second connector 604, various other configurations are possible without departing from the scope of the present disclosure. The second engagement feature can include passive and active structures or components that cause the activation, movement, or transition of the contact barrier from a closed (protective) state to an open state. The actuation can include passive and active mechanisms, such as, but not limited to, a barrier / door rotated by an additional rotating collar (e.g., manually operated), Hall-effect sensors, electronic actuators, magnetic actuators, proximity switches, etc., that can be activated in response to two or more components or elements coming into contact and / or proximity with one another, thus activating an actuation (e.g., a spring or piston, etc.) that moves the door / barrier from one state or position to another. According to embodiments, the actuation of the contact barrier to transition from a closed state to an open state is automatic, such that the act of mating two connectors causes the actuation of the contact barrier to expose the electrical contacts and enable the electrical connection described herein.

[0057] While the illustrated embodiments described above have a contact barrier in the form of two hinged or pivoting panels, those skilled in the art will appreciate that other types of contact barriers can be used without departing from the scope of the present disclosure. For example, a single panel configuration hinged on a single side and covering the entire contact member may be used. In other single-panel configurations, the hinges can be positioned to cause the opening and closing motion to be perpendicular to the connector axis rather than parallel to the connector axis. In some configurations, a sliding or rolling configuration can be used instead of a hinged configuration without departing from the scope of the present disclosure.

[0058] For example, referring to FIG. 14 , a schematic diagram of a connector 700 according to one embodiment of the present disclosure is shown. The connector 700 may be similar to the first connector of the embodiment of FIGS. 13A-13B or the connector of FIGS. 12A-12B . In this embodiment, the connector 700 includes a contact barrier 702 positioned to protect contact members 704, which include a plurality of electrical contacts that are desired to be protected when the connector is not connected to a mating connector. In this embodiment, the contact barrier 702 slides axially within the connector 700 or is slidably movable when the connector 700 is inserted into the mating connector. The contact barrier 702 contacts an engagement feature of the mating connector and is urged to translate axially to slide into the connector 700 and expose the electrical contacts of the contact members 704 for electrical connection with the mating connector.

[0059] Referring to FIG. 15 , a schematic diagram of a connector 800 according to one embodiment of the present disclosure is shown. The connector 800 may be similar to the connector described above with a contact barrier 802. In this embodiment, the connector 800 includes a contact barrier 802 positioned to protect contact members 804, which include multiple electrical contacts that are desired to be protected when the connector is not connected to a mating connector. In this embodiment, the contact barrier 802 pivots or rotates about a hinge 806 when the connector 800 is inserted into the mating connector. The contact barrier 802 contacts an engaging feature of the mating connector and is urged to rotate about the hinge 806, opening the contact barrier 802 and exposing the contact members 804. In this embodiment, due to the length of the contact barrier 802, the contact barrier 802 may extend outward from the side of the connected assembly when the connector 800 engages with the mating connector.

[0060] 16 , a schematic diagram of a connector 900 according to one embodiment of the present disclosure is shown. The connector 900 may be similar to the connectors described above with a contact barrier 902. In this embodiment, the connector 900 includes a contact barrier 902 positioned to protect contact members 904, which include a plurality of electrical contacts that are desired to be protected when the connector is not connected to a mating connector. In this embodiment, when the connector 900 is inserted into a mating connector, the contact barrier 902 rolls up or is wound around a spool 906. The contact barrier 902 contacts an engaging feature of the mating connector and is urged to slide axially and rotate or roll around the spool 906, exposing the electrical contacts of the contact members 904 for electrical connection with the mating connector.

[0061] The embodiments shown in Figures 12A-16 provide examples of types of contact barriers according to the present disclosure. These examples are provided for illustrative and descriptive purposes and are not intended to be limiting to specific arrangements, configurations, and methods of operation. Other types of contact barriers and / or mechanisms for operating such contact barriers are contemplated by the scope of the present disclosure. A feature of the contact barriers described herein is that such contact barriers are normally closed except when an associated connector is inserted into a mating connector and the contact barrier is urged against a biasing closing force to open the contact barrier and expose electrical contacts for engagement with the electrical contacts of the mating connector. The contact barriers of the present disclosure can be formed from any desired material, but preferably from a non-conductive material, which can be a rigid or semi-rigid material. In some non-limiting configurations, the contact barriers can be made from metal(s), metal with a coating, thermoplastic, Mylar, rubber, plastic, PCB substrate material (e.g., resin / epoxy), or other materials. In some configurations employing metal contact barriers, the metal of the contact barrier can be positioned to provide an additional grounding path or grounding characteristics to the system (e.g., for grounding electrostatic discharges). The material is selected to provide a structural, mechanical, and / or physical barrier that prevents fingers or other objects from contacting the electrical contacts of the connector. Thus, according to some embodiments of the present disclosure, the electrical contacts of the connector can be protected from damage, debris, or contact from the user, potentially extending the product life of such connectors. Furthermore, advantageously, embodiments of the present invention can provide improved reliability of such connectors by ensuring that the electrical contacts are protected from damage, etc. The contact barriers described herein can improve the safety of the connector and users installing such components, and such contact barriers can protect the electrical contacts from damage to the connector in a manner that does not significantly increase the size or dimensions of the connector.That is, the contact barriers described herein can be implemented without significant modification to the size and / or operation of such connectors.

[0062] In addition to providing protection for the electrical contacts, embodiments of the present disclosure are directed to ensuring connection and contact between the electrical contacts of the connectors described herein. Some embodiments of the present disclosure can provide a self-aligning feature to ensure alignment and proper seating and engagement of the electrical contacts of the connector assembly. According to some embodiments of the present disclosure, a self-aligning coupling nut is provided that ensures mechanical mating upon engagement with a receptacle and allows a user to reposition their hand and twist the coupling nut to electrically engage the electrical contacts of the two connectors. The self-aligning aspects of the coupling nut allow the connector to always be in a “ready to mate” position, even when not mated with a mating connector. Thus, according to some embodiments, at least one central biasing element can be configured to bias the rotatable coupling member to self-align relative to the housing and ensure the assembly or component is positioned in a ready-to-connect orientation. That is, the rotatable coupling member can be rotatably coupled to the housing and biased toward the ready-to-connect orientation.

[0063] Additionally, according to some embodiments, one or more rollers are incorporated into the housing and self-aligning features to reduce the force required to electrically engage two connectors. The rollers and associated features provide enhanced mating functionality in connectors that require high axial mating forces and the mechanical advantage of torqueing a coupling nut to electrically mate a first connector (e.g., a plug) and a second connector (e.g., a receptacle). Such rollers and self-aligning features can improve the mating experience for the end user. For example, the self-aligning coupling nut can ensure proper alignment of the electrical contacts, and the rollers can reduce the mating torque required to connect two connectors, ensure the application of proper force between the electrical contacts, and ensure an electrical connection therebetween. Such self-aligning and torque-assist features can be particularly beneficial in connector assemblies similar to those shown and described with respect to FIGS. 1-6.

[0064] 17A-17B, schematic diagrams of portions of a connector assembly according to one embodiment of the present disclosure are shown. FIG. 17A shows a view of the contact end of a first connector 1000 (e.g., a plug), and FIG. 17B shows a view of the contact end of a second connector 1002 (e.g., a receptacle). The first connector 1000 includes a coupler 1004 and an interposer 1006 with a printed circuit board disposed below the interposer 1006. The printed circuit board includes electrical contacts that may be supported, such as by pins 1008 of the interposer 1006. The second connector 1002 includes a body 1010 that houses a printed circuit board (PCB) 1012 having a number of electrical contacts 1014 disposed thereon.

[0065] The first connector 1000 mechanically and electrically mates with the second connector 1002. The first connector 1000 can mate with the second connector 1002 as described herein. When the two connectors 1000, 1002 are mechanically coupled, the electrical contacts 1014 of the PCB 1012 of the second connector 1002 will contact the pins 1008 of the interposer 1006. When the mechanical connection is pressed into engagement, the pins 1008 of the interposer 1006 of the first connector 1000 and the electrical contacts 1014 of the second connector 1002 will make physical contact and create an electrical connection through the connector assembly (e.g., between the electrical contacts of the first connector 1000 and the electrical contacts 1014 of the second connector 1002).

[0066] To assist in mating between the first connector 1000 and the second connector 1002, the coupler 1004 and the body 1010 each include features to ensure both a physical and an electrical connection. For example, in this exemplary embodiment, the coupler 1004 includes latch rollers 1016 that are fixed in place on the inner surface of the coupler 1004 but rotate about an axis that passes through the center of the latch rollers 1016. These latch rollers 1016 fit within and move along latch slots 1018 in the body 1010. The latch slots 1018 are formed on the outer surface of the body 1010 and include openings that allow the latch rollers 1016 to slide axially within the latch slots 1018. The latch slots 1018 are molded along with the circumferential channels such that when the first connector 1000 is twisted or rotated relative to the second connector 1002, the latch rollers 1016 rotate along the circumferential channels, securely engaging the first connector 1000 with the second connector 1002. This act of mechanically coupling the first connector 1000 to the second connector 1002 also urges the first connector 1000 and the second connector 1002 axially toward each other, ensuring that electrical contact is properly made.

[0067] 18A-18D, schematic diagrams of a connector 1100 are shown in accordance with one embodiment of the present disclosure. Connector 1100 is configured as a first connector or plug of a connector assembly in accordance with one embodiment of the present disclosure. FIG. 18A is a perspective view of connector 1100, FIG. 18B is an exploded or exploded view of components of connector 1100, FIG. 18C is an exploded or exploded view of a core assembly of connector 1100, and FIG. 18D is an exploded or exploded view of a coupling member of connector 1100.

[0068] As shown in FIGS. 18A-18B , connector 1100 includes a strain relief member 1102, a coupling member 1104, and a plug assembly 1106 disposed within strain relief member 1102 and coupling member 1104. Coupling member 1104 includes an outer coupling housing 1108 and an inner coupling housing 1110. In this exemplary embodiment, outer coupling housing 1108 is a single, unitary body, and inner coupling housing 1110 is formed of two housing sections (e.g., a clamshell arrangement), although each of these components may be unitary or modular in other embodiments. In this exemplary embodiment, plug assembly 1106 includes plug housing 1112, shield spring 1114, plug core assembly 1116, and cable bushing 1118, all disposed within strain relief housing 1120 (shown as a clamshell arrangement). A plug assembly 1106 is housed within the strain relief member 1102 and a coupling member 1104 secures the plug assembly 1106 to one end of the strain relief member 1102 .

[0069] 18C, there is shown a schematic diagram of the components of the plug core assembly 1116. The plug core assembly 1116 includes a plug core base 1122, an overtravel spring 1124, a plug core flex mount 1126, a flex circuit 1128 having electrical pins 1130, an interposer assembly 1132, and one or more interpose mount pins 1133 that secure the interposer assembly 1132 to the plug core flex mount 1126.

[0070] The coupling member 1104 is configured similarly to that shown in FIG. 17A. In this embodiment, the coupling member 1104 includes one or more latch rollers 1134. The latch rollers 1134 are fixed in place on the inner surface of the inner coupling housing 1110. The latch rollers 1134 engage latch slots in the body of a second connector to which the connector 1100 mechanically and electrically connects, as described herein. FIG. 18D shows the coupling member 1104 in a disassembled state, illustrating the components of the coupling member 1104. As shown in FIG. 18D, the coupling member 1104 includes an outer coupling housing 1108 and an inner coupling housing 1110. The inner coupling member 1110 is a two-piece component in this exemplary embodiment. The coupling member 1104 includes one or more latch rollers 1134 attached to the inner coupling housing 1110 by respective mounting posts 1136. Mounting posts 1136 are attached to the inner coupling housing 1110 from the outside and extend radially inward through openings in the inner coupling housing 1110. On the inside, the latch rollers 1134 are connected to and fixed to the inner surface of the inner coupling housing 1110 by the mounting posts 1136. When installed, the latch rollers 1134 are free to rotate about the mounting posts 1136.

[0071] Because the connector 1100 engages with a second connector through a rotational or twisting movement, it is important to ensure that the two connectors are properly aligned so that the electrical connection between the two connectors makes proper contact. According to this exemplary embodiment, one of the mechanisms for ensuring proper alignment is through the use of latch rollers 1134, which are positioned to slide axially into and then circumferentially along the respective latch slots of the other connector. The free rotation of the latch rollers 1134 improves engagement and relative rotation between the two connectors. For example, the use of the latch rollers 1134 reduces the rotational force required to mate the connectors, thus improving the ease of engagement and connection between the two connectors. In this manner, the latch rollers 1134 allow for reduced force when electrically engaging the connector 1100 (e.g., a plug) with a second connector (e.g., a receptacle for the plug).

[0072] In addition to having a limited number of latch rollers 1134 and respective latch slots, alignment between the two connectors can be aided by self-centering features within the connector. For example, as shown in FIG. 18B, the connector 1100 may include a central biasing element 1138. The plug core base 1122 may be movable or rotatable relative to the inner mating housing 1110, such that the plug core base 1122 may be rotatable to a position that may not be immediately aligned with the second connector. However, the central biasing element 1138 provides for self-alignment of the plug core base 1122 relative to the rest of the connector 1100 such that the connector 1100 is positioned in a ready-to-connect orientation due to the central biasing element 1138 biasing to maintain the plug core base 1122 in a predetermined position or state, and if such state is changed (e.g., the plug core base 1122 is rotated relative to the rest of the connector 1100), the central biasing element 1138 will urge the plug core base 1122 back to its original (e.g., ready-to-connect) position.

[0073] Thus, the connector 1100 with the central biasing element 1138 forms or has a self-aligning coupling nut that provides a mechanical lock upon engagement with a second connector (e.g., a plug receptacle) allowing the user to reposition their hand and twist the coupling nut to electrically engage the two connectors. The self-aligning aspect of the coupling nut allows the connector to always be in a "ready to mate" position when not mated with the second connector. While various embodiments are shown and described with two biasing elements, it will be understood that a single biasing element may be used that can urge the coupling nut to a desired position (e.g., a single element centrally positioned to urge it back to the desired position). In other embodiments, three or more biasing elements may be used without departing from the scope of this disclosure.

[0074] 19A-19B, schematic diagrams of a connector 1200 are shown in accordance with one embodiment of the present disclosure. The connector 1200 is configured as a second connector or a receptacle in a connector assembly in accordance with one embodiment of the present disclosure. FIG. 19A is a perspective view of the connector 1200, and FIG. 19B is an exploded or exploded view of the components of the connector 1200. The connector 1200 of FIGS. 19A-19B can be mechanically and electrically engaged with the connector 1100 of FIGS. 18A-18D.

[0075] Connector 1200 includes a strain relief member 1202 that houses an internal connector and a coupling member 1204 that mechanically connects to another connector (e.g., connector 1100 of FIGS. 18A-18D). As shown in FIG. 19B, the connector includes a receptacle assembly 1206 disposed within strain relief member 1202. Receptacle assembly 1206 includes a cable bushing 1208, a shield clamp 1210, a shield spring 1212, and a receptacle core assembly 1214. These components are disposed within strain relief housing 1216 (shown as a clamshell configuration). Receptacle assembly 1206 is housed within strain relief member 1202, and coupling member 1204 secures plug assembly 1206 to one end of strain relief member 1202.

[0076] The coupling member 1204 of the connector 1200 is similar to the second connector shown in FIG. 17B. The coupling member 1204 includes one or more latch slots 1218 positioned to receive respective latch rollers (e.g., as shown and described above) to mechanically connect the two connectors together. The latch slots 1218 have openings at the ends of the coupling member 1204 and extend axially, then rotate to extend around the circumference of the coupling member 1204. The latch slots 1218 can include one or more features to help ensure an electrical connection between the electrical contacts of the two mated connectors. The features can include protrusions, etc. that cause axial movement of the coupling member during the mating or connection process, and can also secure the position by providing stops, etc., to prevent reverse rotation once the position is set.

[0077] 20A-20B, a schematic diagram of a connector assembly 1300 according to one embodiment of the present disclosure is shown. The connector assembly 1300 includes a first connector 1302 and a second connector 1304. In this exemplary embodiment, the first connector 1302 may be configured as a plug, and the second connector may be configured as a receptacle for receiving the plug. FIG. 20B shows an enlarged portion of the second connector 1304. The first connector 1302 may be configured as shown and described above and may include one or more latch rollers for engaging with latch slots 1306 of the second connector 1304. A portion of the latch slots 1306 is shown in the enlarged view of FIG. 20B. The latch slots 1306 receive latch rollers or other latch elements (e.g., non-rotating pins, etc.).

[0078] A latch element (e.g., a roller pin, static pin, protrusion, etc.) enters the latch slot 1306 at the opening 1308 and moves axially relative to the second connector 1304. The latch element then moves circumferentially within the latch slot 1306 to an end stop area 1310. The end stop area 1310 of the latch slot 1306 includes detent features 1312 along the surface defining the latch slot 1306. The detent features 1312 are protrusions, etc. that serve various functions. For example, the detent features 1312 can provide an anti-reverse structure to prevent, resist, or inhibit reverse rotation; once the latch element rotates through the latch slot 1306 and into the end stop area 1310, the detent feature 1312 can prevent or inhibit rotation away from a secured position. In some embodiments, the detent feature 1312 provides resistance to reversal once the latch element passes through the detent feature 1312 and into the end stop area. Further, for example, the detent feature 1312 can provide an obstacle or resistance to rotation of the latch element into the end stop region 1310. In this manner, the detent feature 1312 can force a user to apply a small amount of additional rotational force to ensure that the latch element passes through the detent feature 1312 and into the end stop region 1310. Furthermore, while the detent feature 1312 is configured to provide resistance or prevent relative rotation away from the secured position, it will be understood that a user can apply force to overcome the resistance provided by the detent feature 1312 to decouple the components. That is, the detent feature 1312 can be configured to ensure a rigid connection in the secured position, but at the same time provide a releasable or reversible connection that allows for decoupling and separation of the components after they are secured together.

[0079] The act of the latch element passing over the detent feature 1312 can provide certain advantages. First, for example, because the detent feature 1312 is an axially positioned feature, as the latch element passes over the detent feature 1312, the first connector 1302 will be moved closer to the second connector 1304, thus ensuring that the electrical contacts of the two connectors 1302, 1304 are in proper electrical engagement. Second, for example, because the detent feature 1312 provides some resistance to relative rotation between the two connectors 1302, 1304, the user may need to apply additional rotational force and may feel a snap or tactile feedback of the latch element passing over the detent feature 1312 and into the end stop region 1310. In some embodiments, additional force may be required to move the latch element over and through the detent feature 1312 to decouple the first connector 1302 from the second connector 1304. Such force can be applied by pressing or squeezing the two connectors 1302, 1304 toward each other and then twisting the two connectors 1302, 1304 relative to each other, thus allowing the latch elements to pass through the detent features 1312 and separate the two connectors. In some embodiments, as shown in FIG. 20B , the latch slot 1306 can also include or be defined by an optional angled wall 1314. The angled wall 1314 can be axially angled to narrow the axial dimension of the latch slot 1306. The angled wall 1314 can provide a surface against which the latch elements may rotate, slide, or otherwise interact. Because the angled wall 1314 is angled, when a user rotates the first connector 1302 relative to the second connector 1304, the latch elements will be urged axially, even if only a rotational force is applied by the user. That is, when connecting the first connector 1302 to the second connector 1304, the user does not need to apply axial force to bring the two connectors 1302, 1304 together.Conversely, in such a configuration, application of a rotational force will cause the latch element to slide along the angled wall 1314, causing axial movement of the first connector 1302 toward the second connector 1304.

[0080] Although shown and described with one structural detent feature and another structural latch element, the particular components having each structure / feature are not meant to be limiting, i.e., in other embodiments, components having detent features and latch elements may be interchanged compared to the exemplary embodiment without departing from the scope of the present disclosure.

[0081] 21A-21D , schematic diagrams of the operation of mating a connector assembly 1400 together are shown, according to one embodiment of the present disclosure. The connector assembly 1400 includes a first connector 1402 (e.g., a plug) and a second connector 1404 (e.g., a receptacle). The first connector 1402 and the second connector 1404 may be configured similarly to those shown and described above. The first connector 1402 includes a latch element 1406, such as a pin, roller pin, ball bearing, or the like, which is received in a latch slot 1408 of the second connector 1404. The latch slot 1408 includes a detent feature 1410 and an end stop region 1412, similar to those shown and described above.

[0082] 21A-21D illustrate engagement and connection between a first connector 1402 and a second connector 1404. As shown in FIG. 14A, the latch element 1406 of the first connector 1402 is aligned with the latch slot 1408 and moves axially (e.g., along axis A defined through the connector assembly 1400). Once the latch element 1406 is within the latch slot 1408, the first connector 1402 can rotate relative to the second connector 1404, which will cause the latch element 1406 to move circumferentially around the second connector 1404 within the latch slot 1408, as shown in FIG. 21B. The latch element 1406 will then contact a detent feature 1410, requiring additional axial force, as shown in FIG. 21C. Additional axial force applied with some rotation will move the latch element 1406 over and past the detent feature 1410 and into the end stop area 1412, as shown in Figure 21D. The use of a latch roller as the latch element 1406 reduces the rotational force required to couple the connectors 1402, 1404 during the connection process described herein.

[0083] Advantageously, improved connectors are provided by various embodiments of the present disclosure. Various aspects enhance protection of delicate components of the connector. In a linear connector assembly configuration, electrical contacts of the connectors can be protected when one connector is disconnected from another connector, where such electrical contacts might otherwise be exposed. Furthermore, such protected electrical contacts can prevent direct contact with electrical features, thus preventing damage to the connector. Furthermore, in some embodiments, when a rotary connection is employed, electrical contact and mechanical connection can be assisted by latching rollers and / or detent features on the connector.

[0084] In the context of the description (particularly in the context of the claims that follow), use of the terms "a," "an," "the," and similar referents should be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The modifier "about," used in connection with a quantity, is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity). All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. It should be understood that relative positional terms such as "forward," "upper," "lower," "above," and "below" refer to the configuration and orientation shown and should not be considered otherwise limiting.

[0085] While the present disclosure has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the present disclosure is not limited to such disclosed embodiments. On the contrary, the present disclosure can be modified to incorporate any number of variations, alterations, substitutions, combinations, subcombinations, or equivalent arrangements not heretofore described, but which are compatible with the scope of the present disclosure. Furthermore, while various embodiments of the present disclosure have been described, it should be understood that aspects of the present disclosure may include only some of the described embodiments. Accordingly, the present disclosure should not be deemed limited by the foregoing description, but is limited only by the scope of the appended claims.

Claims

1. 1. An electrical connector, comprising: Housing and a contact member disposed within the housing, the contact member including one or more electrical contacts; An electrical connector comprising: a contact barrier connected to the housing, the contact barrier being movable between a closed state and an open state, wherein in the open state the contact elements are exposed, and in the closed state the contact elements are protected by the contact barrier, and the contact barrier is biased to the closed state.

2. 10. The electrical connector of claim 1, further comprising a coupling nut configured to rotate between a locked position and an unlocked position, the housing being attached to the coupling nut.

3. The electrical connector of claim 1 , wherein the contact barrier is configured to move to the open state during engagement with a second connector.

4. 2. The electrical connector of claim 1, wherein said contact member is a rigid-flexible printed circuit board.

5. 2. The electrical connector of claim 1, wherein the contact barrier comprises a first panel and a second panel, the first panel and the second panel each attached to the housing by at least one respective hinge.

6. The electrical connector of claim 1 , wherein the contact barrier is configured for sliding movement relative to the housing.

7. 10. The electrical connector of claim 1, wherein the contact barrier is configured to wrap around a spool when the contact barrier moves from the closed state to the open state.

8. 2. The electrical connector of claim 1, wherein the contact barrier comprises at least one engagement feature configured to interact with a portion of the second connector to move the contact barrier from the closed state to the open state when the electrical connector is inserted into the second connector.

9. The electrical connector of claim 1 , wherein the contact barrier comprises at least one of a non-conductive material and a semi-rigid material.

10. The electrical connector of claim 1 , wherein the contact barrier defines a ground path therethrough.

11. 1. An electrical connector, comprising: Housing and a core assembly disposed with the housing, the core assembly including at least one electrical contact; a rotatable coupling member rotatably mounted on an end of the housing, the rotatable coupling member comprising: a coupling housing; at least one latch element coupled to an inner surface of the coupling housing; at least one central biasing element configured to bias and self-center the rotatable coupling member in a connection-ready orientation relative to the housing.

12. 12. The electrical connector of claim 11, wherein the at least one latching element is a roller rotatable about an axis of the roller.

13. 12. The electrical connector of claim 11, wherein the rotatable coupling member is configured to couple to a second connector to create a mechanical and electrical connection between the electrical connector and the second connector.

14. 12. The electrical connector of claim 11, wherein the second connector includes at least one latch slot, and the at least one latch element of the rotatable coupling member is configured to engage within the at least one latch slot to secure the electrical connector to the second connector.

15. An electrical connector assembly including the electrical connector of claim 11, a second connector including a second core assembly and a second coupling member configured to connect to the rotatable coupling member to effect a connection between the electrical connector and the second connector; the second coupling member includes at least one latch slot; an electrical connector assembly, wherein each latch element of the rotatable coupling member is receivable within the at least one latch slot, the at least one latch slot including a detent feature configured to resist reverse rotation of the electrical connector relative to the second connector when the at least one latch element is positioned within an end stop area of ​​the at least one latch slot.

16. 16. The electrical connector assembly of claim 15, wherein the at least one latch slot comprises an angled wall that is angled to axially urge the latch element when the rotatable coupling member and the second coupling member rotate relative to one another to effect an electrical connection between the electrical connector and the second connector.

17. 1. An electrical connector, comprising: Housing and a core assembly disposed with the housing, the core assembly including at least one electrical contact; and a coupling member attached to an end of the housing, the coupling member including at least one latch slot defined on an outer surface of the coupling member, the at least one latch slot configured to receive a respective latch element of an additional coupling member, the at least one latch slot having an end stop area defined in part by detent features disposed along a surface of the at least one latch slot, the detent features extending axially of the coupling member and configured to resist reverse rotation of the latch element relative to the coupling member when the latch element is positioned within the end stop area.

18. 18. The electrical connector of claim 17, wherein the detent feature is configured to axially move the additional coupling member closer to the electrical connector as the at least one latch element is forced past the detent feature and into the end stop area.

19. 18. The electrical connector of claim 17, wherein the latch element is a latch roller rotatable about an axis of the roller.

20. 18. The electrical connector of claim 17, wherein the at least one latch slot comprises an angled wall that is angled to axially urge the latch element when the coupling member and the additional coupling member are rotated relative to one another to create an electrical connection between the coupling member and the additional coupling member.

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