Low-profile wire-to-board connector

Abstract

A low-profile wire-to-board connector has features that allow for a height of 1 mm or less while still being robust enough to prevent unintentional separation of the mated connectors. The board connector has a mounting surface configured for surface-mount soldering to a PCB and can include a recess for receiving a complementary connector that terminates multiple wires. The board connector can have blade-like terminals whose middle portions engage with portions of the board connector housing and can be soldered to the PCB at two ends to secure the housing to the PCB. The complementary connector can be inserted at an acute angle to the mounting surface to engage the front portion of the mating connector with the front portion of the board connector. The rear portion of the complementary connector can then be rotated into the recess and secured near the rear portion.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority and benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 62 / 869,511, filed on July 1, 2019, entitled "WIRE TO BOARD CONNECTOR WITH LOW HEIGHT", which is hereby incorporated by reference in its entirety.

Background Art

[0002] Wire - to - board electrical connectors enable the transfer of power and / or data signals between a printed circuit board (PCB) and other components of an electronic system. In one example, power can be provided to a device mounted on a circuit board by a wire - to - board connector that connects a power line to a conductive power trace on the surface of the PCB. In another example, data can be provided to a device mounted on a circuit board by a wire - to - circuit - board connector that connects a data line to a conductive data trace on the surface of the PCB.

Summary of the Invention

Means for Solving the Problems

[0003] Embodiments of a low - profile wire - to - board connector are described. According to some embodiments, the electrical connector is an insulating housing having an opening for receiving a second connector, the opening being surrounded by at least a first wall and a second wall of the insulating housing, the first wall comprising at least one receiving portion configured to receive a protrusion from the second connector, the second wall being transverse to the first wall, the insulating housing, a plurality of conductive terminals attached to the first wall of the insulating housing and extending into the opening, and at least one latching tab attached to the second wall of the insulating housing. The at least one latching tab can comprise a compliant portion configured to engage the surface of the second connector when the second connector is inserted into the opening.

[0004] According to some embodiments, an electrical connector can include an insulating housing, a plurality of conductive terminals supported by the insulating housing, and at least one spring supported by the insulating housing. The insulating housing can include an opening for receiving a second connector. The first connector can include a first retaining feature that engages the second connector at a first end of the opening and a second retaining feature that engages the second connector at a second end of the opening, the first end being offset in a first direction from the second end. The at least one spring can be configured to apply a force to the second connector in the first direction when the second connector is within the opening.

[0005] According to some embodiments, a method of mating a cable connector with a board connector can include inserting the cable connector into a recess of the board connector along a first direction, applying a spring force to the cable connector relative to the board connector at least partially in a second direction that is at least partially opposite the first direction, and fixing the cable connector by preventing movement of the cable connector in a direction perpendicular to the second direction.

Brief Description of the Drawings

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DETAILED DESCRIPTION OF THE INVENTION

[0007] The inventors recognized and understood a design technique for electrical connectors that enables an electrical wire pair substrate (or cable body substrate) receptacle and a plug connector to occupy a small volume while providing reliable operation. Such connectors can have a height of 1 mm or less. The techniques described herein can result in a small connector that prevents unintentional disengagement.

[0008] The inventors recognized that small receptacle connectors and plug connectors can be unintentionally disengaged when pressure is applied to the wire or cable terminated by the receptacle connector. For example, when the wire or cable is pulled away from the plug connector, the receptacle can be removed from the plug connector. The wire can be pulled, for example, when extending outside an electronic device. A wire attached to an earphone can, for example, extend from a portable electronic device and can be unintentionally pulled during use.

[0009] According to some embodiments, the receptacle connector and the plug connector can be securely fixed to each other to reduce the risk of unintentionally disengaging the receptacle connector from the plug connector. In some embodiments, the receptacle connector can be inserted into a recess of the plug connector along an insertion direction, and a member within the plug connector can apply a spring force in a fixing direction against the receptacle connector to fix the receptacle connector to the plug connector.

[0010] For example, the leading edge of the receptacle connector can be inserted into the recess of the plug connector. In the illustrated embodiment, the leading edge of the receptacle connector mates with the blade contacts of the plug connector. The trailing edge of the receptacle connector can be shaped to engage a portion of the plug housing along the opposite side of the plug blade. In this example, the fixing direction is from the blade towards the opposite side of the plug connector. As a result, when the receptacle moves in the fixing direction, a feature at the trailing edge of the receptacle engages a complementary feature in the plug housing, preventing the receptacle from being lifted out of the recess of the plug.

[0011] A spring force can be applied at least partially opposite to the insertion direction and at least partially along the bottom surface of the recess so as to fix the receptacle connector to the plug connector.

[0012] In some embodiments, the leading edge of the receptacle connector can be inserted into the recess of the plug connector along an insertion direction that is angled with respect to the mounting surface of the plug connector. The receptacle can engage the plug connector at the leading edge of the receptacle connector. The leading edge of the receptacle connector can be inserted into the recess of the plug connector and can mate with the blade contacts of the plug connector. The leading edge of the receptacle connector can be shaped to engage a portion of the plug housing along the portion having the blade contacts of the plug connector, thus preventing the receptacle connector from being inadvertently removed upward from the plug connector.

[0013] The rear portion of the plug connector and / or the receptacle connector can further include a feature that prevents the receptacle connector from being inadvertently removed rearward. To fix the receptacle connector within the plug, it may be necessary to rotate the receptacle connector about the front edge where it is engaged, such that the rear portion of the receptacle rotates towards the mounting surface of the plug connector. And the feature of the rear portion of the receptacle connector and / or the plug connector can engage to hold the receptacle connector within the plug connector.

[0014] In some embodiments, the feature can include a member within the plug connector that engages the receptacle connector to fix the receptacle connector to the plug connector. This member can be a locking tab coupled to the sidewall of the plug housing. The locking tab can have portions formed from bent metal pieces disposed on both sides of the sidewall. At least one of those portions of the locking tab can be soldered to the substrate. By this soldering, at least the mounting portion of the plug connector to the substrate can be formed. Thus, the locking tab is securely fixed to the substrate, and when the receptacle connector is inadvertently pulled upward, an appropriate contact force can be provided to hold the receptacle connector within the plug connector and to hold the plug connector to the substrate.

[0015] In some embodiments, the trailing edge of the receptacle connector can include a protrusion that engages a feature of the rear portion of the plug connector when the receptacle connector slides rearward. As a result, the rearward sliding movement can fix the receptacle connector within the plug connector. The rearward sliding movement can be provided by a spring member between the plug and the receptacle that is compressed when the receptacle is inserted into the plug connector.

[0016] Referring to the figures, FIG. 1A is a top perspective view of an electrical interconnect system 100 including a receptacle connector 120 and a plug connector 140 according to some embodiments. FIG. 1B is a cross-sectional side view of the receptacle connector 120 and the plug connector 140.

[0017] For simplicity of explanation, mating connectors are identified as plugs and receptacles based on the shape of their terminals. In this example, the receptacle connector has terminals that include members that flex to generate a contact force when mated. Here, this flexing member is an opposing member that mates with blades from the inserted plug connector. However, the description herein of mating and securing the connectors to each other applies regardless of the shape of the terminals of those connectors. For example, the plug connector 140 is shown as being mounted to a printed circuit board, and the receptacle connector 120 is shown as terminating a plurality of electrical wires. In other embodiments, a connector mounted to a substrate can have terminals shaped for a receptacle, and a connector terminating a cable can have terminals shaped as blades. Alternatively, each connector can have some plug terminals and some receptacle terminals. Further, it is not a requirement that the plug terminals be rigid and non-bending during mating. In some embodiments, the plug terminals and the receptacle terminals can flex during mating.

[0018] As shown in FIGS. 1A and 1B, in some embodiments, a plug connector 140 can be mounted on a substrate 102, which can be a printed circuit board. In this example, the mounting is achieved by placing the mounting surface of the plug connector 140 on the substrate 102 and surface-mount soldering the connector to the substrate. The receptacle connector 120 can terminate two insulated wires 104a and 104b. In the mating configuration shown in FIG. 1A, the receptacle connector 120 and the plug connector 140 can electrically connect the conductors within the insulated wires 104a and 104b to conductive pads (not shown) on the substrate 102. In some embodiments, the electrical interconnect system 100 can have a small form factor, such as a height of less than 1 mm. The height can be measured with respect to the surface of the substrate on which the connector is mounted.

[0019] The receptacle connector 120 includes a receptacle housing 130, which can support receptacle terminals 122a and 122b, with terminal 122a shown in FIG. 1B. The receptacle housing 130 can be formed using an insulating material such as plastic. The receptacle terminals 122a and 122b can be formed using a conductive material such as phosphor bronze. In FIG. 1B, the receptacle terminal 122a can be attached to the conductor of the insulated wire 104a, and the crimp portion 124a of the receptacle terminal 122a holds the conductor. The conductor can be copper or other metal, with or without plating such as silver plating, in some embodiments. Designs as described herein can be used in connection with small-diameter wires. The conductor can have a diameter of less than 32 AWG in some embodiments. In other embodiments, the diameter can be smaller than 34 AWG, such as 36 AWG or 40 AWG.

[0020] The terminal lance 126a of the receptacle terminal 122a projects into the opening of the receptacle housing 130 and, in the illustrated embodiment, through the opening, preventing the receptacle terminal 122a from being removed from the receptacle housing 130 when the insulated electric wire 104a is pulled away from the receptacle housing 130. The terminal lance 126a can be shaped to slide along the bottom wall of the receptacle housing 130 when inserted into the receptacle housing 130. The receptacle terminal 122a is further shown in FIGS. 3C and 3D and FIGS. 4A and 4B. In some embodiments, the receptacle connector 120 can have a height of 1 mm or less such that when the receptacle connector 120 is inserted into the plug connector 140, the height of the mated connectors can be 1 mm or less.

[0021] The plug connector 140 can include a plug housing 150 that can support the plug terminals 142a and 142b and the spring tabs 144a and 144b. The plug housing 150 can be formed using an insulating material such as plastic. The plug terminals 142a and 142b and the spring tabs 144a and 144b can be formed using a conductive material such as phosphor bronze, with or without plating to assist in surface-mount soldering of the plug terminals to the substrate 102 of the plug. The plug terminals 142a and 142b can have blade contacts. As shown in FIG. 1B, the plug terminal 142a has a first portion 162a configured to be surface-mount soldered to a pad on the surface of the substrate 102 and a second portion 162b positioned to contact the receptacle terminal 122a when the receptacle connector 120 is inserted into the plug connector 140. The bottom surface of the plug housing 150 can have openings that allow the plug terminals 142a and 142b and the spring tabs 144a and 144b to be mounted (e.g., soldered) to conductive pads on the substrate 102, thereby securing the plug terminals 142a and 142b and the spring tabs 144a and 144b to the substrate 102.

[0022] In some embodiments, in addition to electrically coupling the plug terminals 142a and 142b to the substrate 102, the plug housing 150 can be mechanically fixed to the substrate 102 by fixing the plug terminals 142a and 142b and the spring tabs 144a and 144b to the substrate 102. In the illustrated embodiment, each of the plug terminals 142a and 142b has an outer portion of the housing 150 configured to be soldered to the substrate 102 and an inner portion of the plug housing 150 that is also soldered. Between the two portions, the plug terminal engages the wall of the housing 150 and fixes the housing to the substrate when the end of the terminal is soldered to the substrate.

[0023] As shown in FIG. 1B, the plug terminal 142a can be electrically coupled to the receptacle terminal 122a to a conductive pad on the surface of the substrate 102 such that the conductor of the insulated wire 104a connected to the receptacle terminal 122a is electrically connected to the substrate 102. In some embodiments, the plug connector 140 can have a height of 1 mm or less.

[0024] In some embodiments, the insulated wires 104a and 104b can have at least one electrical conductor 106 that can be surrounded by an insulator 108 (shown in FIGS. 3C and 3D and FIGS. 4A and 4B). For example, the electrical conductor 106 can include a pair of copper wires around which the plastic 108 is wound. In some embodiments, the wires can be AWG36 or 40 wires. It should be understood that the electrical interconnect system described herein can be configured to support any number of wires.

[0025] Figures 2A to 2J show a method of fitting the receptacle connector 120 with the plug connector 140 of the electrical interconnection system 100. Figures 2A to 2C are top perspective views of the electrical interconnection system 100 when the receptacle connector 120 is inserted into the plug connector 140 and fixed to the plug connector 140. Figures 2D to 2F are side views of the electrical interconnection system 100 when the receptacle connector 120 is inserted into the plug connector 140 and fixed to the plug connector 140. Figures 2H to 2J are side cross-sectional views of the electrical interconnection system 100 when the receptacle connector 120 is inserted into the plug connector 140 and fixed to the plug connector 140. Figure 2G is a top view of the electrical interconnection system 100 in which the receptacle connector 120 is fixed to the plug connector 140, specifying the cross-section X-X shown in Figures 2H to 2J.

[0026] As shown in FIGS. 2A, 2D, and 2H, the receptacle connector 120 can be inserted into the plug connector 140 along the insertion direction 110. The insertion direction 110 is oriented such that the distance between the insulating wires 104a and 104b and the substrate 102 is greater than the distance between the front end portion of the receptacle connector 120 and the substrate 102. As a result of the front end portion of the receptacle connector 120 being inserted into the plug connector 140, an acute angle can be formed with respect to the substrate 102. By the angled insertion, the protrusion from the receptacle connector 120 extends under the feature of the plug housing 150, and the receptacle connector 120 can be partially fixed within the plug connector 140.

[0027] As shown in FIGS. 2A and 2D, the plug housing 150 includes a recess 152 that can be shaped to accommodate the receptacle housing 130. The recess 152 includes receiving portions 152a - 152c that can be shaped to accommodate the receptacle housing protruding portions 138a - 138c, respectively. The receiving portions 152a and 152b and the protruding portions 138a and 138b can be disposed on both sides of the slot 154 at the rear end portions of the plug connector 140 and the receptacle connector 120, respectively. FIGS. 2H - 2J show the receiving portions 152b and 152c and the protruding portions 138b and 138c. As shown in FIGS. 2H - 2J, the receiving portion 152c and the protruding portion 138c are disposed at the front end portions of the plug connector 140 and the receptacle connector 120, respectively. When the receptacle connector 120 is inserted into the recess 152 of the plug connector 140, as shown in FIG. 2H, the protruding portion 138c can enter the receiving portion 152c.

[0028] When the receptacle connector 120 is inserted into the recess 152, the receptacle connector 120 can rotate in the direction 112 toward the substrate 102. The rotation axis of the receptacle connector 120 can be established by the engagement of the front portion of the receptacle connector 120 with the front wall of the plug housing 150 and can be perpendicular to the insertion direction 110. FIGS. 2B, 2E, and 2I show the electrically interconnected system 100 in the inserted and unfixed state after the receptacle connector 120 has rotated in the direction 112. As shown in FIG. 2I, for example, the protruding portion 138c is inserted into the receiving portion 152c, and the protruding portions 138a and 138b are not inserted into the receiving portions 152a and 152b.

[0029] The plug housing 150 can have a slot 154 in the rear wall of the plug housing 150 to accommodate the insulated electric wires 104a and 104b when the receptacle connector 120 is fixed within the plug connector 140. The insulated electric wires 104a and 104b can be elongate in the direction in which they extend through the slot 154.

[0030] As shown in FIGS. 2A - 2C, while the receptacle connector 120 is inserted into the plug connector 140, at least one spring tab 144a of the plug connector 140 can apply a force to the receptacle connector 120. For example, the compliant portion 148a of the spring tab 144a can push the receptacle connector 120 in the fixed direction 114, at least partially along the insertion direction 110, along the bottom surface of the recess 152 of the plug connector 140 (e.g., physically contacting the receptacle connector 120), and can fix the receptacle connector 120 to the plug connector 140. The compliant portions 148a and 148b of the spring tabs 144a and 144b are shown in the depressed state in FIGS. 2A and 2B and in the relaxed state in FIG. 2C. The protruding portions 160a and 160b can be configured to fix the receptacle connector 120 when the spring tabs 144a and 144b push the receptacle connector along the bottom surface of the recess 152. The protruding portions 160a and 160b can be configured to prevent upward movement away from the substrate 102. For example, the protruding portions 160a and 160b of the plug housing 150 can be positioned farther from the substrate 102 than the protruding portions 138a and 138b of the receptacle housing 130 when the receptacle connector 120 is fixed to the plug connector 140. As shown in FIGS. 2H - 2J, the protruding portion 152b is positioned above the receiving portion 152b in the upward direction away from the substrate 102. FIGS. 2C, 2F, and 2J show the inserted and fixed electrical interconnect system 100. As shown in FIG. 2J, for example, the protruding portions 138a and 138b are inserted into the receiving portions 152a and 152.

[0031] Figures 3A to 3D further illustrate the receptacle connector 120 of FIGS. 1A and 1B. FIG. 3A is a bottom perspective view of the receptacle connector 120. FIG. 3B is an enlarged view of a portion of the receptacle connector 120 showing the engagement of the terminal 122a with the receptacle housing 130. As shown in FIGS. 3A and 3B, the receptacle housing 130 includes slots 136 that can be shaped to secure the receptacle housing 130 to the terminal lances 126a and 126b of the receptacle terminals 122a and 122b. In FIGS. 3A and 3B, the terminal lance 126a extends into the slot 136 on the bottom surface of the receptacle housing 130 to prevent the terminal 122a from being pulled out of the receptacle housing 130. FIG. 3A further shows terminal slots 134a and 134b that can be shaped to accommodate the plug terminals 142a and 142b when the receptacle connector 120 is inserted into the plug connector 140.

[0032] FIG. 3C is an exploded view of the receptacle connector 120 of FIGS. 1A and 1B, showing the receptacle housing 130 separately from the receptacle terminals 122a and 122b and the wires 104a and 104b. As shown in FIG. 3C, the receptacle connector 120 can be formed by inserting the receptacle terminals 122a and 122b into the terminal slots 134c and 134d of the receptacle housing 130. Also shown in FIG. 3C, the insulated wires 104a and 104b can include wire insulators 108a and 108b that surround the conductors 106a and 106b. FIG. 3D is a side view of a cross-section of the receptacle connector 120 passing through the insulated wire 104b and the receptacle terminal 122b.

[0033] Figures 4A and 4B further show the receptacle terminals 122a and 122b of the receptacle connector 120 and the insulated wires 104a and 104b. FIG. 4A is a top perspective view of a receptacle terminal 122 that can be either of the receptacle terminals 122a and 122b of the receptacle connector 120 according to some embodiments, and an insulated wire 104 that can be either of the insulated wires 104a and 104b. FIG. 4B is a bottom perspective view of the receptacle terminal 122 and the insulated wire 104. As shown in FIG. 4A, the crimping portion 124 of the receptacle terminal 122 that holds the conductor 106 and the wire insulator 108 is shown. The receptacle terminal 122a and the conductor 106a are electrically connected by the crimping portion around the conductor 106a.

[0034] As shown in FIG. 4B, the receptacle terminal 122 includes a first contact portion 128a and a second contact portion 128b, which are shaped to contact the first and second sides of the receptacle contacts 142a and 142b of the plug connector 140, which can have blade contacts. The contact portions 128a and 128b can be compliant so as to apply a contact force to the plug contacts of the plug connector when the plug connector and the receptacle connector are mated. The contact portions 128a and 128b can include protrusions so as to increase the contact pressure on the mating surface. In one example, by displacing the contact portions 128a and 128b by 0.06 mm, a pressure of 800 MPa can be applied to the contact portions 128a and 128b to generate a contact force of 0.58 N. Also shown in FIG. 4B, the terminal lance 126 can be cut out from the bottom surface of the receptacle terminal 122. The terminal lance 126 is biased away from the bottom surface and turned outward to engage with a feature of the receptacle housing 130 to fix the receptacle terminal 122 to the receptacle housing 130.

[0035] Figures 5A - 5C further illustrate the plug connector 140 of FIGS. 1A and 1B. FIG. 5A is a top perspective view of the plug when the plug connector and the receptacle connector are mated. The contact portions 228a and 229a can include protrusions to increase the contact pressure at the mating surface connector 140. FIG. 5B is an exploded view of the plug connector 140. FIG. 5C is a side cross-sectional view of the plug connector 140 through the plug terminal 142a.

[0036] The spring tabs 144a and 144b of FIGS. 5A - 5C are an example of a spring member that applies a spring force to the receptacle connector 120 when mated, biasing the receptacle connector 120 in the fixed direction 114 (FIG. 2F). According to various embodiments, one or more spring members can be used. As shown in FIG. 5B, two spring tabs 144a and 144b are attached to both sides of the plug housing 150. For example, in FIG. 5B, the spring tabs 144a and 144b are attached to the side surfaces 151a and 151b of the plug housing 150 that are perpendicular to the wall 151d (e.g., the front wall 151d) through which the plug terminals 142a and 142b extend.

[0037] The plug housing 150 can include openings 158a and 158b in side surfaces 151a and 151b, with the opening 158b among them being visible in FIGS. 5A and 5B. The openings 158a and 158b can extend through the wall of the plug housing such that the compliant portions 148a and 148b of the spring tabs 144a and 144b can extend into the openings of the plug housing that receive the receptacle connector. Thus, the compliant portions 148a and 148b can physically contact the receptacle connector 120 when the receptacle connector 120 is inserted into the plug connector 120. In the illustrated example, the compliant portions 148a and 148b of the spring tabs 144a and 144b are separated in the direction in which the plug terminals 142a and 142b are separated and are positioned alongside the plug terminals 142a and 142b. In this position, when the front end of the receptacle connector 120 is inserted into the plug housing 150 as shown in FIGS. 2A and 2B, the spring tabs 144a and 144b can be compressed. Then, as shown in FIG. 2C, the spring force within the spring tabs 144a and 144b can bias the receptacle connector 120 in the securing direction. The openings 158a and 158b can accommodate the compression of the compliant portions 148a and 148b by allowing the corners of the bends in the compliant portions 148a and 148b to move within the openings in the direction in which the compliant portions 148a and 148b are compressed.

[0038] The spring tabs 144a and 144b can be retained within the plug housing 150 by one or more features. The spring tabs 144a and 144b can be retained adjacent to the front wall 151d of the plug housing 150 such that they are captured between the receptacle connector 120 and the plug housing 150 when the receptacle connector 120 is inserted. Alternatively or additionally, the coupling portions 146a and 146b of the spring tabs 144a and 144b can be clipped to the sides of the walls 151a and 151b of the plug housing 150. The elongate portions (e.g., 147b in FIG. 5B) connecting the compliant portions 148a and 148b to the coupling portions 146a and 146b can be disposed outside of the openings 158a and 158b.

[0039] FIG. 6 is a top perspective view of a spring tab 144 which can be either of the spring tabs 144a and 144b of the plug connector 140 according to some embodiments. FIG. 6 shows the coupling portion 146 and the compliant portion 148 of the spring tab 144, with the elongate portion 147 connecting the coupling portion 146 to the compliant portion 148. In some embodiments, the spring tab 144 can generate a force that pushes the receptacle connector into the position where it engages the plug housing. In one example, by displacing the compliant portion 148 by 0.3 mm, a pressure of 800 MPa is applied onto the spring tab 144 and a contact force of 0.44 N is generated.

[0040] FIG. 7A is a top perspective view of an alternative electrical interconnect system 200 including a receptacle connector 220 and a plug connector 250, according to some embodiments. FIG. 7B is a side cross-sectional view of the electrical interconnect system 200. Similar to the plug connector 140 of the electrical interconnect system 100, the plug connector 250 can be mounted on a substrate 202 which can be a printed circuit board in some embodiments, such as by surface mount soldering. In the embodiment of FIG. 7A, the receptacle connector 220 terminates twelve insulated electrical wires, two of which are labeled insulated electrical wires 204a and 204b. In the mating configuration shown in FIG. 7A, the receptacle connector 220 and the plug connector 250 can electrically connect the conductors of the insulated electrical wires to conductive pads (not shown) on the substrate 202. In some embodiments, the insulated electrical wires shown in FIG. 7A can be configured as described for the insulated electrical wires 104a and 104b of FIGS. 1A and 1B. In some embodiments, the electrical interconnect system 100 can have a small form factor, such as a height of less than 1 mm.

[0041] Similar to the receptacle connector 120, the receptacle connector 220 includes a receptacle housing 230, which can be configured to support receptacle terminals for each of the insulated electric wires, and terminal 222a of those terminals is shown in FIG. 2B. The receptacle housing 230 can be formed using an insulating material such as plastic. The receptacle terminals can be formed using a conductive material such as phosphor bronze. In one example, the receptacle terminals can be formed using phosphor bronze having a thickness of 0.75 mm to 0.2 mm, 0.12 mm, etc., 0.1 mm to 0.14 mm. In FIG. 7B, the conductor 206a of the insulated electric wire 204a can be mounted on the receptacle terminal 122a, and the crimping portion 224a of the receptacle terminal 222a holds the conductor 206a. In some embodiments, the conductor 206a can be formed using copper. The terminal lance 226a of the receptacle terminal 122a protrudes into the opening of the receptacle housing 230 and, in the illustrated embodiment, through the opening, to prevent the receptacle terminal 222a from being removed from the receptacle housing 230 when the insulated electric wire 204a is pulled away from the receptacle housing 230. The terminal lance 226a can be shaped to slide along the upper wall of the receptacle housing 230 when inserted into the receptacle housing 230. The receptacle terminal 222a is further shown in FIGS. 11A and 11B and FIGS. 12A and 12B.

[0042] The receptacle connector 220 further includes a wire cover 290 disposed on the upper surface of the receptacle housing 230. In some embodiments, the wire cover 290 can be formed using an insulating material such as plastic. The wire cover 290 can include a plurality of wire slots configured to hold the insulated electric wires in place in the receptacle housing 230. The wire cover 290 is further shown in FIG. 10B. In some embodiments, the receptacle connector 220 can have a height of 1 mm or less.

[0043] Similar to the plug connector 140, the plug connector 250 includes a plug housing 270, which can be configured to support 12 plug terminals, among which the plug terminals 252a and 252b are labeled. In some embodiments, the plug connector 250 can have a height of 1 mm or less.

[0044] The plug housing 270 can be formed using an insulating material such as plastic. The plug terminals can be formed using a conductive material such as phosphor bronze, with or without plating to assist in surface mounting soldering of the plug terminals to the substrate 202. As shown in FIG. 7B, the plug terminal 252a has at least one first portion 262a configured to be surface-mounted soldered to a pad on the surface of the substrate 202, and a second portion 262b positioned to contact the receptacle terminal 222a when the receptacle connector 220 is inserted into the plug connector 250. The plug terminals of the plug connector 250 can have blade contacts. The bottom surface of the plug housing 270 can have an opening that allows the plug terminals to be mounted (e.g., soldered) to conductive pads on the substrate 202, thereby fixing the plug terminals to the substrate 202. In the illustrated embodiment, each of the plug terminals 252a and 252b has an outer portion of the plug housing 270 configured to be soldered to the substrate 202 and an inner portion of the plug housing 270 that is similarly soldered. Between these two portions, the plug terminal engages with the wall of the housing 270 and fixes the housing 270 to the substrate 202 when the end of the terminal is soldered to the substrate 202. In some embodiments, by fixing the plug terminals 252a and 252b to the substrate 202, the plug housing 270 can be mechanically fixed to the substrate 202. As shown in FIG. 7B, the plug terminal 252a can be configured to be electrically coupled to the receptacle terminal 222a to electrically connect one or more pads on the surface of the substrate 202 and the conductor of the insulated wire 204a.

[0045] In the embodiments of FIGS. 7A and 7B, the front portion of the receptacle connector 220 is engaged with the front wall of the plug housing 270 at an acute angle with respect to the surface of the substrate 202, and then the rear portion of the receptacle housing 230 is rotated and inserted into the recess of the plug housing 270, whereby the receptacle connector 220 can be fixed within the plug housing 270. The rear portion of the receptacle connector 220 can be engaged with the features of the plug housing 270 to fix the receptacle connector 220 within the plug connector 250.

[0046] In the illustrated embodiment, the plug housing 270 supports the locking tabs 254a and 254b. The locking tabs 254a and 254b can be formed using a compliant material. In some embodiments, the locking tabs 254a and 254b can be formed using an electrically conductive material such as phosphor bronze, with or without plating to assist in the surface mounting of the locking tabs 254a and 254b to the surface of the substrate 202. In other embodiments, the locking tabs 254a and 254b can be formed using stainless steel or spring steel. The locking tabs 254a and 254b can each have a plurality of bent portions disposed on the sides of the walls of the plug housing 270. One or more of the bent portions can extend to the substrate 202 so as to be mounted (e.g., soldered) to the pads on the surface of the substrate 202. In some embodiments, the locking tabs 254a and 254b can be soldered to the surface of the substrate 202 to mechanically couple the housing 270 to the substrate 202. In some embodiments, the locking tabs 254a and 254b can be configured to electrically couple the structure of the plug connector 250 or the receptacle connector 220 to the conductive pads on the surface of the substrate 202.

[0047] In some embodiments, the insulated wire can have at least one electrical conductor 206 that can be surrounded by an insulator 208 (e.g., as shown in FIGS. 11A and 11B). The electrical conductor 106 can include a pair of copper wires wrapped with plastic 108. The designs as described herein can be used in connection with small-diameter wires. In some embodiments, the conductor can have a diameter less than 32 AWG. In other embodiments, the diameter can be less than 34 AWG, such as 36 AWG or 40 AWG or smaller.

[0048] The electrical interconnection system described herein can be configured to support any number of cables and / or wires. For example, FIGS. 8A-8C show exemplary embodiments of electrical interconnections 200a-200c configured to support different numbers of cables and / or wires using the structure of fixing a receptacle connector within a plug connector as described above with respect to FIGS. 7A and 7B. FIG. 8A is a top perspective view of an electrical interconnection system 200a configured to connect two wires to a substrate. FIG. 8B is a top perspective view of an electrical interconnection system 200b configured to connect four wires to a substrate. FIG. 8C is a top perspective view of an electrical interconnection system 200c configured to connect six wires to a substrate.

[0049] FIGS. 9A-9G show a method of mating a receptacle connector 220 and a plug connector 250 with a structure as described above in relation to FIGS. 7A and 7B. FIGS. 9A and 9B are top perspective views of the electrical interconnection system 200 when the receptacle connector 220 is inserted into and fixed within the plug connector 250. FIGS. 9C and 9D are side views of a cross-section of the electrical interconnection system 200 when the receptacle connector 220 is inserted into and fixed within the plug connector 250. FIGS. 9F and 9G are side views of an alternative cross-section of the electrical interconnection system 200 when the receptacle connector 220 is inserted into and fixed within the plug connector 250. FIG. 9E is the cross-section X 1 -X1 ’and cross-section X of FIGS. 9F and 9G 2 -X 2 ’is a top view of the electrical interconnection system 200 that designates

[0050] As shown in FIGS. 9A, 9C, and 9F, the front end of the receptacle connector 220 can be inserted along the insertion direction 210 into the plug connector 140. The insertion direction 210 can be similar to the insertion direction 110 described in relation to the electrical interconnection system 100. For example, the insertion direction 210 is directed such that the distance between the insulating wire and the substrate 202 is greater than the distance between the front end of the receptacle connector 220 and the substrate 202. As a result of the front end of the receptacle connector 220 being inserted into the plug connector 250, an acute angle can be formed with respect to the substrate 202. By the angled insertion, one or more protrusions from the receptacle connector 220 can extend under the features of the plug housing 270, and the receptacle connector 220 can be partially fixed within the plug connector 250.

[0051] The plug terminals are shown separated from each other in a direction perpendicular to the insertion direction 210 in FIG. 9A (with the reference numeral of the plug terminal 252a). As shown in FIGS. 9A and 9C, the plug housing 270 includes a recess 272 that can be shaped to accommodate the receptacle housing 230.

[0052] The receptacle housing 220 further includes one or more front protruding portions, such as front protrusions 240a and 240b, with the reference numeral of the front protrusion 240a being shown in FIG. 9F. The receptacle housing 220 further includes features that engage with complementary features of the plug connector when the rear portion of the receptacle connector is pushed into the plug housing. In this example, those features are located on the sides of the receptacle connector near the rear portion. These features can be rear side protruding portions 240c and 240d, with the reference numeral of the rear side protruding portion 240d being shown in FIG. 9A.

[0053] The plug housing 270 further includes front receiving portions 284a and 284b (the reference numeral of the front receiving portion 284a is attached in FIG. 9F), and rear side protruding portions 282a and 282b (the reference numeral of the rear side protruding portion 282b is attached in FIG. 9A). The front receiving portions 284a and 284b of the plug housing 270 can be shaped to receive the front protruding portions 240a and 240b of the receptacle housing 230, respectively. The rear side protruding portions 282a and 282b of the plug housing 270 can be positioned to engage with the rear housing protrusions 240c and 240d of the receptacle housing 230, respectively, and can form or be a part of a part of the rear wall of the plug housing. The rear side protruding portions 282a and 282b of the plug housing 270 and the rear side protruding portions 240c and 240d can be arranged on both sides of the slot 276 at the rear ends of the plug connector 250 and the receptacle connector 220, respectively.

[0054] As shown in FIG. 9F, the front protruding portion 240a of the receptacle housing 230 and the front receiving portion 284a of the plug housing 270 are arranged at the front ends of the plug connector 250 and the receptacle connector 220, respectively. As shown in FIGS. 9F and 9G, when the receptacle connector 220 is inserted into the recess 272 of the plug connector 250, the front protruding portion 240a can enter the front receiving portion 284a.

[0055] When the receptacle connector 220 is inserted into the recess 272 of the plug connector 250, the rear portion of the receptacle connector 220 can be rotated in the direction 212 toward the substrate 202. The rotation axis of the receptacle connector 220 can be established by the engagement of the front portion of the receptacle connector 220 with the front wall of the plug housing 270, and can be perpendicular to the insertion direction 210. FIGS. 9B, 9D, and 9G show the receptacle connector 220 fixed to the plug connector 250 after the receptacle connector 220 is rotated in the direction 212.

[0056] The plug housing 170 can have a slot 276 in the rear wall of the plug housing 270 that can be shaped to accommodate the insulated electric wire when the receptacle connector 220 descends into the plug connector 250. The insulated electric wire can be elongate and can extend through the slot 276.

[0057] As shown in FIGS. 9A and 9B, the receptacle connector 220 can be fixed within the plug connector 250 by the engagement of the features of the receptacle connector 220 and the features of the plug connector 250. In this example, the plug connector 250 has at least one locking tab positioned to engage the surface of the receptacle connector 220 when the rear portion of the receptacle connector 220 rotates and enters into the plug connector 250. For example, the locking tabs 254a and 254b shown in FIGS. 9A and 9B can engage the locking ledges 242a and 242b of the receptacle housing 230 to prevent the receptacle connector 220 from rotating out of the recess 272 of the plug connector 250 at least partially about the axis 212. The locking ledge 242b of them is shown in FIG. 9A. The locking ledges 242a and 242b of the receptacle housing 230 can be hooked on the compliant portions 258a and 258b of the locking tabs 254a and 254b to fix the receptacle connector 220 within the recess 272 of the plug connector 250. The rear side protruding portions 282a and 282b of the plug housing 270 can be configured to prevent the receptacle connector 220 from slipping out of the rear end of the recess 272 when the insulated electric wire is pulled rearward. The front protruding portions 240a and 240b of the receptacle housing 230 and the front receiving portions 284a and 284b of the plug housing 270 can be configured to prevent the movement of the receptacle connector 220 in the upward direction away from the substrate 202.

[0058] Figures 10A - 10E further illustrate the receptacle connector 220b of FIGS. 8B and 9A - 9G. FIG. 10A is a top perspective view of the receptacle connector 220b. As shown in FIG. 10A, the receptacle housing 230b further includes terminal lance slots that can be configured to engage with the terminal lances of the receptacle contacts, such as the terminal lance slot 238a is labeled. Also shown in FIG. 10A is a locking shelf portion 242b, which can be configured to engage with the locking tabs of the plug connector 250b when the receptacle connector 220b is inserted into the plug connector 250b. Such a shelf portion can be formed by forming a recess in the plane of the side wall of the receptacle housing 230 above the shelf portion, or by a protrusion from the plane of the side wall below the shelf portion. In the illustrated embodiment, the shelf portion is formed by a recess into the upper wall of the shelf portion. The bottom surface of the locking shelf portion 242b has a rounded edge that can slide on the locking tab when the receptacle connector 220b is inserted into the plug connector 250b, and the upper surface of the locking shelf portion 242b is substantially flat to prevent the upper surface from accidentally sliding over the locking tab when the receptacle connector 220b is fixed in the plug connector 250b and an upward force is applied to the receptacle connector 220b.

[0059] FIG. 10B is a partially exploded view of the receptacle connector 220b with the wire cover 290b removed from the receptacle housing 230b. As shown in FIG. 10B, the wire cover 290b includes protrusions 292 and wire slots 294. The protrusions 292 can be configured to fit into the wire cover slots 234 in the side walls of the receptacle housing 230b to fix the wire cover 290b to the receptacle housing 230b. The wire slots 294 can be shaped to accommodate insulated wires. The wire cover 290b is removed to show the crimping portion (e.g., 224a) of the receptacle terminal that holds the insulated wire.

[0060] Figure 10C is a top perspective view of the receptacle connector 220b. Figure 10C shows the front protruding portions 240a and 240b and the rear side protruding portions 240c and 240d of the receptacle housing 230b. Figure 10C also shows the terminal slots in the front wall of the receptacle housing 230b, with the reference numeral 236a for one of the terminal slots. The terminal slots are shaped to accommodate the plug terminals of the plug connector 250b such that when the receptacle connector 220b is inserted into the plug connector 250b, the receptacle terminals can be electrically coupled to the plug terminals. Figure 10C also shows the terminal lance slots. Figure 10D is an enlarged view of a portion of the receptacle connector 220b showing the engagement of the terminal 222a with the receptacle housing 230b. In Figure 10D, the terminal lances 226a and 227a of the receptacle terminal 222a extend into the terminal lance slot 238a on the top surface of the receptacle housing 230b to prevent withdrawal of the terminal 222a from the receptacle housing 230b.

[0061] Figure 10E is a side view of a cross section of the receptacle connector 220b passing through the insulated wire 204b and the receptacle terminal 222b. The cross section shown in Figure 10E includes one side of the receptacle terminal 222b, including a part of the crimping portions 224b and 225b, one of the terminal lances 226b, and one of the contact portions 228b. As shown in Figure 10E, the insulated wire can include a conductor (e.g., 206b of the insulated wire 204b).

[0062] Figures 11A and 11B and Figures 12A and 12B further illustrate the receptacle terminals of the receptacle connector 220b of Figure 8B. Figure 11A is an exploded view of the receptacle connector 220b of Figure 8B with the wire cover 290 removed, according to some embodiments. Figure 11B is a perspective view of the receptacle terminals 222a and the insulated wire 204 of the receptacle connector 220. The receptacle terminal 222b includes terminal lances 226b and 227b and contact portions 228b and 229b. The terminal lances 226b and 227b can be configured to engage with the terminal lance slots of the receptacle housing 230. The terminal lances 226b and 227b can be cut off from the contact portions 228b and 229b. The terminal lances 226b and 227b can be bent outwardly and biased away from the upper surface so as to engage with the features of the receptacle housing 230b to fix the receptacle terminal 222b to the receptacle housing 230b.

[0063] As shown in FIGS. 11A and 11B, the insulated wire 204b includes a conductor 206b and an insulator 208b. As also shown in FIGS. 11A and 11B, the crimping portion 224b can be configured to hold the insulator 208b, and the crimping portion 225b can be configured to hold the conductor 206b. The crimping portion 225b can be electrically coupled to the conductor 206b. The crimping portion 225b around the conductor 206b electrically connects the receptacle terminal 222b and the conductor 206b.

[0064] As shown in FIG. 11A, the crimping portions 224a and 224b of the adjacent receptacle terminals 222a and 222b can be offset from each other in the direction in which the receptacle terminals 222a and 222b extend. The crimping portion 225a of the receptacle terminal 222a can be positioned adjacent to the crimping portion 224b of the receptacle terminal 222b. By making the crimping portion 224a wider than the crimping portion 225b, and by the offset between the crimping portions 224a and 224b and the positioning of the crimping portion 224a adjacent to the crimping portion 225b, the combined width of the receptacle terminals can be reduced, thereby reducing the width of the receptacle connector 220b. The wire slot 294 of the wire cover 290b can be shaped to accommodate the offset and positioned crimping portions 224a and 224b of the receptacle terminals 222a and 222b.

[0065] The contact portions 228b and 229b can be configured to electrically connect to the plug terminals of the plug connector 250b when the receptacle connector 220b is inserted into the plug connector 250b. In some embodiments, the contact portions 228b and 229b can be compliant such that when the plug connector and the receptacle connector are mated, a contact force is applied to the plug contacts of the plug connector 250b. The contact portions 228a and 229a can include protrusions to increase the contact pressure on the mating surface. In one example, by displacing the contact portions 228b and 229b by 0.06 mm, a pressure of 1,000 MPa is applied to the contact portions 228b and 229b and the slot 276 in the rear wall of the plug housing 270, which can be shaped to accommodate the insulated wire when the receptacle connector 220 drops into the plug connector 250. The insulated wire is elongate and can extend through the slot 276d and generate a contact force of 0.59.

[0066] FIG. 12A is a side view of the receptacle terminal 222b. FIG. 12B is a top view of the receptacle terminal 222b shown in FIG. 11B.

[0067] Figures 13A to 13C further show the plug connector 250b of FIG. 8B. FIG. 13A is a top perspective view of the plug connector 250b. FIG. 13A shows a front receiving portion 284a, rear side protruding portions 282a and 282b, a receiving slot 276 in the rear wall 271c of the plug housing 270b, and locking tabs 254a and 254b disposed on the side walls of the plug housing 270b. FIG. 13B is an exploded view of the plug connector 250b of FIGS. 7A and 7B. In FIG. 13B, the plug terminals and the locking tabs 254a and 254b are removed from the plug housing 270b, showing the terminal slots 274 and the locking tab slots 280a and 280b of the plug housing 270b, which can be configured to hold the plug terminals and the locking tabs 254a and 254b.

[0068] FIG. 13C is a side view of a cross-section of the plug connector 250b through the plug terminal 252b. As shown in FIG. 13C, the locking tab 254a includes coupling portions 256a and 256b and a compliant portion 258. The coupling portions 256a and 256b bend over the sides of the side wall 271a of the plug housing 270b and can attach to protrusions from the side wall 271a of the plug housing 270b extending into the slots of the coupling portions 256a and 256b. The coupling portions 256a and 256b each form a U-shape and can fit over two sides of the side wall 217a.

[0069] The compliant portion 258 can be aligned with the recess 272 of the plug housing 270b such that when the receptacle connector 220b is inserted into the plug connector 250b, it can be pushed into the side wall (e.g., 271b) of the plug housing 270b to provide a gap for the receptacle connector 220b. When the receptacle connector 220b is inserted, the compliant portion 258 rebounds and can engage with the shelf portion 242a or 242b of the receptacle connector 220b.

[0070] In the illustrated embodiment, the compliant portion 258 is in an "M" shape. The "M" shape provides sufficient flexibility / rigidity to the compliant portion 258 to allow for easy insertion of the receptacle connector 220b into the plug housing 270b while applying sufficient holding force to prevent inadvertent removal of the receptacle connector 220b from the plug housing 270b over a range of operating conditions.

[0071] FIG. 14 is a perspective view of a locking tab 254 which can be either of the locking tabs 254a and 254b of the plug connector 250b according to some embodiments. As shown in FIG. 14, the locking tab 254 includes coupling portions 256a and 256b and a compliant portion 258. The locking tab 254 further includes a mounting portion 260 that can be mounted (e.g., soldered) to the pads of the substrate 202. When the compliant portion 258 engages the locking protrusion of the receptacle housing 230b, the coupling portions 256a and 256b can hold the receptacle housing 230b to the plug housing 270b, and the mounting portion 260 can hold the receptacle housing 230 and the plug housing 270b to the substrate 202. In one example, by displacing the compliant portion 258 by 0.08 mm, a pressure of 900 MPa can be applied to generate a contact force of 2.7 N.

[0072] It should be understood that, by virtue of the several aspects of at least one embodiment of the present invention described as above, those skilled in the art will readily conceive of various modifications, variations, and improvements.

[0073] For example, in the illustrated embodiment, two electric wires terminate within the receptacle connector. It will be understood by those skilled in the art that variant forms of such connectors can be fabricated. The cable can be terminated, for example, by a plug connector. A connector with receptacle terminals can be mounted on the substrate. Similarly, more or fewer electric wires can be terminated by the connector.

[0074] As another example, the connector was described as terminating the insulated wires 104a and 104b, each having a single conductor. In other embodiments, the wires can have other configurations, such as coaxial or twinaxial cables. In some embodiments, the insulated wires 104a and 104b or the electrical cable can include another conductor (e.g., a ground and / or shielding conductor) surrounding the wire or cable.

[0075] As a further example, the wire cover is shown as a separate part having features that engage with a receptacle housing to hold the cover in place. Alternatively or additionally, the cover can be formed around the wire by insert molding material.

[0076] Such modifications, variations, and improvements are intended to be part of this disclosure and are intended to be within the spirit and scope of the present invention. Further, while the advantages of the present invention are shown, it should be understood that not all embodiments of the present invention include all of the described advantages. Some embodiments may not implement any of the features described as advantageous in some instances herein. Accordingly, the foregoing description and drawings are by way of example only.

[0077] The various aspects of the present invention can be used alone, in combination, or in various arrangements not specifically contemplated in the embodiments described above, and thus, its application is not limited to the details and arrangements of the components shown in the above description or depicted in the drawings. For example, aspects described in one embodiment can be combined with aspects described in other embodiments in any manner.

[0078] In addition, the present invention can be embodied as a method, and an example thereof is provided. The acts performed as part of the method can be ordered in any suitable manner. Accordingly, embodiments can be configured in which the acts are performed in an order different from that illustrated, which can include performing some acts simultaneously, even if they are shown as consecutive acts in the exemplary embodiments.

[0079] The use of terms such as "first," "second," "third," etc. to indicate the order for changing claim elements in the claims does not, in itself, mean any priority, precedence, or order in which one claim element takes precedence over another claim element, or the temporal order in which the acts of the method are performed. Instead, it is used simply as a label for identifying one claim element having a certain name from another element having the same name (apart from the use of the terms indicating order) to distinguish those claim elements.

[0080] All definitions defined and used herein should be understood to take precedence over dictionary definitions, definitions in incorporated references, and / or the ordinary meaning of the defined terms.

[0081] The indefinite article "a" or "an" as used herein in the specification and claims should be understood to mean "at least one" unless a clearly different meaning is indicated.

[0082] As used in this specification and the claims, the phrase "at least one" with respect to a list of one or more elements means at least one element selected from any one or more of the elements in the list, but not necessarily including at least one of every element specifically listed within the list of elements, and not excluding any combination of elements in the list. By this definition, optionally, elements other than those specifically identified within the list of elements referred to by the phrase "at least one" may exist, whether or not related to those specifically identified elements.

[0083] As used in this specification and the claims, the phrase "and / or" means "either or both" of the elements so combined, i.e., elements that in some cases coexist and in other cases exist separately. A plurality of elements listed together with "and / or" should be construed in the same sense, i.e., "one or more" of the elements so combined. Optionally, other elements may exist, whether or not related to those specifically identified by the "and / or" clause. Thus, by way of non-limiting example, reference to "A and / or B", when used with non-limiting words such as "comprising", may in one embodiment refer to only A (optionally including elements other than B), in another embodiment to only B (optionally including elements other than A), and in yet another embodiment to both A and B (optionally including other elements).

[0084] As used in this specification and the claims, "or" shall 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" is inclusive, i.e., it shall be construed to include at least one of two or more of the elements or list of elements, and optionally further unlisted items. Only terms such as "only one of...", "exactly one of...", or "consisting of...", when used in the claims and where it is clearly indicated otherwise, refer to including exactly one element of a plurality of elements or list of elements. Generally, the term "or" as used in this specification shall be construed to indicate an exclusive alternative (i.e., "one or the other but not both") when preceded by an exclusive term such as "either", "one of...", "only one of...", or "exactly one of...". "Consisting essentially of" shall have its ordinary meaning as used in the field of patent law when used in the claims.

[0085] Also, the syntax and terminology used in this specification are for illustrative purposes and should not be considered limiting. The use of "including", "comprising", "having", "containing", "involving", and their variants in this specification means including additional items together with the items listed previously and their equivalents.

Description of Reference Numerals

[0086] 100 Electrical interconnection system 102 Substrate 104a, 104b Electric wires 106 Electrical conductor 108 Insulator 120 Receptacle connector 122, 122a, 122b Receptacle terminals 124 Crimping portion 126a, 126b Terminal lances 128a First contact portion 128b Second contact portion 130 Receptacle housing 134a, 134b Terminal slots 136 Slot 138a - 138c Protruding portions 140 Plug connector 142a, 142b Plug terminals 144a, 144b Spring tabs 146a, 146b Coupling portions 147 Longitudinal portion 148, 148a, 148b Compliant portions 150 Plug housing 151a, 151b Sides 151d Front wall 152a - 152c Receiving portions 154 Slot 158a, 158b Openings 160a, 160b Protruding portions 162a First portion 162b Second portion 170 Plug housing 200 Electrical interconnection system 202 Substrate 204a, 204b Insulated electric wires 206 Electrical conductor 208 Insulator 217a Side wall 220b Receptacle connector 222a, 222b Receptacle terminals 224a, 224b Crimping portions 225a, 225b Crimping portions 226a, 226b, 227a, 227b Terminal lances 228a, 228b, 229a, 229b Contact portions 230, 230b Receptacle housing 234 Wire cover slot 236a Terminal slot 238a Terminal lance slot Front protrusions of 240a and 240b Rear side protruding parts of 240c and 240d Locking shelves of 242a and 242b Plug connector 250 Plug terminals 252a and 252b Locking tabs 254a and 254b Coupling parts 256a and 256b Compliant part 258 Mounting part 260 First part 262a Second part 262b Plug housing 270 Side walls 271a and 271b Rear wall 271c Recess 272 Terminal slot 274 Receiving slot 276 Locking tab slots 280a and 280b Rear side protruding parts 282a and 282b Front receiving parts 284a and 284b Wire cover 290b Protrusion 292 Wire slot 294

Claims

1. An electrical connector, comprising: An insulating housing having an opening for receiving a second connector, the opening being surrounded by at least a first wall and a second wall of the insulating housing, the first wall comprising at least one receiving portion configured to receive a protrusion from the second connector, the second wall being an insulating housing that crosses the first wall, and A plurality of conductive terminals attached to the first wall of the insulating housing and extending into the opening; At least one locking tab attached to the second wall of the insulating housing; Comprising The at least one locking tab includes a compliant portion configured to engage a surface of the second connector when the second connector is inserted into the opening; The at least one locking tab is bent about an axis parallel to the longitudinal direction of the second wall of the insulating housing such that the at least one locking tab extends across the upper surface of the second wall of the insulating housing. Electrical connector.

2. The at least one receiving portion is configured to receive the protrusion from the second connector when the second connector is inserted in a first direction; The opening of the insulating housing has a bottom surface; The electrical connector is configured such that the first direction is an acute angle with respect to the bottom surface. The electrical connector according to claim 1.

3. The electrical connector according to claim 2, wherein the at least one receiving portion of the first wall includes a slot configured to receive the protrusion of the second connector.

4. The insulating housing further includes a rear wall disposed on the opposite side from the first wall of the insulating housing, the rear wall including a slot configured to receive an electric wire and / or a cable extending from the second connector when the second connector is inserted into the opening. The electrical connector according to claim 2.

5. The electrical connector according to claim 1, wherein the at least one locking tab is disposed on at least one side wall of the insulating housing.

6. The electrical connector according to claim 5, wherein the at least one locking tab includes a U-shaped coupling portion fitted on the at least one side wall.

7. The electrical connector according to claim 6, wherein the at least one locking tab further comprises a compliant portion.

8. The at least one locking tab comprises a first locking tab disposed around a first opposing surface and a second opposing surface of a first side wall of the at least one side wall, and a second locking tab disposed around a first opposing surface and a second opposing surface of a second side wall of the at least one side wall, and the electrical connector according to claim 7, wherein the first side wall and the second side wall are disposed on both sides of the opening.

9. The electrical connector according to claim 7, wherein the at least one locking tab further comprises at least one mounting portion configured to extend from a coupling portion and be mounted on a surface of a substrate.

10. The electrical connector according to claim 1, wherein the plurality of conductive terminals include blade contacts.

11. The electrical connector according to claim 1, having a stacking height of 1 millimeter (mm) or less.

12. An electrical connector, comprising an insulating housing, a plurality of conductive terminals supported by the insulating housing, and at least one spring supported by the insulating housing, wherein the insulating housing includes an opening for receiving a second connector, and a first connector includes a first retaining feature that engages the second connector at a first end of the opening and a second retaining feature that engages the second connector at a second end of the opening, and the first end is offset in a first direction from the second end; the at least one spring is configured to apply a force to the second connector in the first direction when the second connector is within the opening; the insulating housing includes a first wall that supports the plurality of conductive terminals and a second wall that supports the at least one spring; the insulating housing further includes at least one locking tab attached to the second wall of the insulating housing; the at least one locking tab includes a compliant portion configured to engage a surface of the second connector when the second connector is inserted into the opening; the at least one locking tab is bent about an axis parallel to the longitudinal direction of the second wall of the insulating housing such that the at least one locking tab extends across an upper surface of the second wall of the insulating housing.

13. The first retaining feature includes a first receiving portion of the insulating housing for retaining the second connector at the first end of the opening. The electrical connector according to claim 12, wherein the second retaining feature includes a second receiving portion of the insulating housing for retaining the second connector at the second end of the opening. **Claim 14** The first retaining feature further includes a first protruding portion of the insulating housing located above the first receiving portion. The second retaining feature further includes a second protruding portion of the insulating housing located above the second receiving portion. The electrical connector according to claim 13, wherein each of the first protruding portion and the second protruding portion is configured to interconnect with a respective protruding portion of the insulating housing of the second connector. **Claim 15** The plurality of conductive terminals are positioned on a line extending in a second direction perpendicular to the first direction. The electrical connector according to claim 14, wherein the first protruding portion and the second protruding portion are configured to prevent movement of the second connector in a third direction perpendicular to the first direction and the second direction. **Claim 16** The electrical connector according to claim 12, further comprising a member including a coupling portion attached to the insulating housing, a bent portion, and an elongate portion connecting the bent portion to the coupling portion, wherein the at least one spring includes the bent portion of the member. **Claim 17** The electrical connector according to claim 16, wherein the insulating housing includes a side wall having a second opening, the elongate portion is disposed outside the second opening, and the bent portion extends through the second opening. **Claim 18** The electrical connector according to claim 17, wherein the second opening extends in the first direction to accommodate movement of a corner of the bent portion in the first direction when the bent portion is compressed. **Claim 19** The electrical connector according to claim 12, wherein the first retaining feature and the second retaining feature each include a protruding portion configured to engage a protruding portion of the insulating housing of the second connector. **Claim 20** The plurality of conductive terminals are positioned by a line extending in a second direction perpendicular to the first direction. The electrical connector according to claim 19, wherein the protruding portion is configured to prevent movement of the second connector in a third direction perpendicular to the first direction and the second direction.

21. The at least one spring has a surface positioned to contact the second connector when the second connector is inserted into the opening, The electrical connector according to claim 12, wherein the surfaces of the plurality of conductive terminals and the at least one spring are separated in a second direction.

22. The at least one spring includes a first spring and a second spring attached to a first opposing surface and a second opposing surface of the insulating housing, and the first opposing surface and the second opposing surface extend parallel to the first direction. The electrical connector according to claim 12.

23. The electrical connector according to claim 22, wherein the plurality of conductive terminals are attached to a third surface of the insulating housing different from the first opposing surface and the second opposing surface.

24. The plurality of conductive terminals are positioned at a first end portion of the insulating housing adjacent to the first end portion of the opening, The insulating housing has a slot at a second end portion opposite to the first end portion, The electrical connector according to claim 12, wherein the slot is configured to accommodate a plurality of electrical conductors coupled to the second connector when the second connector is inserted into the concave region.

25. The electrical connector according to claim 24, wherein the plurality of electrical conductors include at least one electrical cable and / or a plurality of electric wires.

26. The electrical connector according to claim 12, and A second connector, comprising: A second plurality of conductive terminals configured to receive a first plurality of conductive terminals; A second housing that supports the first plurality of conductive terminals; A plurality of electrical conductors that terminate at the second connector and are electrically coupled to the second plurality of conductive terminals; A second connector comprising; An electrical connector system comprising.

27. A method of mating a cable connector with a board connector, wherein the board connector is the electrical connector according to claim 1, Inserting the cable connector into the recess of the board connector along a first direction; The cable connector to the board connector, at least in part, Applying a spring force to the cable connector in a second direction that is at least partially opposite to the first direction; Preventing movement of the cable connector in a direction perpendicular to the second direction; Thereby, a fixing step; Including; The blade contacts of the board connector are inserted into the receptacle terminals of the cable connector when the cable connector is inserted into and fixed to the board connector. A method. **Claim 28** The method according to claim 27, wherein applying the spring force includes physically contacting the cable connector with at least one spring of the board connector. **Claim 29** The method according to claim 27, wherein the step of inserting the cable connector into the recess of the board connector includes accommodating an electrical conductor coupled to the cable connector in a slot of the board connector. **Claim 30** The method according to claim 29, wherein accommodating the electrical conductor includes accommodating at least one electrical cable or wire in the slot.

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