High Density Electrical Connectors

Abstract

In various embodiments, a compact connector design is provided that can accommodate larger conductors (e.g., 1.4 mm, 1.1 mm, 0.9 mm, etc.) while still allowing for reduced board pitch (e.g., 1.80 mm, 1.50 mm, 1.27 mm, etc.). In this manner, the PCB footprint may be reduced (e.g., by 50% if a staggered connector configuration is used), while maintaining sufficient current carrying capacity (e.g., 2 A, 3 A, 4 A, etc.). Additionally or alternatively, one or more other advantages may be realized, such as durability (e.g., vibration resistance), error-proofing, configuration flexibility, ease of manufacturing, ease of assembly, and / or lower cost.

Description

[Technical Field]

[0001] The present invention relates to high density electrical connectors. [Background technology]

[0002] Many electrical devices are controlled by and / or powered via printed circuit boards (PCBs). For example, in an automobile, an electrical connector may be used to connect an LED lamp to a PCB that controls and / or powers the LED lamp. Such a connector may include electrical terminals configured to be crimped to conductive wires (e.g., wires of a cable connected to the LED lamp) and / or contact pins configured to be soldered onto the PCB.

[0003] In many fields, the trend toward miniaturization of components continues. This creates a constant demand for electrical connectors with higher signal density. Additionally, there is a demand for improved vibration resistance. For example, in automotive applications, it may be desirable to prevent two mating connectors from becoming unmated due to vibrations in the operating environment.

[0004] The '699 patent, among other things, shows an example of a terminal for use in a connector. Such a terminal may be securely crimped onto the wires of an electrical cable. The '699 patent also shows a connector having a core and a housing attached to one another with a retention force greater than that provided between the connector and a mating connector, thereby preventing accidental separation of the core and housing when a user attempts to disconnect the two connectors. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] US Patent Application Publication No. 2015 / 0050838 Summary of the Invention [Means for solving the problem]

[0006] In some embodiments, a terminal is provided for use with a first electrical connector, the terminal including a mating end configured to receive a contact pin of a second electrical connector, a crimp end configured to be crimped to an electrical wire, and an intermediate portion between the mating end and the crimp end, the terminal being elongated along a mating direction, the intermediate portion including a locking means biased outwardly from a centerline of the terminal along the mating direction.

[0007] In some embodiments, an electrical connector is provided that includes a housing, a terminal position assurance (TPA) means attached to the housing, the TPA means being movable between a disengaged state and an engaged state, and a terminal inserted into a cavity in the housing, wherein when the TPA means is in the engaged state, a locking means of the terminal engages with the TPA means to retain the terminal in the cavity.

[0008] In some embodiments, an electrical connector is provided that includes a housing, a terminal position assurance (TPA) means attached to the housing, the TPA means being movable between a disengaged state and an engaged state, and a terminal to be inserted into a cavity in the housing, wherein the TPA means includes a protrusion, and when the TPA means is in the disengaged state, the protrusion of the TPA means aligns with a wall of the cavity to allow the terminal to be inserted into the cavity, and the protrusion of the TPA means has an inclined shape configured to guide the terminal as it is inserted into the housing when the TPA means is in the disengaged state.

[0009] In some embodiments, a first electrical connector is provided that includes a first housing and a terminal position assurance (TPA) means attached to the first housing, the TPA means being movable between a disengaged state and an engaged state, the first electrical connector configured to mate with a second electrical connector having a second housing, the TPA means including a latch configured to engage the second housing to secure the first and second electrical connectors together in the mated state.

[0010] In some embodiments, an electrical connector is provided that includes a housing and a fastener having first, second, and third attachment means, the first attachment means preventing lateral movement between the fastener and the housing, the second attachment means preventing vertical movement between the fastener and the housing, and the third attachment means configured to attach to a printed circuit board (PCB) to secure the electrical connector to the PCB.

[0011] In some embodiments, a first electrical connector is provided that includes a first housing and a connector position assurance (CPA) means attached to the first housing, the CPA means being movable between a disengaged state and an engaged state, the CPA means including a first latch configured to attach the CPA means to the first housing when the CPA means is in the disengaged state, the first electrical connector is configured to mate with a second electrical connector having a second housing, the CPA means including a second latch configured to attach the CPA means to the second housing when the CPA means is in the engaged state, and the first housing is configured to prevent the CPA means from moving to the engaged state when the first and second electrical connectors are not fully mated. [Brief explanation of the drawings]

[0012] [Figure 1A] 1 illustrates an exemplary connector 100 according to some embodiments. [Figure 1B] 1B is an exploded view of the exemplary connector 100 shown in FIG. 1A, according to some embodiments. [Figure 2A] 2 illustrates an exemplary electrical terminal 200 according to some embodiments. [Figure 2B] 2B illustrates the exemplary barrels 212a, 212b, 214a, and 214b of FIG. 2A in a crimped state, according to some embodiments. [Figure 3A] 1 illustrates an exemplary connector 300A according to one embodiment. [Figure 3B] 3 illustrates an exemplary connector 300B according to one embodiment. [Figure 3C]3 illustrates an exemplary connector 300C according to one embodiment. [Figure 3D] 3 illustrates an exemplary connector 300D according to one embodiment. [Figure 3E] 3 illustrates an exemplary connector 300E according to one embodiment. [Figure 3F] 3 illustrates an exemplary connector 300F according to one embodiment. [Figure 4A] 1C illustrates a cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. [Figure 4B] 1C illustrates a cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. [Figure 4C] 1C illustrates a cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. [Figure 4D] 1C illustrates a cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. [Figure 5A] 1C illustrates another cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. [Figure 5B] 1C illustrates another cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. [Figure 6A] 1C illustrates a bottom view of the exemplary socket 130 shown in FIG. 1B with a portion cut away to show an exemplary locking means for inserted terminals, according to some embodiments. [Figure 6B] An enlarged view of portion 602 of FIG. 6A is shown. [Figure 7] 1C illustrates another cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. [Figure 8] 1C illustrates another cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. [Figure 9A] 9 illustrates an exemplary connector 900A according to some embodiments. [Figure 9B] 9 illustrates an exemplary connector 900B according to some embodiments. [Figure 10]10 illustrates exemplary header housings 1002 and 1004 according to some embodiments. [Figure 11A] 11 illustrates an exemplary header 1100 according to some embodiments. [Figure 11B] 11B illustrates a cross-sectional view of the exemplary header 1100 of FIG. 11A, according to some embodiments. [Figure 12A] 12 illustrates an exemplary connector 1200 according to some embodiments. [Figure 12B] 12B illustrates a cross-sectional view of the exemplary connector 1200 of FIG. 12A, according to some embodiments. [Figure 12C] 12A and 12B show an example latch 1237 in contact with the example protrusion 1241 of FIGS. 12A and 12B, according to some embodiments. [Figure 12D] 12A and 12B show an example latch 1237 being biased by an example protrusion 1241, according to some embodiments. [Figure 12E] 12A and 12B in an engaged state, according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0013] In various embodiments, a compact connector design is provided that can accommodate larger conductors (e.g., 1.4 mm, 1.1 mm, 0.9 mm, etc.) while still allowing for reduced board pitch (e.g., 1.80 mm, 1.50 mm, 1.27 mm, etc.). In this manner, the PCB footprint may be reduced (e.g., by 50% if a staggered connector configuration is used), while maintaining sufficient current carrying capacity (e.g., 2 A, 3 A, 4 A, etc.). Additionally or alternatively, one or more other advantages may be realized, such as durability (e.g., vibration resistance), error proofing, configuration flexibility, ease of manufacturing, ease of assembly, and / or lower cost.

[0014] FIG. 1A illustrates an exemplary connector 100 according to some embodiments. In this example, the connector 100 includes a cable interface 110 and a board interface 120. The cable interface 110 may be configured to receive one or more wires of an electrical cable. For example, the cable interface 110 may include an opening 115 into which an electrical terminal may be inserted, and the terminal may be crimped onto the wires of the electrical cable. The board interface 120 may be configured to make an electrical connection with one or more traces of a PCB. For example, the board interface 120 may include contact pins 125 configured to be soldered to the PCB using any suitable technique, such as surface mount device (SMD), pin-in-paste (PiP), etc.

[0015] 1B is an exploded view of the exemplary connector 100 shown in FIG. 1A, according to some embodiments. In this example, the connector 100 includes a socket 130 and a header 140. The exemplary cable interface 110 and the exemplary board interface 120 shown in FIG. 1A may be positioned in the socket 130 and the header 140, respectively.

[0016] In some embodiments, the socket 130 and the header 140 may be configured to mate with each other. When mated, one or more electrical terminals of the socket 130 (e.g., terminals 132 inserted into the openings 115) may be electrically connected to one or more corresponding contact pins of the header 140 (e.g., contact pins 125). In some embodiments, the terminals 132 may be crimped onto wires of an electrical cable, and the contact pins 125 may be soldered to a PCB. Thus, when the socket 130 and the header 140 are mated with each other, an electrical connection may be made between the wires and the conductive traces of the PCB.

[0017] 1B , header 140 includes a cavity 142 configured to receive socket 130. Contact pins 125 may be retained within header 140 such that, when socket 130 is inserted into cavity 142, mating ends of contact pins 125 make electrical connections with mating ends of terminals 132. Additionally or alternatively, header 140 may include one or more means (e.g., fasteners 144) configured to secure header 140 to a PCB.

[0018] 1B , the socket 130 includes a connector position assurance (CPA) means 134 and a terminal position assurance (TPA) means 136. In some embodiments, the CPA means 134 may be in one of at least two states, such as a disengaged state and an engaged state. When the socket 130 is not mated with any header, the CPA means 134 may be in a disengaged state and may be prevented from moving to an engaged state. When the socket 130 is mated with a header (e.g., header 140), the CPA means 134 may be moved to an engaged state, in which case the CPA means 134 may prevent the socket 130 and header 140 from becoming disengaged (e.g., due to vibration in the operating environment). In some embodiments, the TPA means 136 may be engaged to prevent one or more terminals (e.g., terminal 132) from becoming disengaged within the socket 130 (e.g., due to vibration in the operating environment). Additionally or alternatively, TPA means 136 may be used to ensure that an electrical connection is only made when the terminal is in the desired position.

[0019] Figure 2A illustrates an exemplary electrical terminal 200 according to some embodiments. Terminal 200 may be used in any suitable connector, such as exemplary connector 100 shown in Figures 1A and 1B. For example, terminal 200 may be used as exemplary terminal 132 shown in Figure 1B.

[0020] In the example of FIG. 2A , terminal 200 includes a crimp end 210 and a mating end 220. Crimp end 210 may be configured to be crimped onto wires of an electrical cable. For example, crimp end 210 may include one or more barrels (e.g., 212a and 212b) configured to be crimped onto an insulated portion of an electrical cable and / or one or more barrels (e.g., 214a and 214b) configured to be crimped onto a stripped portion of an electrical cable where the insulation has been stripped and the conductive wires are exposed. FIG. 2B shows the example barrels 212a, 212b, 214a, and 214b of FIG. 2A in a crimped state, according to some embodiments.

[0021] In some embodiments, barrels 212a and 212b may be offset from one another so that when crimped, barrels 212a and 212b may hold portions of the cable's insulation at different positions along the length of the cable, which may improve retention. Additionally or alternatively, barrels 214a and 214b may be elongated along the length of terminal 200, which may increase the contact area between terminal 200 and the wire to which terminal 200 is crimped (thus improving the electrical connection). The inventors have realized that one or more of these techniques may be used to improve vibration resistance (e.g., in automotive applications).

[0022] 2A, mating end 220 includes a contact beam 222 configured to mate with a corresponding contact pin (e.g., exemplary contact pin 125 shown in FIGS. 1A and 1B). For example, contact beam 222 may be a box-shaped beam configured to receive contact pin 125. However, it should be understood that aspects of the present disclosure are not limited to the use of a box-shaped beam, as other mating contact configurations may also be suitable.

[0023] 2A , terminal 200 includes an intermediate portion 230 between crimp end 210 and mating end 220. In some embodiments, intermediate portion 230 may include locking means 232 configured to engage one or more features of socket 130, e.g., to hold terminal 200 in a desired position within socket 130. For example, locking means 232 may be biased outward from a centerline of terminal 200 and may fit within a corresponding recess in socket 130 to prevent terminal 200 from becoming dislodged (e.g., due to vibration in the operating environment).

[0024] Additionally or alternatively, intermediate portion 230 may include blocking means 234 configured to engage with a TPA means (e.g., exemplary TPA means 136 shown in FIG. 1B). For example, as described below with respect to FIG. 4C, when the TPA means is in an engaged state, a protrusion of the TPA means may contact blocking means 234, thereby preventing terminal 200 from being disengaged.

[0025] The inventors have recognized and appreciated that it may be desirable to provide different connector configurations for use in different applications. For example, it may be desirable to provide connectors having different configurations (e.g., top latches vs. side latches, staggered vs. side-by-side, single row vs. dual row, etc.) but that can accept terminals of the same design (e.g., exemplary terminal 200 shown in FIG. 2A ). This facilitates manufacturing and / or installation. Furthermore, the cost of tooling to fabricate terminals may be higher than the cost of the terminals themselves, and amortizing the tooling costs over many terminals can reduce overall costs. Therefore, it may be desirable to provide a terminal design that may be used in many different connector configurations. However, it should be understood that aspects of the present disclosure are not limited to the use of a universal design for terminals.

[0026] 3A-3F illustrate exemplary connectors 300A-300F, respectively, according to some embodiments. For example, each of the connectors 300A-300F may be configured for use with a terminal having the exemplary design shown in FIG. 2A.

[0027] In the example shown in FIG. 3A , connector 300A includes a socket with two terminals, 302A and 304A, and a header with two pins, 312A and 314A. Terminals 302A and 304A may be staggered. For example, terminal 302A may be offset both horizontally and vertically from terminal 304A, as may pins 312A and 314A. In this manner, the horizontal distance between pins 312A and 314A may be reduced while maintaining the overall distance between pins 312A and 314A (the square root of the sum of the squares of the horizontal distance and the vertical distance). Therefore, it may be possible to reduce the board pitch while still using conductors large enough to carry high currents.

[0028] In this disclosure, a "vertical" direction may be perpendicular to the PCB to which the connector is attached, and a "horizontal" direction may be parallel to the PCB. Additionally, a first feature of a connector may be said to be "above" (or "below") a second feature of the connector if the first feature is vertically offset from the second feature and further (or closer) from the PCB than the second feature. Similarly, the "top" of the connector may face away from the PCB, and the "bottom" of the connector may face the PCB.

[0029] Returning to the example of FIG. 3A , the socket of connector 300A includes a latch 322A (mostly obscured in this view), and the header of connector 300A includes an opening 324A configured to engage with the latch 322A. The latch 322A and opening 324A may be disposed on connector 300A and may engage with each other when the socket is mated with the header. When engaged, the latch 322A and opening 324A may prevent the socket and header from becoming unmated (e.g., due to vibrations in the operating environment).

[0030] In the example shown in Figure 3B, connector 300B is similar to exemplary connector 300A shown in Figure 3A, except that latch 322B (largely obscured in this view) and corresponding opening 324B may be located on the side of connector 300B rather than on top of connector 300B. Such a side latch may be used in applications where vertical space is limited and / or top access is limited.

[0031] In the example shown in FIG. 3C, connector 300C is similar to exemplary connector 300A shown in FIG. 3A, except that terminals 302C and 304C are in a side-by-side configuration rather than a staggered configuration, as are pins 312C and 314C. For example, terminals 302C and 304C may be in the same horizontal row, as may pins 312C and 314C. Such a side-by-side configuration may be used in applications where vertical space is limited. Additionally, using different configurations in the same environment reduces the likelihood of mating connectors that are not intended to mate with each other.

[0032] In the example shown in Figure 3D, connector 300D is similar to exemplary connector 300B shown in Figure 3B, except that terminals 302D and 304D are in a side-by-side configuration rather than a staggered configuration, as are pins 312D and 314D. For example, terminals 302D and 304D may be in the same horizontal row, as may pins 312D and 314D.

[0033] In the example shown in FIG. 3E, connector 300E is similar to exemplary connector 300A shown in FIG. 3A, except that the mating orientation between header 302E and socket 304E of connector 300E is vertical rather than horizontal.

[0034] In the example shown in FIG. 3F, connector 300F has two horizontal rows of terminals and two horizontal rows of corresponding contact pins. For example, there may be an upper row 302F and a lower row 304F. In this example, terminals 302F in the upper row may be oriented with one or more engagement means (e.g., the exemplary locking means 232 and the exemplary blocking means 234 shown in FIG. 2A) facing upward to engage with an upper TPA means, while terminals 304F in the lower row may be oriented with one or more engagement means (e.g., the exemplary locking means 232 and the exemplary blocking means 234 shown in FIG. 2A) facing downward to engage with a lower TPA means. However, it should be understood that aspects of the present disclosure are not limited to any particular terminal orientation or the use of any TPA means.

[0035] 4A-4C illustrate cross-sectional views of the exemplary socket 130 shown in FIG. 1B according to some embodiments. In the example of FIG. 4A, the housing 402 of the socket 130 includes elongated cavities 404 and 406 configured to receive the terminals 132 and 138, respectively. The terminal position assurance (TPA) means 136 is shown in FIG. 4A in a disengaged state, providing sufficient clearance within the cavities 404 and 406 to allow the insertion of the terminals 132 and 138.

[0036] In the example of Figure 4B, terminals 132 and 138 are fully inserted into cavities 404 and 406, respectively. TPA device 136 may then engage terminals 132 and 138 and hold them in their respective positions within housing 402. For example, in the example of Figure 4C, TPA device 136 is pressed into housing 402 to engage terminals 132 and 138.

[0037] In some embodiments, TPA means 136 may include one or more protrusions configured to engage one or more terminals, respectively, inserted into housing 402. For example, in the example of FIG. 4C , TPA means 136 includes protrusion 408 configured to fit within recess 412 formed in terminal 138, as well as protrusion 410 configured to fit within recess 414 formed in terminal 132. Protrusions 408 and 410 may be of different heights. For example, protrusion 410 may be shorter than protrusion 408 because terminals 132 may be located in a lower row of socket 130, while terminals 138 may be located in an upper row.

[0038] 2A and described above. When the TPA means 136 is pressed into the housing 402, the protrusion 410 may be positioned adjacent to the blocking means 416 of the terminal 132. In this engaged state, when the terminal 132 is moved in the withdrawal direction, the blocking means 416 may contact the protrusion 410, thereby preventing the terminal 132 from being withdrawn from the cavity 404.

[0039] 4D illustrates a cross-sectional view of the exemplary connector 100 shown in FIG. 1B , according to some embodiments. In this example, the TPA means 136 is in a disengaged state and may block the header 140 from fully mating with the socket 130. For example, as shown at 416, the TPA means 136 may be aligned longitudinally with the bottom edge of the header 140 in the disengaged state, thereby blocking the header 140. When the TPA means 136 is pushed up into the engaged state, sufficient clearance is provided for the socket 130 to be inserted into the header 140. In this manner, an electrical connection is only made between the terminals of the socket 130 and the respective contact pins of the header 140 when the TPA means 136 is in the engaged position, which may ensure that the terminals of the socket are in the desired position when the electrical connection is made.

[0040] 5A and 5B illustrate another cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. The views shown in FIGS. 5A and 5B may be perpendicular to the views shown in FIGS. 4A-4C. In the example of FIG. 5A, the TPA device 136 is in a disengaged state. For example, as shown in 502A, the housing 402 may include two protrusions configured to engage with protrusions of the TPA device 136. In some embodiments, when the TPA device 136 is in a disengaged state, only one of the two protrusions of the housing 402 (e.g., the lower protrusion) may engage with the TPA device 136. In this manner, the TPA device 136 may be attached to the housing 402 while leaving sufficient clearance for inserting terminals (e.g., exemplary terminals 132 and 138).

[0041] In some embodiments, when TPA means 136 is in an engaged state (e.g., as shown in FIG. 5B), both of the protrusions of housing 402 may engage with TPA means 136 (e.g., as shown in 502B). In this manner, the protrusions of TPA means 136 (e.g., exemplary protrusions 408 and 410) may fit into corresponding recesses of the inserted terminals (e.g., exemplary terminals 132 and 138) to hold the inserted terminals in their respective positions.

[0042] In some embodiments, TPA means 136 may include one or more recesses (e.g., recess 504) configured to receive a corresponding locking means of an inserted terminal (e.g., exemplary locking means 232 shown in FIG. 2A). For example, in the example shown in FIG. 5B, the locking means may be longitudinally aligned with recess 504 when the corresponding terminal is properly inserted, and recess 504 may fit over the locking means when TPA means 136 is pushed up to the engaged position.

[0043] Figure 6A shows a bottom view of the exemplary socket 130 shown in Figure 1B with a portion cut away to show an exemplary locking means for inserted terminals, according to some embodiments. Figure 6B shows an enlarged view of portion 602 of Figure 6A.

[0044] 6A and 6B, housing 402 and TPA means 136 each have one or more recesses configured to receive the locking means of an inserted terminal. For example, housing 402 may have a recess (e.g., recess 606) configured to receive the locking means of an inserted terminal (e.g., locking means 608T) in the upper row, and TPA means 136 may have a recess (e.g., recess 604) configured to receive the locking means of an inserted terminal (e.g., locking means 608B) in the lower row.

[0045] The inventors have realized and understand that the spacing between terminals (and therefore board pitch) may be reduced by providing one or more recesses in TPA means 136 rather than providing all recesses in housing 402. However, it should be understood that aspects of the present disclosure are in no way limited to having any recesses in TPA means 136 or to using any TPA means to receive the locking means of an inserted terminal.

[0046] 7 illustrates another cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. In this example, the protrusions 410 of the TPA means 136 have a sloped top surface shape 702 configured to help guide the terminals 132 into the cavities 404. For example, the sloped top surface shape 702 may prevent the terminals 132 from being damaged by bumping during insertion.

[0047] 8 illustrates another cross-sectional view of the exemplary socket 130 shown in FIG. 1B, according to some embodiments. In this example, the TPA feature 136 has a tapered side profile 802 configured to facilitate guiding the terminals into the cavities adjacent the tapered side profile 802. For example, the tapered side profile 802 may prevent the terminals from being damaged by bumping during insertion.

[0048] 9A shows an exemplary connector 900A according to some embodiments. In this example, the connector 900A has a socket with a latch 902A as well as a header with an opening 904A configured to engage with the latch 902A. The latch 902A and the opening 904A may engage with each other when the socket is mated with the header. When engaged, the latch 902A and the opening 904A may prevent the socket and header from becoming unmated (e.g., due to vibration in the operating environment).

[0049] In the example of Figure 9A, connector 900A also includes TPA means 906A, which may be similar to exemplary TPA means 136 in the example of Figure 1B. For example, TPA means 906A may be configured to retain terminals inserted into sockets of connector 900A.

[0050] 9B illustrates an exemplary connector 900B according to some embodiments. Connector 900B may be similar to exemplary connector 900A shown in FIG. 9A, but while connector 900A may have one row of terminals, connector 900B may have two rows of terminals. Additionally, in some embodiments, connector 900B may have two TPA means instead of one. For example, lower TPA means 906B may be configured to engage with the lower row of terminals, and upper TPA means 908B may be configured to engage with the upper row of terminals.

[0051] In the example of FIG. 9B, connector 900B includes a socket with a latch 902B and a header with an opening 904B configured to engage with the latch 902B. The latch 902B and the opening 904B may engage with each other when the socket is mated with the header. When engaged, the latch 902B and the opening 904B may prevent the socket and header from becoming unmated (e.g., due to vibration in the operating environment). However, unlike the exemplary latch 902A in the example of FIG. 9A, which is located on the socket housing, the latch 902B in the example of FIG. 9B is located on the upper TPA feature 908B.

[0052] The inventors have realized and understand that by providing the latches on the upper TPA means (e.g., as in the example of FIG. 9B ) rather than on the socket housing (e.g., as in the example of FIG. 9A ), the molding operation may be simplified. For example, the number of mold sliders may be reduced, which may reduce manufacturing costs. However, it should be understood that aspects of the present disclosure are in no way limited to any particular location for the latches or to the use of any latches.

[0053] FIG. 10 illustrates exemplary header housings 1002 and 1004 according to some embodiments. In this example, the header housings 1002 and 1004 are configured to be attached to one another. For example, the header housing 1002 may include a tongue 1006, the header housing 1004 may include a similar tongue (obscured in this view), the header housing 1004 may include a groove 1008, and the header housing 1002 may include a similar groove (obscured in this view). The tongue of the header housing 1004 and the groove of the header housing 1002 may be configured to slidingly engage with one another, thereby attaching the header housings 1002 and 1004 to one another. In this manner, two or more connectors may be attached together to provide a desired number of electrical connections.

[0054] 10, the tongue of header housing 1004 and the groove of header housing 1002 form a dovetail joint, which may provide improved tensile strength. However, it should be understood that aspects of the present disclosure are not limited to the use of any particular technique for coupling multiple connectors together, or to the use of coupled connectors.

[0055] 11A illustrates an exemplary header 1100 according to some embodiments. The header 1100 may be used in any suitable connector, such as the exemplary connector 100 shown in FIGS. 1A and 1B. For example, the header 1100 may be used as the exemplary header 140 shown in FIG. 1B.

[0056] 11A, header 1100 has a housing 1105 with a cavity 1142 configured to receive a socket (e.g., the exemplary socket 130 shown in FIG. 1B). One or more contact pins, e.g., contact pin 1125, may be retained within housing 1105 such that, when the socket is inserted into cavity 1142, mating ends of contact pin 1125 make electrical connection with mating ends of terminals of the socket (e.g., the exemplary terminals 132 shown in FIG. 1B).

[0057] 11A , the header 1100 includes fasteners 1144 configured to be secured to the header 1100 and the PCB. For example, each longitudinal edge of the fasteners 1144 may be configured to slide into a respective longitudinal groove, such as groove 1110, formed in the housing 1005. In this manner, when the fasteners 1144 are secured to the PCB, the header 1100 may be prevented from moving laterally (e.g., in the x or y direction) relative to the PCB.

[0058] Additionally or alternatively, as shown at 1115, the fasteners 1144 may include one or more beams, such as beam 1120, configured to apply a spring force against the housing 1105. FIG. 11B shows a cross-sectional view of the example header 1100 of FIG. 11A, according to some embodiments. In this example, the beam 1120 has an angled end portion configured to engage a ledge 1130 formed on a sidewall of the housing, thereby applying a downward spring force to the housing 1105. Therefore, when the fasteners 1144 are secured to the PCB, the header 1100 may be prevented from moving vertically (e.g., in the z-direction) relative to the PCB.

[0059] Although not visible in FIGS. 11A and 11B , fasteners similar to fastener 1144 may be similarly secured to the opposite side of housing 1105. These fasteners may together hold header 1100 in place despite vibrations in the operating environment (e.g., in an automotive application). However, it should be understood that aspects of the present disclosure are not limited to any particular fastener design or use of any fasteners. FIG. 12A shows an exemplary connector 1200 according to some embodiments. Connector 1200 may be similar to exemplary connector 100 shown in FIG. 1A and may include a socket 1230 and a header 1240 configured to mate with each other.

[0060] In some embodiments, connector 1200 may include connector position assurance (CPA) means configured to provide an indication of whether socket 1230 and header 1240 are properly mated with one another. For example, in the example shown in FIG. 12A, connector 1200 includes CPA means 1234 that is movable between a disengaged state and an engaged state.

[0061] Figure 12B illustrates a cross-sectional view of the exemplary connector 1200 of Figure 12A, with the socket 1230 and header 1240 partially mated and the CPA means 1234 in a disengaged state, according to some embodiments.

[0062] 12A and 12B, the CPA means 1234 includes a first latch 1235 configured to engage with the socket 1230. The first latch 1235 may be made of a resilient material and configured to apply a spring force to the socket 1230, thereby preventing the CPA means 1234 from disengaging from the socket 1230. Additionally or alternatively, an end portion of the first latch 1235 may have a protrusion configured to engage with a corresponding protrusion 1236 formed on the housing of the socket 1230, thereby preventing the CPA means 1234 from disengaging from the socket 1230.

[0063] In some embodiments, the CPA means 1234 may be prevented from moving into the engaged state when the socket 1230 is not fully mated with the header 1240. For example, in the example shown in Figures 12A and 12B, the CPA means 1234 includes a second latch 1237, and a protrusion 1238 is formed on the housing of the socket 1230 to stop the second latch 1237, thereby preventing the CPA means 1234 from moving into the engaged state.

[0064] 12A and 12B , the second latch 1237 may be made of a resilient material and a protrusion 1241 may be formed on the housing of the header 1240, such that when the socket 1230 is inserted into the header 1240, the protrusion 1241 biases the second latch 1237 away from the protrusion 1238 formed on the socket 1230. Once the second latch 1237 passes over the protrusion 1238 formed on the socket 1230, the CPA means 1234 may be pushed fully into the socket 1230.

[0065] 12C shows an example latch 1237 contacting the example protrusion 1241 of FIGS. 12A and 12B, according to some embodiments. In this example, the protrusion 1241 formed on the header 1240 has a sloped surface 1242 configured to guide the latch 1237. When the socket 1230 is inserted into the header 1240 along the mating direction D, an end portion of the second latch 1237 may slide along the sloped surface 1242, causing the second latch 1237 to deflect against the protrusion 1238 formed on the socket 1230. (In FIG. 12C, the protrusion 1238 is obscured by the protrusion 1241.)

[0066] 12D shows the exemplary latch 1237 being deflected by the exemplary protrusion 1241 of FIGS. 12A and 12B, according to some embodiments. In this example, the second latch 1237 is about to pass through a protrusion 1238 formed on the socket 1230. (In FIG. 12C, the protrusion 1238 is obscured by the protrusion 1241.) Once the second latch 1237 passes through the protrusion 1238, the second latch 1237 may enter the passage 1239, thereby allowing the CPA means 1234 to be fully pushed into the socket 1230.

[0067] 12A and 12B in an engaged state, according to some embodiments. In this state, the CPA means 1234 is fully pressed into the socket 1230, and an end portion of the second latch 1237 may engage with a protrusion 1241 formed on the header 1240, thereby preventing the socket 1230 and the header 1240 from becoming unmated (e.g., due to vibrations in the operating environment).

[0068] The techniques described herein may also be used in connectors having configurations other than those described above. For example, the techniques described herein may be used in mezzanine connectors or backplane connectors.

[0069] Such modifications, improvements, and refinements are intended to be part of this disclosure and are intended to be within the subject matter and scope of the present invention. Furthermore, while advantages of the present invention have been described, it should be understood that not every embodiment of the present invention includes all of the advantages discussed above. Some embodiments may not implement every feature described herein as advantageous, and in some instances, the features described herein as advantageous. Accordingly, the foregoing description and drawings are by way of example only.

[0070] Various aspects of the present invention may be used alone, in combination, or in various arrangements not specifically described in the above embodiments, and therefore are not limited in their application to the details and arrangements of components set forth in the above description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any way with aspects described in other embodiments.

[0071] The use of ordinal numbers such as "first," "second," "third," etc. to modify claim elements in the claims does not in itself indicate any priority, hierarchy, or order of one claim element over other elements, or the chronological order in which acts of a method are performed, but is merely used as a descriptive indicator to distinguish one claim element having a particular name from other elements having the same name (except for the use of ordinal numbers).

[0072] All definitions defined and used herein should be understood to supersede dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0073] The indefinite articles "a" and "an," as used herein in the specification and claims, should be understood to mean "at least one," unless expressly stated otherwise.

[0074] As used herein in the specification and claims, the phrase "at least one," in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in that list of elements, and not necessarily including at least one of each element specifically listed in the list of elements, nor excluding any combinations of elements in that list of elements. This definition also allows for elements to optionally be present in addition to elements specifically named in the list of elements to which the phrase "at least one" refers, whether related or unrelated to the elements specifically named.

[0075] The term "and / or," as used herein in the specification and claims, should be understood to mean "either or both" of the elements connected thereby, i.e., elements that are present conjunctively in some cases and disjunctively in other cases. Multiple elements listed with "and / or" should be construed similarly, i.e., "one or more" of the elements so connected. Other elements, related or unrelated to the elements specifically identified, may optionally be present other than the elements specifically identified by the term "and / or." Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," can refer in one embodiment to A only (optionally including elements other than B), in another embodiment to B only (optionally including elements other than A), or in yet another embodiment to both A and B (optionally including other elements).

[0076] As used in this application in the specification and claims, "or" should be understood to have the same meaning as "and / or," as defined above. For example, when separating items in a list, "or" or "and / or" shall be construed as inclusive, i.e., including not only at least one of a plurality of elements or a list of elements, but also including a plurality and, optionally, additional unlisted items. Only terms expressly stated otherwise, such as "only one of" or "exactly one of," or, when used in the claims, "consisting of," shall refer to the inclusion of a plurality of elements or exactly one element of a list. In general, the term "or," as used in this application, shall be construed to indicate exclusive alternatives (i.e., "one or the other, but not both") when preceded by the exclusive terms "either," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in the claims, shall have its ordinary meaning as used within the realm of patent law.

[0077] Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the words "including," "comprising," "having," "containing," "involving," and variations thereof are intended to include the items listed thereafter and equivalents thereof, as well as additional items. [Aspect 1] The housing and a fastener having first attachment means, second attachment means, and third attachment means; In an electrical connector comprising: the first attachment means prevents lateral movement between the fastener and the housing; the second attachment means prevents longitudinal movement between the fastener and the housing; The third attachment means is configured to be attached to a printed circuit board (PCB) to secure the electrical connector to the PCB. [Aspect 2] the first attachment means of the fastener includes a longitudinal edge configured to slide into a longitudinal groove formed in the housing; 2. The electrical connector according to embodiment 1. [Aspect 3] the second attachment means of the fastener includes a beam configured to apply a spring force to the housing. 2. The electrical connector according to embodiment 1. [Aspect 4] the beam includes an angled end portion configured to engage a ledge formed on a sidewall of the housing; 4. The electrical connector according to embodiment 3. [Aspect 5] the fastener includes a first fastener attached to a first sidewall of the housing; The electrical connector further includes a second fastener attached to a second side wall of the housing, the second side wall being opposite the first side wall. 2. The electrical connector according to embodiment 1. [Aspect 6] A first housing; a connector position assurance (CPA) means attached to the first housing, the CPA means being movable between a disengaged state and an engaged state; In a first electrical connector comprising: the CPA means includes a first latch configured to attach the CPA means to the first housing when the CPA means is in the disengaged state; the first electrical connector is configured to mate with a second electrical connector having a second housing; the CPA means includes a second latch configured to attach the CPA means to the second housing when the CPA means is in the engaged state; The first electrical connector, wherein the first housing is configured to prevent the CPA means from moving to the engaged state when the first and second electrical connectors are not fully mated. [Aspect 7] the first housing includes a protrusion configured to block the second latch of the CPA means, thereby preventing the CPA means from moving to the engaged state when the first and second electrical connectors are not fully mated; 7. The first electrical connector according to embodiment 6. [Aspect 8] the second housing is configured to bias the second latch away from the protrusion of the first housing blocking the second latch when the first and second electrical connectors are fully mated, thereby allowing the CPA means to move to the engaged state. The first electrical connector of embodiment 7 in combination with the second electrical connector. [Explanation of symbols]

[0078] 100 Connectors 105 Cable Interface 110 Cable Interface 115 Aperture 120 board interface 125 contact pins 130 sockets 132 terminals 134 Connector Position Assurance (CPA) Measures 136 Terminal Position Assurance (TPA) Measures 140 Header 142 Cavity 144 Fasteners 200 Electrical terminals 210 Crimped End 212a barrel 212b barrel 214a Barrel 214b barrel 220 Mating end 222 Contact Beam 230 Middle part 232 Locking means 234 Blocking Measures

Claims

1. a first electrical connector, The housing and a terminal position assurance (TPA) means attached to the housing, the TPA means being movable in a first direction between a disengaged state and an engaged state, the TPA means including a recess having a bottom surface facing the first direction; A terminal that is inserted into the cavity of the housing and is long along the mating direction, a mating end configured to receive contact pins of a second electrical connector; a crimp end configured to be crimped onto an electrical wire; an intermediate portion between the mating end and the crimping end, locking means biased outward from the center line of the terminal along the mating direction; a blocking means configured to contact a protrusion of the TPA means to prevent withdrawal of the terminal from the first electrical connector, the blocking means extending inwardly toward a centerline of the terminal along a direction perpendicular to the mating direction; an intermediate portion comprising: a terminal having In an electrical connector comprising: When the TPA means is in the engaged state, the locking means of the terminal is in the recess of the TPA means to hold the terminal in the cavity, and when the TPA means moves in the first direction from the disengaged state to the engaged state, the distance between the locking means of the terminal and the bottom surface of the recess decreases. First electrical connector.

2. the terminals include a first terminal; the cavity includes a first cavity, the electrical connector further includes a second terminal inserted into a second cavity of the housing, the second terminal having a configuration similar to that of the first terminal, a locking means on the second terminal engages the housing to retain the second terminal within the second cavity; The first electrical connector of claim 1 .

3. the housing includes a recess configured to receive the locking means of the second terminal; The first electrical connector of claim 2 .

4. a first plurality of similar terminals arranged in a first row; a second plurality of similar terminals arranged in a second row; further comprising the first terminals are arranged in the first row; the second terminals are arranged in the second row; the first row is vertically offset from the second row; for each terminal in said first row, when said TPA means is in said engaged state, said locking means of said terminal engages said TPA means to retain said terminal within a respective cavity of said housing; For each terminal in the second row, locking means on the terminal engages the housing to retain the terminal in a respective cavity in the housing. The first electrical connector of claim 2 .

5. the terminals in the first row have the same pitch as the terminals in the second row, but are horizontally offset therefrom; 5. The first electrical connector of claim 4.

6. When the TPA means is in the engaged state, a protrusion of the TPA means contacts the blocking means to prevent the terminal from being withdrawn from the cavity. The first electrical connector of claim 1 .

7. a first electrical connector, The housing and a terminal position assurance (TPA) means attached to the housing, the TPA means being movable between a disengaged state and an engaged state; A terminal that is inserted into the cavity of the housing and is long along the mating direction, a mating end configured to receive contact pins of a second electrical connector; a crimp end configured to be crimped onto an electrical wire; an intermediate portion between the mating end and the crimping end, locking means biased outward from the center line of the terminal along the mating direction; a blocking means configured to contact a protrusion of the first electrical connector to prevent the terminal from being pulled out of the first electrical connector, the blocking means extending inwardly toward a centerline of the terminal along a direction perpendicular to the mating direction; an intermediate portion comprising: a terminal having In an electrical connector comprising: said TPA means including a protrusion; When the TPA means is in the disengaged state, the protrusions of the TPA means are aligned with the walls of the cavity to allow the terminal to be inserted into the cavity; the protrusion of the TPA means has an inclined shape configured to guide the terminal as it is inserted into the housing when the TPA means is in the disengaged state; the wall includes a first wall; the cavity includes a second wall perpendicular to the first wall; the second wall includes a gap that is occupied by a portion of the TPA means when the TPA means is in the disengaged state; a portion of the TPA means occupying the gap in the second wall has a tapered shape configured to guide the terminal as it is inserted into the housing when the TPA means is in the disengaged state; First electrical connector.

8. When the TPA means is in the engaged state, the protrusion of the TPA means protrudes into the cavity to prevent the terminal from being withdrawn from the cavity.

8. The first electrical connector of claim 7.

9. the portion of the TPA means includes a first portion of the TPA means; the cavity includes a third wall opposite the second wall; the third wall includes a second gap occupied by a second portion of the TPA means when the TPA means is in the disengaged state; the second portion of the TPA means occupying the second gap in the third wall has a tapered shape configured to guide the terminal as it is inserted into the housing when the TPA means is in the disengaged state.

8. The first electrical connector of claim 7.

10. A first electrical connector configured to mate with a second electrical connector having a second housing, the first electrical connector comprising: A first housing; A terminal that is inserted into the cavity of the housing and is long along the mating direction, a mating end configured to receive contact pins of a second electrical connector; a crimp end configured to be crimped onto an electrical wire; an intermediate portion between the mating end and the crimping end, locking means biased outward from the center line of the terminal along the mating direction; a blocking means configured to contact a protrusion of the first electrical connector to prevent the terminal from being pulled out of the first electrical connector, the blocking means extending inwardly toward a centerline of the terminal along a direction perpendicular to the mating direction; an intermediate portion comprising: a terminal having a terminal position assurance (TPA) means attached to the first housing, the TPA means being movable between a disengaged state and an engaged state; the TPA means includes a latch configured to engage the second housing to secure the first and second electrical connectors together in a mated state; The latch is disposed on a side portion of the first housing. First electrical connector.

11. a first electrical connector and a second electrical connector, the first electrical connector comprising: A first housing; A terminal that is inserted into the cavity of the housing and is long along the mating direction, a mating end configured to receive contact pins of a second electrical connector; a crimp end configured to be crimped onto an electrical wire; an intermediate portion between the mating end and the crimping end, locking means biased outward from the center line of the terminal along the mating direction; a blocking means configured to contact a protrusion of the first electrical connector to prevent the terminal from being pulled out of the first electrical connector, the blocking means extending inwardly toward a centerline of the terminal along a direction perpendicular to the mating direction; an intermediate portion comprising: a terminal having a terminal position assurance (TPA) means attached to the first housing, the TPA means being movable between a disengaged state and an engaged state; Including, the first electrical connector is configured to mate with the second electrical connector having a second housing; the TPA means includes a latch configured to engage the second housing to secure the first and second electrical connectors together in a mated state; the second electrical connector includes an opening configured to receive the latch of the TPA means; A first electrical connector and a second electrical connector.

12. the latch is disposed on an upper portion of the first housing; 12. The first electrical connector and the second electrical connector according to claim 11.

13. the second housing of the second electrical connector includes a first sidewall and a second sidewall opposite the first sidewall; a tongue formed on the first side wall configured to slide into a groove of a similar connector housing; a groove formed on the second side wall configured to receive a tongue of a similar connector housing; 12. The first electrical connector and the second electrical connector according to claim 11.

14. The terminal is a first plurality of terminals arranged in a first row; a second plurality of terminals arranged in a second row; Including, the first row is vertically offset from the second row; 12. The first electrical connector and the second electrical connector according to claim 11.

15. said TPA means including a first TPA means; when said first TPA means is in said engaged state, said first TPA means engages said first plurality of terminals to retain said first plurality of terminals within said first housing; the first electrical connector further includes a second TPA means movable between a disengaged state and an engaged state; when said second TPA means is in said engaged state, said second TPA means engages said second plurality of terminals to retain said second plurality of terminals within said first housing; 15. The first electrical connector and the second electrical connector of claim 14.

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