Connector keying device, connector system, and methods of use thereof

Abstract

The connector keying system includes at least one keying device including a flange portion and a keying portion. The flange portion includes a front surface and a rear surface. Each of the front surface and the rear surface extends generally parallel to a flange plane. The flange portion further includes a connector opening through the flange portion. The keying portion extends around an opening perimeter of the connector opening and projects outwardly from the flange portion. The keying portion includes and extends between a first key end located at the front surface and a second key end opposite the first key end. The second key end defines a keying perimeter around the connector opening. The keying portion has a height between the first key end and the second key end, and the height between the first key end and the second key end along the keying perimeter is not consistent.

Description

[Technical Field]

[0001] This application claims priority to U.S. Patent Application No. 17 / 467,820, filed September 7, 2021, which is incorporated herein by reference in its entirety. [Background technology]

[0002] The present disclosure relates generally to electrical connectors, and more particularly to a keying system for preventing misconnections between electrical connectors.

[0003] Electrical and electronic systems, such as computer systems, test equipment systems, and controllers, often include electrical connectors that must be properly mated with their intended counterparts for the system to operate properly. In some cases, a system may include multiple electrical connectors, which may have similar appearances, shapes, and / or pin-socket configurations. Therefore, there is a risk of misconnection of the connectors due to user error, for example, during system assembly or repair. To address the risk of misconnection of connectors, some prior art electrical connectors are fitted with custom jacking hardware that includes keying features configured to assist users in mating the connectors. However, in some cases, using the jacking hardware for this purpose requires users to physically modify existing electrical connectors to fit the custom jacking hardware. Users may also need to manually configure the keying features (e.g., pins) of the jacking hardware for each connector pair. Furthermore, if the jacking hardware is improperly keyed, the benefits of the keying features may be negated. In other words, conventional connector keying systems can add undesirable complexity when attempting to prevent misconnection of connectors. Therefore, there is a need for a keying system that prevents misconnections between electrical connectors while addressing one or more of the above problems associated with conventional keying systems. Summary of the Invention

[0004] It should be understood that any or all of the features or embodiments described herein can be used or combined in any combination with any other feature or embodiment described herein, unless stated otherwise.

[0005] According to an aspect of the present disclosure, a connector keying system for use with a connector pair includes at least one keying device including a flange portion and a keying portion. The flange portion includes a front surface and a rear surface opposite the front surface. Each of the front surface and the rear surface extends generally parallel to a flange plane. The flange portion further includes a connector opening extending through the flange portion from the rear surface to the front surface. The keying portion extends around an opening periphery of the connector opening and protrudes outward from the flange portion in a direction generally perpendicular to the flange plane. The keying portion includes and extends between a first key end located on the front surface and a second key end opposite the first key end. The second key end defines a keying periphery around the connector opening. The keying portion has a height between the first key end and the second key end, and the height between the first key end and the second key end along the keying periphery is not consistent.

[0006] In any of the aspects or embodiments described above and herein, the at least one keying device may include a first keying device and a second keying device, and when the second key end of the first keying device is attached to the second key end of the second keying device at the keying periphery of each of the first keying device and the second keying device, the flange plane of the first keying device may be approximately parallel to the flange plane of the second keying device.

[0007] In any of the aspects or embodiments described above and herein, the second key end of the keying portion may be angled relative to the flange plane along the first portion of the keying periphery.

[0008] In any of the aspects or embodiments described above and herein, the second key end of the keying portion may be generally parallel to the flange plane along a second portion of the keying periphery.

[0009] In any of the aspects or embodiments described above and herein, the flange portion may include at least one fastening hole that passes through the flange portion from the rear surface to the front surface.

[0010] In any of the aspects or embodiments described above and herein, the at least one keying device may include at least one attachment mechanism.

[0011] In any of the aspects or embodiments described above and herein, the keying portion may extend from the flange portion at the periphery of the opening.

[0012] According to another aspect of the present disclosure, a connector system includes a first connector pair including a first male connector and a first female connector configured to electrically couple with the first male connector. Each of the first male connector and the first female connector includes a connector flange portion and a connector shell portion extending outwardly from the connector flange portion. The connector shell portion of the first male connector surrounds a plurality of pins, and the connector shell portion of the first female connector surrounds a plurality of sockets configured to receive each of the plurality of pins. The connector system further includes a first connector keying system having at least one first keying device including a flange portion and a keying portion. The flange portion includes a front surface and a rear surface opposite the front surface. Each of the front surface and the rear surface extends generally parallel to a flange plane. The flange portion further includes a connector opening extending through the flange portion from rear surface to front surface. The keying portion extends around an opening periphery of the connector opening and protrudes outwardly from the flange portion in a direction generally perpendicular to the flange plane. The keying portion includes a first key end located on a front surface and a second key end opposite the first key end, extending therebetween. The second key end defines a keying perimeter around the connector opening. The keying portion has a height between the first key end and the second key end, and the height between the first key end and the second key end along the keying perimeter is not consistent. The at least one keying device is configured for installation on one or both of the male and female connectors such that a rear surface of the flange portion contacts the connector flange portion and the keying portion surrounds the connector shell portion.

[0013] In any of the aspects or embodiments described above and herein, the first at least one keying device may include a first keying device mounted on the first male connector and a second keying device mounted on the first female connector. The first at least one keying device may be configured such that, when the second key end of the first keying device is attached to the second key end of the second keying device at the keying periphery of each of the first and second keying devices, the flange plane of the first keying device is substantially parallel to the flange plane of the second keying device.

[0014] In any of the aspects or embodiments described above and herein, the connector system may further include a second connector pair including a second male connector and a second female connector configured to electrically mate with the second male connector. The second male connector may be configured to electrically mate with the first female connector, and the second female connector may be configured to electrically mate with the first male connector. The connector system may further include a second connector keying system having a second at least one keying device, the second at least one keying device including a third keying device mounted on the second male connector and a fourth keying device mounted on the second female connector.

[0015] In any of the aspects or embodiments described above and herein, the first keying device and the second keying device may have a first matching color, and the third keying device and the fourth keying device may have a second matching color that is different from the first matching color.

[0016] In any of the aspects or embodiments described above and herein, the first keying device may be configured to physically prevent electrical coupling between the second female connector and the first male connector, and the second keying device may be configured to physically prevent electrical coupling between the second male connector and the first female connector.

[0017] In any of the aspects or embodiments described above and herein, the third keying device and the fourth keying device may be different from the first keying device and the second keying device, respectively.

[0018] In any of the aspects or embodiments described above and herein, the keying portions of the third keying device and the fourth keying device may have different shapes than the keying portions of the first keying device and the second keying device, respectively.

[0019] In any of the aspects or embodiments described above and herein, the first at least one keying device may include at least one attachment mechanism, and the at least one attachment mechanism may attach the first at least one keying device to the connector flange portion.

[0020] In any of the aspects or embodiments described above and herein, the connector shell portion may include and extend between a first shell end that contacts the connector flange portion and a second shell end opposite the first shell end. The connector shell portion may have a second height between the first shell end and the second shell end. The second height may be greater than the maximum height between the first key end and the second key end.

[0021] According to another aspect of the present disclosure, a method for preventing electrical misconnection of a connector system is provided. The method includes providing a first connector pair including a first male connector and a first female connector configured to electrically couple with the first male connector. Each of the first male connector and the first female connector includes a connector flange portion and a connector shell portion extending outwardly from the connector flange portion. The connector shell portion of the first male connector surrounds a plurality of pins, and the connector shell portion of the first female connector surrounds a plurality of sockets configured to receive each of the plurality of pins. The method further includes installing the first at least one keying device on one or both of the male connector and the female connector such that a rear surface of the flange portion of the first at least one keying device contacts the connector flange portion and a keying portion of the at least one keying device surrounds the connector shell portion. The flange portion includes a front surface and a rear surface opposite the front surface. Each of the front surface and the rear surface extends substantially parallel to a flange plane. The flange portion further includes a connector opening extending through the flange portion from the rear surface to the front surface. The keying portion extends around the periphery of the connector opening and projects outward from the flange portion in a direction generally perpendicular to the plane of the flange. The keying portion includes a first key end located on the front surface and a second key end opposite the first key end, extending therebetween. The second key end defines a keying periphery around the connector opening. The keying portion has a height between the first key end and the second key end, and the height between the first key end and the second key end along the keying periphery is not consistent.

[0022] In any of the aspects or embodiments described above and herein, the first at least one keying device may include a first keying device and a second keying device, and the step of installing the first at least one keying device may include installing the first keying device in the first male connector and installing the second keying device in the first female connector. When the first at least one keying device is installed, the first at least one keying device may be configured such that, when the second key end of the first keying device is attached to the second key end of the second keying device at the keying peripheries of the first and second keying devices, the flange plane of the first keying device is substantially parallel to the flange plane of the second keying device.

[0023] In any of the aspects or embodiments described above and herein, the method may further include providing a second connector pair including a second male connector and a second female connector configured to electrically couple with the second male connector. The second male connector may be configured to electrically couple with the first female connector, and the second female connector may be configured to electrically couple with the first male connector. The first keying device may be configured to physically prevent electrical coupling between the second female connector and the first male connector, and the second keying device may be configured to physically prevent electrical coupling between the second male connector and the first female connector.

[0024] In any of the aspects or embodiments described above and herein, the method may further include attaching the first at least one keying device to the connector flange portion with at least one attachment mechanism.

[0025] The present disclosure, and all aspects, embodiments, and advantages associated therewith, will become more readily apparent from consideration of the detailed description provided below, including the accompanying drawings. [Brief explanation of the drawings]

[0026] [Figure 1] 1 illustrates a perspective view of a connector pair according to one or more embodiments of the present disclosure. [Figure 2] 1 illustrates a perspective view of a connector pair according to one or more embodiments of the present disclosure. [Figure 3] 1 illustrates a perspective view of a connector keying system according to one or more embodiments of the present disclosure. [Figure 4] 4 illustrates a top view of a connector keying device of the connector keying system of FIG. 3 in accordance with one or more embodiments of the present disclosure. [Figure 5] 5A-5B show cross-sectional side views of a connector keying device taken along line 5-5 of FIG. 4, including an exemplary mechanical attachment mechanism, according to one or more embodiments of the present disclosure. [Figure 6] 6A-6B show cross-sectional side views of a connector keying device taken along line 6-6 of FIG. 4, including an exemplary mechanical attachment mechanism, according to one or more embodiments of the present disclosure. [Figure 7] 1 illustrates a top view of an exemplary connector keying system in accordance with one or more embodiments of the present disclosure. [Figure 8] 1 illustrates a top view of an exemplary connector keying system in accordance with one or more embodiments of the present disclosure. [Figure 9] 1 illustrates a top view of an exemplary connector keying system in accordance with one or more embodiments of the present disclosure. [Figure 10] 1 illustrates a top view of an exemplary connector keying system in accordance with one or more embodiments of the present disclosure. [Figure 11] 4 illustrates a perspective view of the connector keying system of FIG. 3 in a mated state in accordance with one or more embodiments of the present disclosure. [Figure 12] 12 shows a top view of the connector keying system of FIG. 11 in accordance with one or more embodiments of the present disclosure. [Figure 13] 1 illustrates an exploded perspective view of a connector system including a connector pair and a connector keying system in accordance with one or more embodiments of the present disclosure. [Figure 14]14 shows a perspective view of the connector system of FIG. 13 in an assembled state with the connectors electrically coupled, in accordance with one or more embodiments of the present disclosure. [Figure 15] 1 illustrates a perspective view of an exemplary connector system according to one or more embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0027] The present disclosure relates to electrical connector keying systems and to electrical connector systems including such connector keying systems. As will become apparent from the description below, the connector keying systems can be used with a wide variety of connectors. Embodiments of the connector keying systems of the present disclosure can be configured for use with many existing types of connectors (e.g., currently commercially available connectors) having a variety of different electrical and geometric configurations.

[0028] For ease of description herein, embodiments of the connector keying system 20 of the present disclosure will be primarily described as being usable with a connector pair 22 (e.g., a male connector 24 and a female connector 26 configured to electrically mate with the male connector 24). FIGS. 1 and 2 show examples of such connector pairs 22. FIG. 1 shows an exemplary "micro-D" style electrical connector pair. FIG. 2 shows an exemplary "subminiature-D" style electrical connector pair. Each of the exemplary connectors 24, 26 includes respective flange portions 28, 30 and shell portions 32, 34 extending outwardly from the flange portions 28, 30. For clarity, the configurations of the connectors 24, 26 shown in FIGS. 1 and 2 are exemplary, and the connector keying system 20 of the present disclosure is not limited to use with the connectors 24, 26 shown.

[0029] In the male connector 24, the shell portion 32 defines an outer housing of a plug 36 that includes a plurality of pins 38, which are surrounded by the shell portion 32. In the female connector 26, the shell portion 34 defines an outer housing of a receptacle 40 that includes a plurality of sockets 42, which are surrounded by the shell portion 34. The sockets 42 are configured to receive and make electrical contact with each of the pins 38 of the male connector 24. In some embodiments, the shell portion 32 of the male connector 24 and the shell portion 34 of the female connector 26 are sized so that the shell portion 32 can be inserted into the shell portion 34, or vice versa. As used herein, the term "electrical coupling" refers to establishing electrical contact between the pins 38 of the male connector 24 and the sockets 42 of the female connector 26 by fully and properly inserting the male connector 24 into the female connector 26.

[0030] The flange portions 28, 30 of the connectors 24, 26, respectively, may include fastening holes 46, 48. When the connectors 24, 26 are in a connected state, i.e., when the female connector 26 is electrically coupled to the male connector 24, the fastening holes 48 of the female connector 26 may align with the fastening holes 46 of the male connector 24, such that jacking hardware (not shown) can position and / or secure the connectors 24, 26 in a connected state. The jacking hardware may include, for example, jack screws configured to pass through the fastening holes 46, 48 of the connectors 24, 26 for threaded engagement with the respective jack posts. The jacking hardware may further include one or more locking devices configured to hold the connectors 24, 26 in a connected state and / or prevent disengagement between one or more jack screws and the respective jack posts. In some embodiments, one or both of the connectors 24, 26 may include integrated jacking hardware, e.g., the jacking hardware may be attached to or formed with the connectors. In some alternative embodiments, such as the connector embodiment shown in Figures 1 and 2, the connectors 24, 26 may not include integrated jacking hardware, and in some cases, custom jacking hardware may be used to position and / or secure the connectors 24, 26 in connection. In some cases, the connectors may not require the use of any jacking hardware, and the present disclosure is not limited to any particular jacking hardware configuration for the connectors. Furthermore, the connectors 24, 26 of the present disclosure are not limited to any particular number of fastener holes 46, 48, and some connectors may not include fastener holes at all.

[0031] Some common commercial connectors, such as the connector styles shown in Figures 1 and 2, may not include integrated keying or polarization features, which may present a high potential for misconnection during assembly of an associated electrical or electronic system. As used herein, the term "misconnection" refers to the act of inadvertently electrically connecting two connectors that may or may not be configured to electrically mate with each other and that are not intended to be electrically connected to each other (e.g., by system design). Misconnections between electrical connectors in electrical and / or electronic systems may cause system malfunctions or system failures, and in some cases may even result in damage to electrical and / or electronic equipment.

[0032] 3-4 , an embodiment of a connector keying system 20 according to the present disclosure includes a first keying device 50 and a second keying device 52. Each of the keying devices 50, 52 includes a flange portion 54 and a keying portion 56. The flange portion 54 includes a front surface 58 and a rear surface 60 opposite the front surface 58. Each of the front surface 58 and the rear surface 60 extends generally parallel to a flange plane 62. The flange portion 54 further includes a connector opening 64 extending therethrough from the rear surface 60 to the front surface 58. The connector opening 64 may be sized to closely accommodate the shape of the shell portions 32, 34 of the respective connectors 24, 26 and may have a shape substantially similar to the shell portions 32, 34 of the respective connectors 24, 26 (see FIGS. 1 and 2 ). For example, the connector opening 64 may have a cross-sectional shape that corresponds substantially to a circular, oval, elliptical, square, rectangular, trapezoidal, D-shaped, or the like. With respect to corresponding connectors 24, 26, the present disclosure is not limited to any particular cross-sectional shape of connector opening 64 or to any size or shape of connector opening 64. Connector opening 64 is defined about a connector axis 74 that is generally perpendicular to flange plane 62. Connector opening 64 includes an opening perimeter 66 defined by flange portion 54. As used herein, the term "substantially" when referring to an angular relationship refers to ±5 degrees of the stated angular relationship (e.g., "parallel," "perpendicular," etc.).

[0033] The flange portion 54 may further include at least one fastener hole 44 extending through the flange portion 54 from the rear surface 60 to the front surface 58. As discussed in more detail, the at least one fastener hole 44 may have a predetermined location corresponding to the location of the fastener holes 46, 48 of the connectors 24, 26, and the connector keying system 20 is configured for use with the fastener holes 46, 48 of the connectors 24, 26 (see FIGS. 1 and 2). In some embodiments, the flange portion 54 may not include the at least one fastener hole 44. For example, the flange portion 54 may be configured to be disposed entirely between the fastener holes 46, 48 of the respective connectors 24, 26. Like the connectors 24, 26, the keying devices 50, 52 of the present disclosure are not limited to any particular number of fastener holes 44, and some keying devices may not include any fastener holes at all.

[0034] The keying portion 56 projects outward from the flange portion 54, e.g., in a direction generally perpendicular to the flange plane 62 and generally parallel to the connector axis 74. The keying portion 56 includes and extends between a first end 68 located at, contacting, or attached to the front surface 58 of the flange portion 54 and a second end 70 opposite the first end 68. In some embodiments, the keying portion 56 extends from the flange portion 54 at the opening perimeter 66. However, in some other embodiments, all or part of the keying portion 56 may be spaced apart from the opening perimeter 66. For example, all or part of the keying portion 56 may be spaced apart from the opening perimeter 66 in a radial direction relative to the connector axis 74. The keying portion 56 extends around the opening perimeter 66 of the connector opening 64. The second end 70 of the keying portion 56 defines a keying perimeter 72 (shown in bold in FIG. 4 , for example) that is located around the connector opening 64. In some embodiments, the flange portion 54 and the keying portion 56 may form a unitary structure of the respective first keying device 50 and / or second keying device 52. As used herein, the term "unitary structure" means a single component, where all elements of the first keying device 50 and / or second keying device 52 (e.g., the flange portion 54 and the keying portion 56) form an inseparable body (e.g., formed of a single material). In some other embodiments, the keying portion 56 may be attached to the flange portion 54, for example, by welding, adhesive, snap lock, or other mechanical connection, and / or any other suitable attachment means.

[0035] The first keying device 50 and the second keying device 52 of the connector keying system 20 can be made from a wide variety of materials, including, but not limited to, metals or other lightweight, easily processed materials such as plastics or composites. The keying devices 50, 52 can be formed, for example, by injection molding or additive manufacturing. The present disclosure is not limited to any particular material or means for forming the keying devices 50, 52.

[0036] The keying portion 56 has a height H1 between the first end 68 and the second end 70. The height H1 between the first end 68 and the second end 70 of the keying portion 56 may vary in different regions of the keying portion 56. For example, the height H1 between the first end 68 and the second end 70 of the keying portion 56 may not be consistent along the keying perimeter 72. In some embodiments, the keying perimeter 72 may be non-planar, e.g., the entire keying perimeter 72 may not lie on a single geometric plane. In some embodiments, the second end 70 of the keying portion 56 may be angled relative to the flange plane 62 along a portion of the keying perimeter 72. Alternatively or additionally, in some embodiments, the second end 70 of the keying portion 56 may be generally parallel to the flange plane 62 along a portion of the keying perimeter 72. Furthermore, in some embodiments, the portion of the second end 70 of the keying portion 56 along the keying perimeter 72 may include a curve, a corner, a step, and / or other geometric shape. Although FIGS. 3 and 7-10 show exemplary keying portion 56 shapes, the connector keying system 20 of the present disclosure is not limited to any particular shape for the keying portion 56.

[0037] In some embodiments, as will be discussed in more detail, one or both of the first keying device 50 and the second keying device 52 may optionally include an attachment mechanism configured to attach the first keying device 50 and / or the second keying device 52 to the respective connectors 24, 26. For example, as shown in FIG. 4 , in some embodiments, one or both of the first keying device 50 and the second keying device 52 may include an adhesive 76 disposed on the back surface 60 of the flange portion 54 to securely attach the keying devices 50, 52 to the respective connectors 24, 26. Non-limiting examples of the adhesive 76 include glue, adhesive tape, spray adhesive, and the like. In some embodiments, the keying devices 50, 52 may include a release liner 78 extending along and covering the adhesive 76. The release liner 78 may aid in preventing inadvertent adhesion of the adhesive 76 during packaging and / or handling of the keying devices 50, 52 prior to installation. The release liner 78 is not limited to any particular material. Preferably, the release liner 78 may be made from a material that can be firmly held by the adhesive 76, but that can be selectively removed from the adhesive 76 with little effort without reducing the adhesive properties of the adhesive 76. Non-limiting examples of materials for the release liner 78 may include paper or a polymer sheet. In some embodiments, the release liner 78 may be coated with a release agent configured to reduce the adhesion of the release liner 78 to the adhesive 76.

[0038] 3-6, in some embodiments, the attachment mechanism may be a mechanical attachment mechanism 80 for one or both of the first keying device 50 and the second keying device 52. The mechanical attachment mechanism 80 may be used as an alternative to, or in addition to, the adhesive 76 to secure the keying devices 50, 52 to the connectors 24, 26. In some embodiments, the mechanical attachment mechanism 80 may form part of an integral structure with the flange portions 54. In some embodiments, the mechanical attachment mechanism 80 may be configured to couple with and attach to the outer surfaces of the connector flange portions 28, 30. FIGS. 5A and 5B show side cross-sectional views of the keying devices 50, 52 taken along line 5-5 of FIG. 4, including an exemplary mechanical attachment mechanism 80. As shown in FIG. 5A, in some embodiments, the keying devices 50, 52 may include a retaining member 82 extending from the flange portions 54 of the keying devices 50, 52. For example, the retaining member 82 may extend from the back surface 60 of the keying device 50, 52 in a direction away from the flange portion 54. In some embodiments, the retaining member 82 may extend entirely around the flange portion 54 relative to the connector axis 74. In some other embodiments, the retaining member 82 may be segmented or may extend around only one or more portions of the flange portion 54 relative to the connector axis 74. The retaining member 82 includes a retaining surface 84 that is configured to contact and securely attach to the connector flange portions 28, 30 (e.g., via a friction fit). For example, the retaining surface 84 of the retaining member 82 may wrap snugly around the outer periphery of the connector flange portions 28, 30. As shown in FIG. 5B , in some embodiments, the keying device 50, 52 may include one or more clips 86 extending from the flange portion 54 of the keying device 50, 52. For example, the clip 86 may extend from the back surface 60 of the keying device 50, 52 in a direction away from the flange portion 54. The clip 86 may be configured to snap into a mounting location on, for example, the connector flange portions 28, 30, such that the connector flange portions 28, 30 are secured between the flange portions 54 and the clip 86, which contacts the back surface of the connector flange portions 28, 30.

[0039] In some embodiments, the mechanical attachment feature 80 can be configured to mate with and be attached to an inner surface of the connector flange portions 28, 30. Figures 6A and 6B show side cross-sectional views of the keying devices 50, 52 taken along line 6-6 of Figure 4, including an exemplary mechanical attachment feature 80. As shown in Figure 6A, in some embodiments, the keying devices 50, 52 can include a retention member 82 that extends from the back surface 60 of the flange portions 54 of the keying devices 50, 52 in a direction away from the flange portions 54. With respect to one or more fastening holes 44 of the keying devices 50, 52, the retention member 82 can extend around the fastening hole 44. As previously described, the retention member 82 includes a retention surface 84 that is configured to contact the connector flange portions 28, 30 and be securely attached to the connector flange portions 28, 30 (e.g., via a friction fit). For example, the retaining members 82 may fit snugly within the corresponding connector fastening holes 46, 48, with the retaining surfaces 84 contacting the inner surfaces of the connector flange portions 28, 30 that define the connector fastening holes 46, 48. As shown in FIG. 6B , in some embodiments, the keying devices 50, 52 may include one or more clips 86 that extend from the back surface 60 of the flange portions 54 of the keying devices 50, 52 in a direction away from the flange portions 54. The clips 86 may be configured to pass through the corresponding connector fastening holes 46, 48 and snap into mounting positions on the connector flange portions 28, 30, for example, such that the connector flange portions 28, 30 are secured between the flange portions 54 and the clips 86, which contact the back surfaces of the connector flange portions 28, 30.

[0040] 3-12, in the present disclosure, the keying portion 56 of the keying devices 50, 52 can take on a variety of different geometric shapes. While FIGS. 3, 4, and 7-10 illustrate various exemplary keying portion 56 shapes and configurations, the present disclosure is not limited to the specific keying portion 56 shapes and configurations shown herein. The first keying device 50 and the second keying device 52 of the connector keying system 20 of the present disclosure can be shaped so that the keying portions 56 of the respective keying devices 50, 52 can mate with each other along their respective keying perimeters 72. When the second end 70 of the keying portion 56 of the first keying device 50 is attached to the second end 70 of the keying portion 56 of the second keying device 52, the flange plane 62 of the first keying device 50 can be substantially parallel to the flange plane 62 of the second keying device 52. In some embodiments, the respective keying portions 56 of the first keying device 50 and the second keying device 52 may be shaped such that the respective keying portions 56 may be placed in contact with one another along all or nearly all of their respective keying perimeters 72. In some embodiments, the first keying device 50 and the second keying device 52 may be substantially identical to one another. In some other embodiments, such as those shown in Figures 7-10, the first keying device 50 and the second keying device 52 may include respective keying portions 56 that are differently shaped, but may be configured to mate along their respective keying perimeters 72, as described above.

[0041] 13 and 14, the following description of the operation of connector keying system 20 will be described and illustrated with respect to a connector pair 22, such as the connector pair 22 shown in Figure 1 or Figure 2. As noted above, the connector keying system 20 of the present disclosure is not limited to use with any particular connector pair 22 configuration, and the connector pair 22 and associated connector keying system 20 configuration shown in Figures 13 and 14 are used herein solely for purposes of describing the operation of connector keying system 20.

[0042] To utilize connector keying system 20, a first keying device 50 and a second keying device 52 are installed on, for example, male connector 24 and female connector 26 of connector pair 22, which are intended to be electrically coupled to complete, for example, an electrical / electronic signal path and / or current path between the two components. As shown in Figures 13 and 14, first keying device 50 can be installed on male connector 24 such that rear surface 60 of flange portion 54 contacts flange portion 28 of male connector 24 and keying portion 56 surrounds shell portion 32 of male connector 24. Similarly, second keying device 52 can be installed on female connector 26 such that rear surface 60 of flange portion 54 contacts flange portion 30 of female connector 26 and keying portion 56 surrounds shell portion 34 of female connector 26. When the connector keying system 20 is installed on the connector pair 22 and the male connector 24 and female connector 26 are electrically coupled, the keying portions 56 of the first keying device 50 and the second keying device 52 may completely surround the shell portions 32, 34 of the male connector 24 and the female connector 26, as shown, for example, in FIG. 14 .

[0043] As previously mentioned, in embodiments of the connector keying system 20 that include an attachment mechanism, such as an adhesive 76 (see FIG. 4 ) or a mechanical attachment mechanism 80 (see FIGS. 5 and 6 ), the attachment mechanism may be used to attach the keying devices 50, 52 to the respective connectors 24, 26. For example, prior to installation of the first keying device 50 and / or the second keying device 52, the adhesive 76 may first be applied to the back surface 60 of one or both of the keying devices 50, 52, or a release liner 78 may be removed to expose the adhesive 76. Subsequent installation of the first keying device 50 and / or the second keying device 52 may then attach the keying devices 50, 52 to the flange portions 28, 30 of the respective connectors 24, 26 using the adhesive 76 or the mechanical attachment mechanism 80.

[0044] As shown in FIG. 13 , the shell portion 32 of the male connector 24 has a height H2, and the shell portion 34 of the female connector 26 has a height H3. In some embodiments, the height H2 of the shell portion 32 of the male connector 24 may be greater than the height H1 (see FIG. 4 ), e.g., the maximum height H1 of the keying portion 56 of the first keying device 50, such that a portion of the shell portion 32 extends beyond the keying portion 56. Additionally or alternatively, the height H3 of the shell portion 34 of the female connector 26 may be greater than the height H1 (see FIG. 4 ), e.g., the maximum height H1 of the keying portion 56 of the second keying device 52, such that a portion of the shell portion 34 extends beyond the keying portion 56. The reduced height H1 of the keying portion 56 compared to one or both of the heights H2 and H3 may allow the male connector 24 to be fully inserted into the female connector 26, facilitating a secure electrical coupling between the connectors 24, 26.

[0045] 13-15, when connector keying system 20 is installed on connectors 24, 26 of connector pair 22, connector keying system 20 allows male connector 24 and female connector 26 to be electrically coupled as shown in FIG. 13, while at the same time preventing either male connector 24 or female connector 26 from being misconnected with a connector other than that of connector pair 22. As an example, FIG. 15 shows a first connector pair 22A and a second connector pair 22B. First connector pair 22A is installed with a first unique connector keying system 20A. Second connector pair 22B is installed with a second unique connector keying system 20B that is different from first connector keying system 20A. Connector pairs 22A, 22B include a common connector format such that, in the absence of connector keying systems 20A, 20B, respectively, male connector 24A and female connector 26A of first connector pair 22A can be electrically and mechanically mated with female connector 26B and male connector 24B of second connector pair 22B. However, because first connector keying system 20A and second connector keying system 20B have different shapes, electrical and mechanical mating between connectors 24A, 26A of first connector pair 22A and connectors 24B, 26B of second connector pair 22B is physically prevented, for example, by physically preventing full insertion of female connector 26A and male connector 24B, or female connector 26B and male connector 24A. In other words, the first keying device 50A of the first connector keying system 20A installed on the male connector 24A physically prevents electrical coupling between the male connector 24A and the female connector 26B on which the second keying device 52B of the second connector keying system 20B is installed. Similarly, the first keying device 50B of the second connector keying system 20B installed on the male connector 24B physically prevents electrical coupling between the male connector 24B and the female connector 26A on which the second keying device 52A of the second connector keying system 20A is installed.

[0046] In some embodiments, to assist a user in correctly identifying the connectors 24, 26 that belong to a particular connector pair 22, different instances of the connector keying system 20 may have different colors, thereby reducing the risk of misconnection. For example, an electrical and / or electronic system may include numerous connector pairs, such as connector pair 22, and may be susceptible to misconnection of the connectors. To assist a user in correctly identifying the connectors 24, 26 that belong to a particular connector pair 22, different instances of the connector keying system 20, each associated with a respective connector pair 22, may be assigned different colors. Referring again to FIG. 15 as a non-limiting example, a first connector keying system 20A may have a first color and a second connector keying system 20B may have a second color that is different from the first color. Thus, by ensuring that electrical coupling occurs only between connectors 24, 26 that have connector keying systems 20 of the same color, a user may be able to more easily avoid misconnection of the connectors. While the above embodiments have described the use of color to visually distinguish the connector keying system 20 and prevent misconnection of connectors, other visual cues may be used, such as, but not limited to, shapes, symbols, text, serial numbers, bar codes, etc.

[0047] The connector keying system 20 of the present disclosure reduces the likelihood of misconnection between electrical connectors and does not require any modifications to existing connectors such as those shown in Figures 1 and 2 or any subsequent configuration after installation of the connector keying system 20. Furthermore, because the connector keying system 20 is held entirely between electrically mating connectors, the connector keying system cannot loosen or fall off from the associated connector pair and, compared to prior art keying systems, does not include any additional keying components (e.g., keying pins) that may separate.

[0048] It should be noted that the foregoing description and drawings show various connections between elements. It should be noted that these connections are general and may be direct or indirect unless otherwise specified, and that the specification is not intended to be limiting in this regard. A coupling between two or more entities may refer to a direct connection or an indirect connection. An indirect connection may incorporate one or more intervening entities. It should further be noted that various method or process steps of embodiments of the present disclosure are described in the following description and drawings. In the description, method and / or process steps may be presented in a particular order. However, unless the method or process relies on the particular order of steps described herein, the method or process should not be limited to the particular order of steps described. As will be understood by one of ordinary skill in the art, other orders of steps may be possible. Thus, the particular order of steps described in the description should not be construed as limiting.

[0049] Furthermore, no element, component, or method step of the present disclosure is intended to be publicly disclosed regardless of whether the element, component, or method step is expressly recited in a claim. No claim element herein is to be construed under 35 U.S.C. § 112(f) unless the element is expressly recited using the phrase "means for." As used herein, the terms "comprises," "comprising," or any other variation thereof, are intended to refer to a non-exclusive inclusion; thus, a process, method, product, or apparatus that includes a list of elements may include not only those elements, but also other elements not expressly recited or that are specific to such process, method, product, or apparatus.

[0050] While various aspects of the present disclosure have been disclosed, it will be apparent to those skilled in the art that many more embodiments and implementations are possible within the scope of the present disclosure. For example, the present disclosure described herein includes several aspects and embodiments that include particular features. These particular features may be described individually but are within the scope of the disclosure, and some or all of these features may be combined with any one of the aspects and remain within the scope of the disclosure. References to "various embodiments," "one embodiment," "embodiment," "exemplary embodiment," etc. indicate that the described embodiment may include a particular feature, structure, or characteristic, but not every embodiment may necessarily include the particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Furthermore, if a particular feature, structure, or characteristic is described in connection with an embodiment, it is believed to be within the knowledge of one skilled in the art that such feature, structure, or characteristic be used in connection with another embodiment, whether or not explicitly stated. Accordingly, the present disclosure is not limited, except in light of the appended claims and their equivalents.

Claims

1. 1. A connector keying system for use with a connector pair, said connector keying system comprising: at least one keying device including a flange portion and a keying portion; the flange portion includes a front surface and a back surface opposite the front surface, each of the front surface and the back surface extending generally parallel to a flange plane; the flange portion further includes a connector opening extending through the flange portion from the rear surface to the front surface; the keying portion extends around a periphery of the connector opening and projects outwardly from the flange portion in a direction generally perpendicular to the plane of the flange; the keying portion includes a first key end located on the front surface and a second key end opposite the first key end, the second key end extending therebetween, the second key end defining a keying perimeter around the connector opening; the keying portion has a height between the first key end and the second key end, and the height between the first key end and the second key end along the keying periphery is not consistent; the at least one keying device includes at least one attachment mechanism, the at least one attachment mechanism including a clip extending from the back surface in a direction away from the flange portion and configured to snap into an attachment position on a connector flange portion of the connector pair; Connector keying system.

2. 2. The connector keying system of claim 1, wherein the at least one keying device includes a first keying device and a second keying device, and wherein, at the keying periphery of each of the first keying device and the second keying device, when the second key end of the first keying device is attached to the second key end of the second keying device, the flange plane of the first keying device is substantially parallel to the flange plane of the second keying device.

3. 2. The connector keying system of claim 1, wherein the second key end of the keying portion includes a portion that is angled relative to the flange plane.

4. 4. The connector keying system of claim 3, wherein the second key end of the keying portion includes a portion that is generally parallel to the flange plane.

5. 2. The connector keying system of claim 1, wherein said flange portion includes at least one fastener hole extending through said flange portion from said rear surface to said front surface.

6. 2. The connector keying system of claim 1, wherein said keying portion extends from said flange portion at a periphery of said opening.

7. 1. A connector system comprising: a first connector pair; and a first connector keying system, the first connector pair includes a first male connector and a first female connector configured to electrically couple with the first male connector, each of the first male connector and the first female connector including a connector flange portion and a connector shell portion extending outward from the connector flange portion; the connector shell portion of the first male connector surrounds a plurality of pins, and the connector shell portion of the first female connector surrounds a plurality of sockets configured to receive each of the plurality of pins; the first connector keying system comprises a first at least one keying device including a flange portion and a keying portion; the flange portion includes a front surface and a back surface opposite the front surface, each of the front surface and the back surface extending generally parallel to a flange plane; the flange portion further includes a connector opening extending through the flange portion from the rear surface to the front surface; the keying portion extends around a periphery of the connector opening and projects outwardly from the flange portion in a direction generally perpendicular to the plane of the flange; the keying portion includes a first key end located on the front surface and a second key end opposite the first key end, the second key end extending therebetween, the second key end defining a keying perimeter around the connector opening; the keying portion has a height between the first key end and the second key end, and the height between the first key end and the second key end along the keying periphery is not consistent; the first at least one keying device is configured to be mounted on one or both of the first male connector and the first female connector such that the back surface of the flange portion contacts the connector flange portion and the keying portion surrounds the connector shell portion; the first at least one keying device includes at least one attachment mechanism, the at least one attachment mechanism including a clip extending from the back surface in a direction away from the flange portion and configured to snap into an attachment position on the connector flange portion, the at least one attachment mechanism attaching the first at least one keying device to the connector flange portion; Connector system.

8. the first at least one keying device includes a first keying device mounted on the first male connector and a second keying device mounted on the first female connector; the first at least one keying device is configured such that, when the second key end of the first keying device is attached to the second key end of the second keying device at the keying periphery of each of the first keying device and the second keying device, the flange plane of the first keying device is substantially parallel to the flange plane of the second keying device; 8. The connector system of claim 7.

9. the connector system further comprising a second connector pair and a second connector keying system; the second connector pair includes a second male connector and a second female connector configured to electrically couple with the second male connector, the second male connector configured to electrically couple with the first female connector, and the second female connector configured to electrically couple with the first male connector; the second connector keying system comprises a second at least one keying device, the second at least one keying device including a third keying device mounted on the second male connector and a fourth keying device mounted on the second female connector; 9. The connector system of claim 8.

10. 10. The connector system of claim 9, wherein the first keying device and the second keying device have a first matching color, and the third keying device and the fourth keying device have a second matching color different from the first matching color.

11. 10. The connector system of claim 9, wherein the first keying device is configured to physically prevent electrical coupling between the second female connector and the first male connector, and the second keying device is configured to physically prevent electrical coupling between the second male connector and the first female connector.

12. 12. The connector system of claim 11, wherein the third keying device and the fourth keying device are different from the first keying device and the second keying device, respectively.

13. 13. The connector system of claim 12, wherein the keying portions of the third and fourth keying devices each have a different shape than the keying portions of the first and second keying devices, respectively.

14. the connector shell portion includes a first shell end that contacts the connector flange portion and a second shell end opposite the first shell end and extending therebetween; the connector shell portion has a second height between the first shell end and the second shell end; the second height is greater than the maximum height between the first key end and the second key end; 8. The connector system of claim 7.

15. 1. A method for preventing electrical misconnection of a connector system, comprising: A first connector pair is provided, comprising: a first male connector; and a first female connector configured to electrically couple with the first male connector, Each of the first male connector and the first female connector includes a connector flange portion and a connector shell portion extending outward from the connector flange portion; the connector shell portion of the first male connector encloses a plurality of pins, and the connector shell portion of the first female connector encloses a plurality of sockets configured to receive each of the plurality of pins; To provide and installing the first at least one keying device on one or both of the first male connector and the first female connector such that a back surface of a flange portion of the first at least one keying device contacts the connector flange portion and a keying portion of the first at least one keying device surrounds the connector shell portion; the flange portion includes a front surface and a back surface opposite the front surface, each of the front surface and the back surface extending generally parallel to a flange plane; the flange portion further includes a connector opening extending through the flange portion from the rear surface to the front surface; the keying portion extends around a periphery of the connector opening and projects outwardly from the flange portion in a direction generally perpendicular to the plane of the flange; the keying portion includes a first key end located on the front surface and a second key end opposite the first key end, the second key end extending therebetween, the second key end defining a keying perimeter around the connector opening; the keying portion has a height between the first key end and the second key end, and the height between the first key end and the second key end along the keying periphery is not consistent; To install and attaching the first at least one keying device to the connector flange portion with at least one attachment mechanism, the at least one attachment mechanism including a clip extending from the back surface in a direction away from the flange portion and configured to snap into an attachment position on the connector flange portion; A method comprising:

16. the first at least one keying device includes a first keying device and a second keying device; the step of installing the first at least one keying device includes installing the first keying device in the first male connector and installing the second keying device in the first female connector; When the first at least one keying device is installed, the first at least one keying device is configured such that, when the second key end of the first keying device is attached to the second key end of the second keying device at the keying periphery of each of the first keying device and the second keying device, the flange plane of the first keying device is substantially parallel to the flange plane of the second keying device.

16. The method of claim 15.

17. providing a second connector pair comprising a second male connector and a second female connector configured to electrically couple with the second male connector, the second male connector is configured to electrically couple with the first female connector, and the second female connector is configured to electrically couple with the first male connector; the first keying device is configured to physically prevent electrical coupling between the second female connector and the first male connector, and the second keying device is configured to physically prevent electrical coupling between the second male connector and the first female connector; To provide, 17. The method of claim 16, further comprising:

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