an outer housing having at least one conductive tab and for receiving a seal spring therein;

Abstract

The present invention relates to an outer housing having a tab or tabs, the housing receiving a seal (seal spring), a second outer housing, and a third outer housing. The tab is formed with a conductive coating to provide an element or part of a grounding system for a connector assembly including the outer housing. The tab is in substantial contact with the third outer housing to complete a portion of the connector assembly grounding system. If the outer housing is provided with a seal spring, the seal spring provides a greater force, additional force, to increase the contact pressure with the third outer housing than would be the case without the seal spring.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This patent application claims priority to Provisional Patent Application No. 63 / 169,511, filed April 1, 2021, the entire contents of which are incorporated herein by reference. [Background technology]

[0002] Preferably, the outer housing includes tabs that provide contact pressure against the inner housing and further include a conductive coating surface to complete the grounding system in the completed connector assembly. The outer housing can also contain a seal (seal spring) that provides additional force against the tabs, providing a higher contact pressure against the inner housing when used in the completed connector assembly. Summary of the Invention [Means for solving the problem]

[0003] The present invention relates to an outer housing having a tab or tabs within an internal cavity. The outer housing, during use, can accommodate a seal (seal spring), a second outer housing, and a third outer housing within its internal cavity. The tabs on the outer housing extend within the internal cavity of the outer housing toward an opening in the outer housing. The outer housing also has a seal advancement stop to prevent further forward movement of the seal (seal spring) into the internal cavity. The seal (seal spring) interacts with the tab when inserted into the internal cavity, and applies a spring force to the tab when the seal (seal spring) is fully inserted.

[0004] The tabs on the outer housing are formed with a conductive coating to provide an element or portion of a grounding system for a connector assembly including the outer housing. When the outer housing is used in a completed connector assembly, the tabs can substantially contact a third outer housing to complete a portion of the connector assembly grounding system. If the outer housing is provided with a seal spring, the seal spring provides a greater or additional force to increase contact pressure with the third outer housing than would be possible without the seal spring. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 is a perspective end view of the outer housing of the present invention. [Figure 2] FIG. 2 is a cross-sectional view of the outer housing and seal spring, with the seal spring residing within the outer housing. [Figure 3] FIG. 3 is a cross-sectional view of an outer housing having a seal spring inserted into a cavity in the outer housing and a second outer housing installed thereon. [Figure 4] FIG. 4 is a cross-sectional view of a completed connector assembly having an outer housing with a seal spring inserted into and residing in the outer housing cavity, an installed second outer housing, and an installed conductive third outer housing. DETAILED DESCRIPTION OF THE INVENTION

[0006] FIG. 1 illustrates an outer housing 200 of a connector assembly. The outer housing 200 has a body 206. One end of the body 206 is a first end 212 and an opposite end is a second end 222. The body 206 also has an internal cavity 204, the internal cavity 204 having a sidewall 214. The internal cavity 204 of the outer housing 200 also has an opening 202 at the first end 212 of the outer housing 200. The opening 202 opens into the internal cavity 204. The internal cavity 204 of the outer housing 200 also has a seal advancement stop 250 having a surface 252. The seal advancement stop 250 with surface 252 extends along its length from the sidewall 214 substantially perpendicular to the longitudinal direction of the outer housing 200 (defined as the direction from the first end 212 to the second end 222, or vice versa). The seal advancement stop 250 and its surface 252 are provided to interact with the seal spring 100 when the seal spring 100 is inserted into the internal cavity 204 and is in use with the outer housing 200. The seal advancement stop 250 is provided to prevent and stop the seal spring 100 from being inserted further forward into the internal cavity 204 toward the second end 222 (see FIGS. 2-4).

[0007] Preferably, the outer housing 200 is constructed as a continuous, single structure or configuration without welding or brazing. Furthermore, the outer housing 200 of the present invention is substantially a continuous, single structure throughout its entirety. No parts or portions of the outer housing 200 of the present invention are constructed from welded, soldered, or brazed parts or portions.

[0008] FIG. 1 also shows a first tab 230a and a second tab 230b of the outer housing 200. The outer housing 200 may have a pair of first tabs 230a as shown, but the number of the first tabs 230a is not limited to this. The outer housing 200 may have a pair of second tabs 230b as shown, but the number of the second tabs 230b is not limited to this. The first tab 230a and the second tab 230b of the outer housing 200 extend into the internal cavity 204 and extend substantially perpendicularly from a rear wall 240 of the outer housing 200. The rear wall 240 is within the internal cavity 204 and extends along its length from the side wall 214 of the internal cavity 204 of the outer housing 200 substantially perpendicular to the longitudinal direction of the outer housing 200 (defined as the direction from the first end 212 to the second end 222, and vice versa). The first tab 230a and the second tab 230b each have a tip 232a, 232b located at the end of each tab 230a, 230b. The tabs 230a, 230b extend toward the opening 202 within the interior cavity 204, with the tips 232a, 232b pointing substantially toward the opening 202 in the outer housing 200. The opposite ends of the tabs 230a, 230b are mounting ends 239a, 239b. The mounting ends 239a, 239b are the portions of the tabs 230a, 230b that are attached to the rear wall 240 of the outer housing 200. Each tab 230a, 230b has a cantilever arm 238a, 238b, respectively. Cantilever arms 238a, 238b are formed along the length of tabs 230a, 230b, and more specifically, by the portion of tabs 230a, 230b between attachment ends 239a, 239b and tips 232a, 232b.

[0009] The first tab 230a also has a beveled leading portion 236a, and the second tab 230b also has a beveled leading portion 236b. Each of the beveled leading portions 236a, 236b is beveled or tapered generally along its length toward the tip 232a, 232b, tapering in a direction relative to the longitudinal direction of the outer housing 200 (defined as the direction from the first end 212 to the second end 222, or vice versa). Each of the beveled leading portions 236a, 236b substantially faces the sidewall 214 of the internal cavity 204 of the outer housing 200. The beveled leading portions 236a, 236b of each of the first tab 230a and the second tab 230b are configured to contact the seal spring 100 in use, as described below.

[0010] The first tab 230a also has a first surface 234a and a second surface 235a, and the second tab 230b also has a first surface 234b and a second surface 235b. Each first surface 234a, 234b faces the interior cavity 204 of the outer housing 200. Each first surface may be opposite the other first surface 234a, 234b. As shown in FIG. 1 , along its length, the first surface 234a of the first tab 230a substantially faces the opposite first surface 234b of the second tab 230b, and vice versa. The second surfaces 235a, 235b face the sidewall 214 of the interior cavity 204 of the outer housing 200.

[0011] 2 shows the outer housing 200 with the seal spring 100 inserted therein. Here, the seal spring 100 is inserted into the outer housing 200 with the first face 102 first toward the rear 222 of the outer housing 200. The first face 102 and the first face surface 112 of the seal spring 100 may also abut against its advancement stop 250 and surface 252. The first and second tabs 230a and 230b of the outer housing 200 enter the internal aperture 108 of the seal spring 100 with their respective tips 232a and 232b first entering the internal aperture 108 of the seal spring 100 and making contact with the seal spring 100. Additionally, the angled leading portion 236a, 236b of each of the one or more tabs 230a, 230b further contacts the inner sidewall 109 of the seal spring 100 as the seal spring 100 is inserted further into the outer housing 200, as shown.

[0012] As shown in Figure 3, the seal spring 100 may be inserted into the outer housing 200, and the seal spring 100 is held within the outer housing 200 by a second outer housing 300. The cavity of the outer housing 200 and the seal spring 100 has a space into which a third outer housing 400 may be inserted and accommodated, as shown in Figure 4.

[0013] As described above, the tabs 230a, 230b abut adjacent the surface 110 of the interior sidewall 109 of the seal spring 100. More specifically, the tabs 230a, 230b abut adjacent to and contact the flared or angled portion of the interior sidewall 109. When the tabs 230a, 230b enter the interior aperture 108 and contact the seal spring 100, the flared or angled portion of the interior sidewall 109 of the seal spring 100 compresses, causing the seal spring 100 to exert a spring-like force against the tabs 230a, 230b. The tabs 230a, 230b are press-fit into the interior surface 109 of the seal spring 100, as shown in FIG. 2 . The seal spring 100 can be further inserted into the outer housing 200 and tabs 230a, 230b, and when a second outer housing 300 and then a third outer housing 400 are inserted (see FIGS. 3 and 4), they are further pressed into the inner surface 109 of the seal spring 100. In use, the seal spring 100 provides and exerts an appropriate spring force against the tabs 230a, 230b, and pushes itself outward against the tips 232a, 232b, the angled leading portions 236a, 236b, and the second surfaces 235a, 235b of the tabs 230a, 230b to apply the spring force. Additionally, the angle or taper of the inner sidewall 109 is such that when the tabs 230a, 230b are in substantial contact with the inner sidewall surface 110 of the seal spring 100, the partially angled leading portions 236a, 236b of the tabs 230a, 230b reside above the flared or angled portion of the inner sidewall 109. The tip 232a, 232b of each tab 230a, 230b may not substantially contact the first surface 102 of the seal spring 100 when inserted into the housing 200. When the seal spring 100 is inserted, the first surface 102 resides therein below the tips 232a, 232b, angled leading portions 236a, 236b, and second surfaces 235a, 235b. Additionally, the angle or taper of inner sidewall 109 is such that the flared or sloped portions of inner sidewall 109 are below the sloped leading edges of portions 236a, 236b of respective tabs 230a, 230b. Thus, the sloped or tapered portions of inner sidewall 109 exert a spring force of seal spring 100 that is applied to tabs 230, 230b.More specifically, the spring force is generally directed toward the partial beveled leads 236a, 236b of the tabs 230a, 230b. The tabs 230a, 230b are preferably slightly flexible, with cantilever arms 238a, 238b being flexible along their lengths. The tabs 230a, 230b flex when the tips 232a, 232b, or beveled leads 236a, 236b, or second surfaces 235a, 235b, contact the seal spring 100 (see FIGS. 3 and 4), as in this case. The angle or taper of the interior sidewall 109 of the seal 100 also prevents the seal spring 100 from being damaged, distorted, torn, ripped, or destroyed during use when the seal spring 100 comes into contact with the tabs 230a, 230b or similar features of the connector housing when inserted and used. Similarly, the angled leads 236a, 236b prevent the seal spring 100 or other inserted seal from being damaged, warped, torn, ripped, or destroyed during use.

[0014] The tabs 230a, 230b of the outer housing 200 have a conductive coating, and thus the tabs 230a, 230b can provide an element or portion of a grounding system for a connector assembly including the outer housing 200. Here, the conductive coating enables the grounding system including the outer housing 200 to interact with the inserted third housing 400. More specifically, the cantilevered portions of the tabs 230a, 230b may be in substantial contact with the third outer housing 400. The seal spring 100 also applies compression and spring force to the tabs 230a, 230b when assembled, pressing the tabs 230a, 230b against the third outer housing 400. Thus, when the tabs 230a, 230b contact the third outer housing 400, the grounding system portion of the connector assembly is completed.

[0015] 4 shows an example of an assembled outer housing 200 in a completed connector assembly, including the seal spring 100, second outer housing 300, and third outer housing 400. Here, as described above, the cantilever arms 238a, 238b are slightly deflected, with the deflection being opposite or counter to the direction in which the tabs 230a, 230b contact the interior sidewall 109 of the seal spring 100. The deflection of the tabs 230a, 230b is generally inward, i.e., toward the interior cavity 204, the interior aperture 108, or the other opposing tab 230a, 230b (as described above). Thus, as shown in FIG. 4, the first surface 234a, 234b of each tab 230a, 230b is inserted into and rests within the outer housing 200 of the completed connector assembly, further contacting the surface of the third outer housing 400 residing therein. The third outer housing 400 now engages the first surfaces 234a, 234b, further pressing the tabs 230a, 230b against the inner sidewall 109 of the seal spring 100. This compresses the seal spring 100, resulting in an upward spring force on the tabs 230a, 230b, providing a greater, additional force to increase the contact pressure of the tabs 230a, 230b against the third outer housing 400 than would be possible without the seal spring 100. This force and subsequent pressure are much more resistant to stress relaxation compared to using tabs 230a, 230b, cantilever arms 238a, 238b, and housing 200 made solely from resin. An advantage of the seal spring 100 is the higher contact pressure between the outer housing 200 and the third outer housing 400. The third outer housing 400 is preferably a plated resin housing that is electrically conductive and aids in shielding the connector assembly. Outer housing 200 is also preferably conductive and constructed from metal-infused resin to aid in shielding of the connector assembly during use. Tabs 230a, 230b, preferably conductively coated, can contact conductive third outer housing 400 to complete the grounding portion of the connector assembly using outer housing 200.

[0016] It should be noted that while the foregoing description is directed to preferred embodiments of the invention, other variations and modifications will be apparent to those skilled in the art and can be made without departing from the spirit or scope of the invention. Furthermore, features described in connection with one embodiment of the invention may be used in conjunction with other embodiments, even if not explicitly stated above.

Claims

1. The main body and an interior cavity having a sidewall; a tab located within the internal cavity, the tab having a first surface, a second surface, and an inclined leading portion, the inclined leading portion abutting and contacting a seal spring such that the seal spring applies a spring force to the tab and the tab can receive a spring force from the seal spring; an opening leading to the internal cavity; The back wall and An outer housing characterized by:

2. The outer housing of claim 1 , wherein said interior cavity includes a seal advancement stop.

3. 2. The outer housing of claim 1, wherein said outer housing has a tab separate from said tab.

4. 2. The outer housing of claim 1, wherein the outer housing has the tab, the tab being a first tab, and the outer housing has a tab other than the tab, the tab other than the tab being a second tab.

5. 2. The outer housing of claim 1, wherein said outer housing has a tab, said tab having a conductive coating formed thereon.

6. 2. The outer housing of claim 1, wherein the outer housing has the tab, the tab being a first tab, the outer housing has another tab other than the tab, the other tab being a second tab, and the first tab and the second tab are coated with a conductive coating.

7. 2. The outer housing of claim 1, wherein the outer housing has the tab, the tab being a first tab, the outer housing has another tab, the other tab being a second tab, and the first tab and the second tab are opposite each other.

8. 2. The outer housing of claim 1, wherein the outer housing has the tab, the tab being a first tab, the outer housing has another tab other than the tab, the other tab being a second tab, the first tab and the second tab facing each other, and a conductive coating is formed on the first tab and the second tab.

9. inserting a seal spring into the interior cavity of the outer housing; press-fitting the seal spring into the internal cavity of the outer housing; then press-fitting the seal spring into the outer housing so as to align the seal spring with a tab within the internal cavity of the outer housing, causing the tab with an inclined leading portion to abut and contact the seal spring, thereby providing and applying a spring force to the tab; then inserting a second outer housing into the interior cavity of the outer housing; then applying a spring force to the tab; then inserting a third outer housing into the interior cavity of the outer housing; then contacting the tab with the third outer housing; 1. A method for assembling an outer housing to a connector assembly, comprising:

10. 10. The method of assembling an outer housing to a connector assembly according to claim 9, wherein after the step of applying a spring force to the tab, the seal spring is pressed against a seal advance stop on the outer housing.

11. 10. The method of assembling the outer housing with the seal spring according to claim 9, wherein after the step of applying a spring force to the tab, the seal spring contacts a third outer housing and the third outer housing is inserted into an internal aperture of the seal spring.

12. The method of assembling the outer housing with the seal spring according to claim 9, characterized in that the tab applies pressure to the third outer housing.

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