Modular connectors and components therefor

Abstract

A modular connector includes: a shell having a floor, opposing first and second side walls, and a ceiling; and a plurality of contact inserts. Each of the contact inserts includes a generally rectangular main body and one or more contacts contained therein. Each of the contact inserts further includes: at least one first projection extending from a first wall; and at least one second projection extending from a second wall opposite the first wall, the at least one second projection being of a different configuration than the first projection. The shell includes at least one first recess on an inner surface of the first side wall, the at least one first recess configured to complement the at least one first projection, and further includes at least one second recess on an inner surface of the second side wall, the at least one second recess configured to complement the at least second projection.

Description

Attorney Docket No. 1729.40001.WOMODULAR CONNECTORS AND COMPONENTS THEREFORRelated Application

[0001] The present application claims priority from and the benefit of U.S. Provisional Patent Application No. 63 / 789,551, filed April 16, 2025, the disclosure of which is hereby incorporated herein by reference in full.Field

[0002] The present invention is directed generally to connectors, and more specifically to modular connectors.Background

[0003] Connectors for power and signal are ubiquitous, with many specialized types of connectors available for different applications. In some instances a manufacturer may wish to provide different configurations of specialized connectors. As such, it may be desirable to provide configurations that enable a manufacturer to easily provide connectors in a wide variety of arrangements and configurations that can be created by the manufacturer, distributor or end userSummary

[0004] As a first aspect, embodiments of the invention are directed to a modular connector. The modular connector comprises: a shell having a floor, opposing first and second side walls, and a ceiling; and a plurality of contact inserts. Each of the contact inserts includes a generally rectangular main body and one or more contacts contained therein. Each of the contact inserts further includes: at least one first projection extending from a first wall; and at least one second projection extending from a second wall opposite the first wall, the at least one secondAttorney Docket No. 1729.40001.WOprojection being of a different configuration than the first projection. The shell includes at least one first recess on an inner surface of the first side wall, the at least one first recess configured to complement the at least one first projection, and further includes at least one second recess on an inner surface of the second side wall, the at least one second recess configured to complement the at least second projection.

[0005] As a second aspect, embodiments of the invention are directed to a modular connector comprising: a shell having a floor, opposing first and second side walls, and a ceiling; and_a plurality of contact inserts, each of the contact inserts including a generally rectangular main body and one or more contacts contained therein. Each of the contact inserts further includes: at least one first projection extending from a first wall; and.two second projections extending from a second wall opposite the first wall, the at second projections being of a different configuration than the first projection. The shell includes at least one first recess on an inner surface of the first side wall, the at least one first recess configured to complement the at least one first projection; and further includes two second recesses on an inner surface of the second side wall, the second recesses configured to complement the at least second projection.

[0006] As a third aspect, embodiments of the invention are directed to a grommet for a modular connector comprising: a generally rectangular main body; a plurality of first projections extending from a first edge of the main body; a plurality of second projections extending from a second edge of the main body, the second edge being opposed to the first edge the second projections being complementary to the first projections; a third projection extending from a third edge of the main body; a fourth projection extending from a fourth edge of the main body that is opposite the third edge; and a lip extending around the periphery of the grommet, the lip including discontinuities, such that a first portion of the lip is offset from a second portion of the lip in a thickness dimension of the main body. The first and second portions of the lip form a double seal when the second edge of a first grommet are interdigitated with the first edge of a second identical grommet.

[0007] As a fourth aspect, embodiments of the invention are directed to a modular connector comprising: a shell having a floor, opposing first and second side walls, and a ceiling; a plurality of contact inserts, each of the contact inserts including a generally rectangular main body and one or more contacts contained therein. Each of the contact inserts includes: at least one first alignment feature mounted on a first wall; and at least one first alignment featureAttorney Docket No. 1729.40001.WOmounted on a second wall opposite the first wall, the first alignment feature of the first wall and the first alignment feature of the second wall are configured so that each of the contact inserts has 180 degree radial symmetry. The shell includes at least one third alignment feature on an inner surface of the first side wall, the at least one third alignment feature configured to complement the at least one first alignment feature. The shell further includes at least one third alignment feature on an inner surface of the second side wall, the at least one third alignment feature is configured to complement the at least one first alignment feature.Brief Description of the Figures

[0008] FIG. 1 is a perspective view of a connector according to embodiments of the invention.

[0009] FIG. 2 is an exploded perspective view of the connector of FIG. 1.

[0010] FIG. 3 A is a front perspective view of the shell of the connector of FIG. 1.

[0011] FIG. 3B is a rear perspective view of the shell of FIG. 3 A.

[0012] FIG. 4A is a top perspective section view of the shell of FIG. 3 A.

[0013] FIG. 4B is a bottom perspective section view of the shell of FIG. 3 A.

[0014] FIG. 4C is a side perspective section view of the shell of FIG. 3 A.

[0015] FIG. 4D is a side section view of the shell of FIG. 3 A.

[0016] FIG. 4E is an enlarged partial perspective section view of the upper portion of the shell of FIG. 3 A.

[0017] FIG. 5 is a perspective view of the locking lever of the connector of FIG. 1.

[0018] FIG. 6A is a front view of two contact inserts of the connector of FIG. 1.

[0019] FIGS. 6B and 6C are perspective views of the contact inserts of FIG. 6A illustrating how they can be joined horizontally with a relative sliding motion.

[0020] FIG. 7A is a side section view of the shell of FIG. 3 and one of the contact inserts of FIG. 6A.

[0021] FIG. 7B is a perspective section view of the shell and contact inserts of FIG. 7A illustrating how the inserts can be installed via a relative sliding motion.

[0022] FIG. 7C is a partial top perspective view of one of the contact inserts of FIG. 6A.

[0023] FIG. 7D is a partial top perspective view of a lower recess in the shell of FIG. 3.

[0024] FIG. 8A is a perspective view of one of the grommets of the connector of FIG. 1.Attorney Docket No. 1729.40001.WO

[0025] FIGS. 8B and 8C are partial and perspective views of the grommets of the connectors of FIG. 1 illustrating how they are joined.

[0026] FIGS 9A and 9B are a perspective view and an enlarged perspective view of the shell of FIG. 3 showing the grooves that receive the grommets of FIGS 8A-C. FIG. 9C is a perspective view illustrating how a grommet of FIG. 8A is installed in the shell of FIG. 3.

[0027] FIG. 10A is an exploded view of the shell of FIG. 3 with a rear shell.

[0028] FIG. 10B is an assembled perspective view of the shell and rear shell of FIG. 10 A.

[0029] FIG. 11 is a perspective view of the secondary locking tab of the connector of FIG. 1.

[0030] FIG. 12A is a top partial perspective view of the connector of FIG 1., with the latch in a latched condition and the secondary locking tab ready to be moved secure the latch.

[0031] FIG. 12B is a partial side section view of the connector of FIG. 1 as in FIG. 12 A.

[0032] FIG. 13 A is a perspective view of a mating connector (appropriate for mounting in an equipment panel) for the connector of FIG. 1.

[0033] FIG. 13B is an exploded perspective view of the mating connector of FIG. 13A.

[0034] FIG. 13A is a perspective view of the connector of FIG. 1 mated with a mating connector.

[0035] FIG. 13B is a side section view of the mated connectors of FIG. 13 A.

[0036] FIG. 13C is a top section view of the mated connectors of FIG. 13A.

[0037] FIG. 14 is a perspective view of different shells for connectors according to embodiments of the invention.

[0038] FIGS. 15A and 15B are perspective views of alternative contact inserts that can be used with the shells of FIGS. 3A and 14. FIGS. 15C-15F are perspective views illustrating how the contact inserts of FIGS. 15A and 15B can be joined vertically with a relative sliding motion.

[0039] FIG. 16 are front and perspective views of various contact inserts that may be employed in connectors according to embodiments of the invention.

[0040] FIG. 17A-17F is a series of perspective views shown different combinations of inserts of FIG. 16 inserted into mating connectors of FIG. 1 and FIG. 13 A.Attorney Docket No. 1729.40001.WO

[0041] FIG. 18A is a perspective view of an alternative latch for use with connectors according to embodiments of the invention, wherein the latch is shown in a latched configuration.

[0042] FIG. 18B is a perspective view of the shell and latch of FIG. 18A, wherein the latch is shown in an unlocked configuration.

[0043] FIG. 18C is a perspective view of the shell of FIG. 18A.

[0044] FIG. 18D is a perspective view of the secondary latching tab used with the latch of FIG. 18 A.

[0045] FIG. 18E is a partial side section view of the latch, secondary latching tab and shell of FIG. 18 A.

[0046] FIG. 19A is a rear perspective view of a shell for connectors according to alternative embodiments of the invention.

[0047] FIG. 19B is a side rear perspective view of the shell of FIG. 19A.

[0048] FIG. 20A shows perspective views of contact inserts according to alternative embodiments of the invention.

[0049] FIG. 20B is a perspective views of the contact inserts of FIG. 20A showing how they mate together for insertion into a shell.

[0050] FIGS. 21 A and 21B are front and rear perspective view of blind-mated contact inserts for connectors according to embodiments of the invention.

[0051] FIG. 22 illustrates three “blank” inserts that can be employed to occupy space within connectors according to embodiments of the invention.

[0052] FIGS. 23A-23D are perspective and side views of a grommet according to alternative embodiments of the invention.

[0053] FIGS. 24A and 24B are front and rear perspective views of a frame insert that can be used to secure and / or seal contact inserts in / to the shell of a connector according to embodiments of the invention. FIGS. 24C and 24D are a front perspective view and a side view showing the frame insert in place in the shell.

[0054] FIGS. 25A and 25B are a partial end view and a partial perspective view of the ridge of the projection on a contact insert according to embodiments of the invention. FIGS. 25C and 25D show an alternative ridge configuration.Attorney Docket No. 1729.40001.WO

[0055] FIGS. 26A and 26B are front and side section views of a shell and a contact insert according to embodiments of the invention, wherein the shell is configured so that the contact insert is installed from the front side of the shell.

[0056] FIGS. 27A and 27B are exploded and mated perspective views of the shells of mating connectors according to embodiments of the invention that employ an integrated latch.

[0057] FIG. 28A is a side section view of a shell and contact insert according to embodiments of the invention in which the shell includes an internal latch to maintain the contact insert in place. FIGS. 28B and 28C are partial perspective and side views of the internal latch. \

[0058] FIGS. 29A and 29B are perspective and side views of a contact insert with a latch on its ridge to encourage the contact insert in the shell after insertion. FIG. 29C is a perspective view of the groove in the shell that mates with the ridge and latch of FIGS. 29A and 29B. FIG.29D is a side section view of the contact insert of FIGS. 29A and 29B inserted into the shell of FIG. 29C.

[0059] FIGS. 30A and 30B are front and perspective views of a contact insert according to further embodiments of the invention.

[0060] FIG. 30C is a front view of a contact insert of FIG. 30A joined to two contact inserts of FIG. 31 A.

[0061] FIG. 31 A is a top perspective view of a contact insert according to still further embodiments of the invention.

[0062] FIG. 3 IB is a bottom perspective view of the contact insert of FIG. 31 A.

[0063] FIG. 31C is a perspective view of two contact inserts of FIG. 31 A joined in a vertical stack.

[0064] FIG. 3 ID is a front view of two contact inserts of FIG. 31 A showing how they can be joined horizontally.

[0065] FIG. 32A is a front view of a grommet that can be used with the contact inserts of FIGS. 30A and 31A.

[0066] FIG. 32B is a side view of the grommet of FIG. 32A.

[0067] FIG. 33A is a perspective view of a grommet useable in connectors according to alternative embodiments of the invention.

[0068] FIG. 33B is an inverted perspective view of the grommet of FIG. 33A.Attorney Docket No. 1729.40001.WO

[0069] FIG. 33C is a top view of two grommets of FIG. 33A joined to form a composite 2x2 grommet.

[0070] FIG. 34A is a perspective view of another grommet usable in connectors according to embodiments of the invention.

[0071] FIG. 34B is a front view of the grommet of FIG. 34 A.

[0072] FIG. 34C is a perspective view of two grommets of FIG. 34A joined to form a composite 2x2 grommet.

[0073] FIG. 35 A is a perspective view of a further grommet usable in connectors according to embodiments of the invention.

[0074] FIG. 35B is a perspective view of two grommets of FIG. 35 A joined to form a composite 2x1 grommet, with the lower grommet inverted from its position in FIG. 35 A.

[0075] FIG. 35C is a still further grommet usable in connectors according to embodiments of the invention.

[0076] FIG. 35D is a perspective view of two grommets of FIG. 35C joined to form a composite 2x1 grommet, with the lower grommet inverted from its position in FIG. 35C.

[0077] FIG. 36 is a perspective view of two grommets of FIG. 35A and two grommets of FIG. 35C joined to form a composite 2x2 grommet.

[0078] FIG. 37 is a perspective view of two grommet of FIG. 35A and a grommet of FIG. 34A joined to form a composite 2x2 grommet.

[0079] FIG. 38A is perspective view of two grommets of FIG. 34A, two grommets of FIG. 35A and two grommets of FIG. 35C joined to form a 2x4 composite grommet.

[0080] FIG. 38B is a top view of the composite grommet of FIG. 38B.

[0081] FIG. 39A is a perspective view of a further 2x1 grommet usable in connectors according to embodiments of the invention.

[0082] FIG. 39B is a perspective view of another 2x1 grommet usable in connectors according to embodiments of the invention.

[0083] FIG. 39C is a perspective view of another 1x1 grommet usable in connectors according to embodiments of the invention.

[0084] FIG. 39D is a perspective view of a further 1x1 grommet usable in connectors according to embodiments of the invention.Attorney Docket No. 1729.40001.WO

[0085] FIG. 40 is a perspective view of two grommets of FIG. 39B, one grommet of FIG.39A, two grommets of FIG. 39C, and two grommets of FIG. 39D joined to form a composite 2x5 grommet.

[0086] FIG. 41 is a top view of the composite grommet of FIG. 40.

[0087] FIGS. 42A-42D are various views of a shell that is usable with connectors according to embodiments of the invention.

[0088] FIGS. 43A and 43B are perspective and front views of a 2x1 contact insert usable with the shell of FIGS. 42A-D.

[0089] FIG. 43C is a perspective view of two contact inserts of FIG. 43A joined to form a composite of 2x2 contact inserts.

[0090] FIGS. 44A and 44B are perspective and front views of a 1x1 contact insert usable with the shell of FIGS. 42A-D.

[0091] FIG. 45 is a front view of a composite of two contact inserts of FIG. 44A and one contact insert of FIG. 43 A.

[0092] FIG. 46 is a front view of the shell of FIG. 42A with the composite of contact inserts of FIG. 45.

[0093] FIG. 47 is a perspective view of a contact insert according to embodiments of the invention.

[0094] FIGS. 48A and 48B are partial perspective and partial front views, respectively, of a contact insert according to embodiments of the invention.

[0095] FIG. 48C is a section view of the contact insert of FIG. 48 A installed in a shell.

[0096] FIG. 49A is a perspective view of a retention frame that can be used with shells and contact inserts according to embodiments of the invention.

[0097] FIG. 49B is a perspective view of the retention frame of FIG. 49A used to retain contact inserts in a shell according to embodiments of the invention.

[0098] FIG. 50A is a perspective view of a blade useful for disengaging a contact insert from a shell according to embodiments of the invention.

[0099] FIG. 50B is perspective view of a tool with four blades of FIG. 50A.Attorney Docket No. 1729.40001.WODetailed Description[000100] The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.[000101] Like numbers refer to like elements throughout. In the figures, the thickness of certain lines, layers, components, elements or features may be exaggerated for clarity. Broken lines illustrate optional features or operations unless specified otherwise.[000102] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as "between X and Y" and "between about X and Y" should be interpreted to include X and Y. As used herein, phrases such as "between about X and Y" mean "between about X and about Y." As used herein, phrases such as "from about X to Y" mean "from about X to about Y."[000103] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and / or clarity.[000104] It will be understood that when an element is referred to as being "on", "attached" to, "connected" to, "coupled" with, "contacting", etc., another element, it can be directly on,Attorney Docket No. 1729.40001.WOattached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, "directly on", "directly attached" to, "directly connected" to, "directly coupled" with or "directly contacting" another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed "adjacent" another feature may have portions that overlap or underlie the adjacent feature.[000105] Referring now to the drawings, a connector, designated broadly at 10, is illustrated in FIGS. 1-13C. As shown in FIGS. 1 and 2, the connector 10 includes a shell 12, a latch 14, two contact inserts 16, 18, a pair of grommets 20, a rear shell 22, and a secondary locking tab 24. These components are described in greater detail below.[000106] Referring now to FIGS. 3A-4E, the shell 12 is generally box-shaped and open on both ends, with a floor 30, side walls 32, 34 and a ceiling 36. A shoulder 38 causes the shell 12 to “step down” in height and width, such that the front portion of the shell 12 is larger than the rear portion. Two registration keys 40 extend downwardly from the floor 30, and two keys 42 extend upwardly from the ceiling 36. Posts 42, 44 extend laterally a short distance from each side wall 32, 34. The rear inner surface of the side wall 32 has two recesses 46, and the rear inner surface of the side wall 34 has three recesses 48. The rear portion of the floor 30 includes two recesses 50, and the rear portion of the ceiling has two recesses 52 located above the recesses 50. As shown in FIGS. 4A and 4B, each of the recesses 50, 52 has three shallow pits 56 (see also FIG. 7D). Two grooves 59 are present in the rear portion of the shell 12 and are routed about the entire inner periphery of the shell 12 (see FIGS. 4A, 4C and 4D). The grooves 59 have discontinuities that are described below in connection with the grommets 20.[000107] An elongated vertical nub 57 and an angled stop 61 are present on the outer surface of the rear portion of each of the side walls 32, 34. Slots 63 are located on the front edges of the side walls 32, 34. Also, a gasket 25 is located just forwardly of the shoulder 38.[000108] Referring to FIGS. 4A-4E, a platform 58 is present on the front portion of the ceiling 36. Fingers 60 extend upwardly and inwardly from the edges of the platform 58. A ridge 62 extends upwardly from the rear portion of the ceiling 36 and surrounds a capture member 64 with a slot 66.[000109] Referring now to FIG. 5, the latch 14 is generally U-shaped, with a main body 70 and two arms 72 extending generally perpendicularly away from the main body 70. A receptacleAttorney Docket No. 1729.40001.WO74 is located on the inner surface near the free end of each arm 72. A finger 76 extends from the end of each arm 72. An arcuate slot 78 is present in each finger 76. A stop 80 extends inwardly from each arm 72. A tab 82 extends from the main body 70 toward the free ends of the arms 72.[0001101 As can be seen in FIGS. 1 and 2, the latch 14 is assembled on the shell 12 by inserting the posts 42, 44 into the receptacles 74 of the latch 14. This arrangement defines an axis A between the posts 42, 44 about which the latch 14 can pivot.[000111] Referring now to FIGS. 6A-6C, the contact inserts 16, 18 are shown therein. Each of the contact inserts 16, 18 is generally a rectangular block, with a respective main body 17, 19. On one side wall 80, two projections 82 extend outwardly. On the opposite side wall 84, three projections 86 extend outwardly. On the upper and lower walls 88, 90, projections 92, 94 are present. Each of the projections 92, 94 includes three dimples 96 (see also FIG. 7C).[000112] Within the block that makes up each contact insert 16,18, one or more contacts 98 is present (e.g., two contacts 98 are present in contact insert 18). The contacts 98 may be of any configuration known to be suitable for the connector’s intended use. Exemplary contacts include, but are not limited to, signal contacts (e.g., 20 and 22D signal contacts), power contacts such as Radsok® contacts (e.g., 3.6 and 5.7 mm Radsok contacts), data carrying contacts, high speed contacts, and combinations of any or all of the above. Some exemplary contacts within inserts are shown in FIG. 16.[000113] FIGS. 6B and 6C illustrate how the contact inserts 16, 18 can be nested together. More specifically, the projections 86 of the contact insert 16 are interdigitated with the projections 82 of the contact insert 18. The contact inserts 16, 18 can be inserted via a sliding motion into the shell 16 in the manner illustrated in FIGS. 7A and 7B (only the contact 18 is shown therein). As shown therein, the projection 92 on the lower wall 88 and the projection 94 on the upper wall 90 are received in the complementary recesses 50, 52 in the floor 30 and ceiling 36 of the shell 16. The projections 82 are interdigitated with the complementary recesses 46, and the projections 88 are received in the complementary recesses 48. The interdigitation of (a) each contact insert 16, 18 with the shell 12 and (b) each contact insert 16, 18 with the other contact insert 18, 16, along with the interaction of the upper and lower projections 90, 94 with the recesses in the floor and ceiling, firmly secure the contact inserts 16, 18 within the shell 12.[000114] Referring now to FIGS. 7C and 7D, it can be understood that when the contact inserts 16, 18 are inserted into the shell 12, the dimples 96 on the projections 92, 94 are receivedAttorney Docket No. 1729.40001.WOin the pits 56 of the recesses 50, 52. This interaction can provide additional securing force for the contact inserts 16, 18. In some embodiments, and as shown FIGS. 3B and 4C, the pits 56 and the dimples 96 diminish in size from front of the connector 10 toward the rear. This arrangement can facilitate the insertion of the contact inserts 16, 18 and render their removal more difficult.[000115] Referring now to FIGS. 8A-8C, the grommets 20 are shown therein. As shown in FIG. 8A, each grommet 20 has a main body 100. Like the inserts 16, 18, the grommet 20 has one bottom projection 102, a top projection 104, two projections 106 on one side, and three projections 108 on the opposite side. The lower and upper projections 102, 104 are sized and positioned to be received in the recesses 50, 52 of the shell 12. The projections 106 are sized and positioned to interdigitate with the recesses 46, and the projections 108 are sized and positioned to interdigitate with the recesses 48.[000116] In addition, the grommet 20 includes lips (which are semicircular in profile) that help to provide seals with the shell 12. Specifically, a lip 110a begins at the edge of the middle projection 108 and is routed over the upper projection 108, over the top projection 104, and along the top edge of the upper projection 106 to terminate at the free end of the upper projection 106. A lip 110a’ extends from the center of the space between the projections 106 and extends to the corner formed by the side wall and lower wall of the main body 100. The lips 110a, 110a’ are located flush with the front of the main body 100. A lip 110b begins at the center of the projection 108 and is routed over the lower projection 108, under the bottom projection 102, and terminates adjacent the end of the lip 110a’. A lip 110b’ extends from the upper end of the lip 110a’ to the end of the lip 110a. The lips 110b, 110b’ are offset rearwardly from the lips 110a, 110a’ (see FIG. 8A). Lips 110c, 100c’ follow the same path as the lips 110a, 110a’, but are offset rearwardly from the lips 110b, 110b’. Finally, lips 1 lOd, 110d’ follow the same path as the lips 110b, 110b’, but are offset rearwardly from the lips 110c, 110c’ and are flush with the rear surface of the main body 100.[000117] As can be seen in FIGS. 8B and 8C, when the grommets 20 are joined together, the projections 108 of one grommet 20 interdigitate with the projections 106 of the other grommet 20. When the two grommets 20 are joined, at the junction the lips 110b, 110b’ are positioned between the lips 110a, 110c, and the lips 110c, 110c’ are positioned between the lips 110b, 1 lOd. As a result, a substantial seal is formed at the junction of the two grommets 20.Attorney Docket No. 1729.40001.WO[000118] The joined grommets 20 can be press-fit into the rear portion of the shell 12. The lips 110a, 110b, 110c, 1 lOd are received within the aforementioned grooves 59. As noted above, the grooves 59 are discontinuous; this arrangement enables the grooves 59 be properly positioned to receive the lips 110a-l lOd. Thus, the grommets 20 also form a tight seal with the shell 12.[000119] Referring now to FIGS. 10A and 10B, the rear shell 22 is shown therein. The rear shell 22 is generally funnel-shaped, with a rectangular profde. At its narrower end, the rear shell 22 has a rear wall 120, with a cylindrical ring 122 extending rearwardly therefrom to serve as a port for cables / cords that are connected with the contacts of the contact inserts 16, 18. At its front end, the rear shell 22 has two open clips 124. As shown in FIG. 10B, the clips 124 deflect and receive the vertical nubs 57 on the shell 12 to attach the rear shell 22 to the shell 12. A gasket 126 (see FIG. 1) is interposed between the front end of the rear shell 22 and a shoulder 65 on the shell 12 to provide a seal between these two components. Also, the rear shell 22 can help to hold the contact inserts 16, 18 and / or the gaskets 22 in place.[000120] Referring now to FIG. 11, the secondary locking tab 24 is shown therein. The secondary locking tab 24 includes a main platform 130 and a lower foot 132 attached to the forward end of the main platform 130 with two pillars 134. A rear flange 136 extends upwardly from the rear edge of the main platform 130. Tabs 138 extend laterally from the center and the rear end of the main platform 130. A dimple 140 (see FIG. 12B) projects downwardly from the lower surface of the main platform 130.[000121] The secondary locking tab 24 is mounted on the shell 12 such that the tabs 138 are received in pockets 67 of the shell 12 (see FIG. 4D). The dimple 140 is positioned above a slot 69 in the platform 58 of the shell 12. In this position, the secondary locking tab 24 is able to slide forwardly and rearwardly relative to the shell 12, confined by the tabs 138 in the pockets 67.[000122] In use, the connector 10 can be mated with a mating connector 200. As shown in FIGS. 13A and 13B, the mating connector 200 includes contacts 204 within a housing 206. The contacts 204 mate with the contacts 98 of the contact inserts 16, 18. The housing 206 has a wall 208 that fits within the floor 30, walls 32, 34, and ceiling 36 of the shell 12 of the connector 10. The gasket 25 (which is located just forwardly of the shoulder 38 of the shell 12) engages the end of the wall 208 of the housing 206 and provides a seal between the connectors 10, 200.Attorney Docket No. 1729.40001.WO[000123] Two posts 210 are located on opposite sides of the outer surface of the housing 206. Each of the posts 210 has a head 211. When the connectors 10, 200 are mated (see FIGS.13C-13E), the posts 210 fit within the slots 63 of the shell 12. In this position, the posts 210 are located so that, when the latch 14 is rotated about the axis A, the slots 78 receive the posts 210, with the heads 211 providing lateral stability. Pivoting of the latch 14 ceases when the main body 70 reaches the ceiling adjacent the front end of the rear shell 22. The tab 82 extends into the slot 66 defined by the capture member 64; the capture member 64 flexes downwardly and slightly rearwardly to accept the tab 82, then recovers toward its original position once the tab 82 “clears” the capture member 64 (see FIG. 12B).[000124] Once the latch 14 has pivoted into place and the tab 82 is captured by the capture member 64, the user slides the secondary locking tab 24 forwardly. The foot 132 slides beneath the capture member 64, thereby preventing it from deflecting downwardly and allowing the tab 82 to be released. The secondary locking tab 24 remains in place because the dimple 140 is held in the slot 69. The secondary locking tab 24 can help to maintain the latch 14 in place (and therefore help to maintain the connectors 10, 200 in a mated condition), particularly in harsh conditions (e.g., wherein the mated connectors 10, 200 are subjected to vigorous and repeated vibration).[000125] The mating connector 200 is illustrated as a connector that is mounted on a piece of equipment. However, it will be understood that the connector 200 may also be unmounted (e g., attached to the end of a free cable or cord).[000126] It should also be recognized that the contacts 204 of the mating connector 200 may also be provided as contacts inserts like the contact inserts 16, 18 of the connector 10. In such an instance, the interior of the housing 210 would have the same recesses, grooves, etc. that enable the contact inserts 16, 18 to be mounted within the connector 10.[000127] Those of skill in this art will recognize that, although the connector 10 is shown as a “2x2” connector, with two contact inserts 16, 18 (each having two contacts), other configurations are also possible. FIG. 14 shows alternative shells 212 and 312 along with the 2x2 shell 12 as well as the shells for mating connectors 200, 200’, 200”. The shell 212 is similar to the shell 12, but includes room for three different contact inserts (i.e., it is a 2x3 shell). The shell 312 is also similar to the shell 12 but has room for four different contact inserts (i.e., it is aAttorney Docket No. 1729.40001.WO2x4 shell). In each instance the contact inserts 16, 18 engage with each other and are inserted into the shell in the manner described above.[000128] FIGS. 15A-15F illustrate alternative contact inserts that may be employed by any of the shells 12, 212, 312. Contact inserts 416a, 416b are shown in FIGS. 15A and 15B. Each of the contact inserts 416a, 416b includes a single contact. The contact insert 416a includes two ridges 485 on its lower surface, and the contact insert 416b includes two complementary grooves 487 on its upper surface. When the contact inserts 416a, 416b are brought together (FIG. 15F), the ridges 485 fit within the grooves 487, such that the combination has the same peripheral profile as the contact inserts 16, 18, with two projections (not shown) on one side, three projections 486 on the opposite side, and projections 494, 490 on the top and bottom surfaces, each with dimples 496. As a result, the combined contact inserts 416a, 416b can be substituted in place of a “two-contact” insert like 16, 18 within any of the shells 12, 212, 312 discussed above.[000129] FIGS. 17A-17F illustrate different arrangements of contact inserts that may be employed with the connector 10 and the mating connector 200. FIGS. 17A, 17B and 17D show a connector 10 (FIG.17D) and connectors 200 (FIGS. 17A and 17B) with two “2x1” contact inserts 16, 18, much like those shown in FIG. 2 above, but shown as different types of contact inserts. FIGS. 17C and 17F show a connector 200 (FIG. 17C) and a connector 10 (FIG. 17F) with a 2x1 contact insert and two 1x1 contact inserts. FIG. 17E shows a connector 10 with four 1x1 contact inserts (such as those shown in FIGS. 15A-15F). As long as the contact inserts of a connector 10 are of the correct type and are arranged to mate correctly with the contact inserts of a mating connector 200, any arrangement may be suitable.[000130] FIGS. 18A-18E illustrate an alternative latching arrangement that is suitable foe use with the connectors discussed above. FIGS. 18A and 18B show the latch 14’ in a latched and unlatched condition. It can be seen that the latch 14’ is attached to the shell 12 of the connector 10 and pivots about an axis A, and it can be envisioned that the slots 78’ of the fingers 76’ will capture the posts 210 of a mating connector. FIG. 18C shows that the shell of the connector 10 has a T-shaped projection 58’ that helps to capture a secondary latching tab 24’ (FIG. 18D). As shown in FIG. 18B, the secondary locking tab 24’ is mounted on and pivots with the latch 14’; once the latch 14’ is pivoted to the latched position of FIG. 18A, the secondaryAttorney Docket No. 1729.40001.WOlocking tab 24’ can slide to engage the T-shaped projection 58’ to maintain the latch 14’ in the latched condition.[000131] FIGS. 19A and 19B illustrate an alternate shell 512 for the connector 10. In this embodiment, the grooves 59 that receive the lips of the grommets 20 are absent. As a result, grommets to be used with the shell 512 would also be missing the lips 110. The shell 512 may prove to be easier to manufacture than the shell 12, particularly if made via injection molding, while still providing a sealing function between (a) the shell 512 and the grommets 20 and (b) the grommets 20 themselves.[000132] FIGS. 20A and 20B illustrate contact inserts 616a, 616b are that similar to the 1x1 contact inserts 416a, 416b shown in FIGS. 15A-15F, with the exception that the contact insert 616b includes closed-ended grooves 687 on its upper surface. Thus, as shown in FIG. 20B, the contact inserts 616a, 616b can be joined by inserting the ridges 685 of the contact insert 616a into the grooves 687 from above, such that the contact inserts 616a, 616b are joined (typically with a slight interference fit). The joined contact inserts 616a, 616b can then be used in the manner described above for the contact inserts 416a, 416b.[000133] FIGS. 21 A and 21B show a blind-mate contact inserts 716, 718 that may be used when a blind-mate connection is desired. FIG. 22 shows a “blank” insert 816 that may be employed as a spacer within a connector 10, 200 when no contact is need at a particular position.[000134] FIGS. 23A-23D illustrate a grommet 20’ according to embodiments of the invention. The grommet 20’ has the same configuration as the grommet 20 with the exception that, instead of the lips 110a-l lOd having discontinuities where adject lips meet, the grommet 20’ has angled transitional sections 1 lOe that connect the lip 110a’ with 110b’ and the lip 110c’ with the lip 110d’ . Such an arrangement can maintain the complementary nature of the grommets 20’ when they are joined together, but the grommets 20’ may have superior sealing capability.[000135] FIGS. 24A-24D illustrate another manner of securing contact inserts within a shell. FIGS. 24A and 24B illustrated a boxed-shaped frame insert 790 that includes a rim 791 that extends about the inner periphery. Nubs 792 project laterally from the side walls. As shown in FIG. 24C, the frame insert 790 can be inserted into a shell 712. The rim 791 captures the contact inserts 716, 718 and retains them in place. The nubs 792 are received in holes 793 in the shell 712 to keep the frame insert 790 in place and to provide a seal.Attorney Docket No. 1729.40001.WO[000136] FIGS. 25A-25D illustrate different configurations for the ridges on the top and bottom of the contact inserts. FIGS. 25 A and 25B show a T-shaped projection 892 that can be used on the top and / or bottom of a contact insert 816. The T-shaped projection 892 is intended to fit within a complementary groove in a shell, and can reduce any tendency of the contact insert 816 to shift vertically within the shell. FIGS. 25C and 25D show a similar projection 892’ that has chamfered edges, such that the projection 892’ has a profile that is trapezoidal rather than T-shaped; the projection 892’ is configured to fit within a complementary trapezoidal groove in the shell. Those of skill in this art will recognize that these features can be on any side of the inserts and mate to each other and to the interior of the shell. Those of skill in this art will also appreciate that the projections 892, 892’ may also have dimples, such as those shown at 496 in FIG. 15F, and / or may have different structures, such as transverse ribs, on the projections 892, 892’ that provide grip between nesting or mating parts. Moreover, the projections 892, 892’ may also have rounded edges; for example, the upper portion of the “T”-shape of the projection 892 may have rounded lateral edges.[000137] FIGS. 26A and 26B illustrate a connector 910 with a shell 912 that is configured to receive contact inserts 916, 918 from the front rather than the rear. As shown in FIG. 28B, recesses 950, 952 are opened toward the front of the shell 912, such that the contact inserts 916, 918 are loaded into the shell 912 from the front (i.e., from the right side as shown in FIG. 26B). As discussed below in connection with FIGS. 28A-29D, either the shell 912 or the contact inserts 916, 918 may include structures to facilitate retention of the contact inserts 916, 918 within the shell 912.[000138] FIGS. 27A and 27B illustrate shells that utilize a latch that is integrated with the shell. As seen in FIG. 27A, a latch 1014 is attached to each of the side walls of the shell 1012 and extends forwardly therefrom. The latch 1014 has fingers 1076 that extend inwardly from the free ends of the latches 1014. The shell 1002 of the mating connector has detents 1004 in its side walls. Thus, as shown in FIG. 27B, when the shells 1012 and 1002 are mated, the fingers 1076 fit within the detents 1004 to maintain the shells 1012, 1002 (and, in turn, their connectors) in a mated condition.[000139] FIGS. 28A-28C illustrate a front-loaded shell 1112 like that shown in FIGS. 26A and 26B. At the front end of the recess 1150, the shell 1112 has a flexible finger 1177. When the contact insert 1116 is inserted into the shell 1112 and into the recess 1150, the finger 1117Attorney Docket No. 1729.40001.WOdeflects out of the way (see FIG. 28C). When the contact insert 1116 is fully inserted, the projection 1192 “clears” the finger 1177, such that the finger 1177 can recover to its original position as seen in FIG. 28A. Sufficient space remains on either side of the finger 1177 that a tool can be inserted and used to deflect the finger 1177 out of the way when / if the contact insert 1116 needs to be removed.[000140] FIGS. 29A-29D illustrate another technique for maintaining the contact inserts within the shell. FIGS. 29A and 29B show the projection 1290 of a contact insert 1216, wherein the projection 1290 includes a finger 1291 at its forward end. FIG. 29C shows a recess 1250 of a shell 1212. The recess 1250 has a slot 1251. As shown in FIG. 29D, when the contact insert 1216 is inserted into the shell 1212, the finger 1291 is deflects until it reaches the slot 1251, at which point it recovers to its original configuration. By so recovering the finger 1291 extends into the slot 1251 and maintains the contact insert 1216a in position.[000141] FIGS. 30A and 30B illustrate a contact insert 1316 that has the capability of being inverted and used with another identical contact insert 1316 in a 2x2 arrangement. More specifically, the contact insert 1316 has a main body 1380 and top and bottom projections 1392, 1394 similar to the contact inserts discussed above, but on each side includes a projection 1376 and a recess 1378. As seen in FIG. 30A, the projection 1376 is opposite the recess 1378 on the top half of the contact insert 1316, and these positions are reversed on the bottom half of the contact insert 1316. As a result, two contact inserts 1316 can be joined to form a 2x2 arrangement, and either can be inverted 180 degrees and still be used in the same arrangement. In addition, the contact insert 1316 can be used with two 1x1 contact inserts 1416 (described below) to form a 2x2 arrangement (see FIG. 30C). Thus, this arrangement of projections and recesses can provide significant flexibility to the designer. (Those skilled in this art will appreciate that the contact insert 1316 can be used with a shell (not shown) that has the same arrangement of projections and recesses as the contact insert 1316).[000142] FIGS. 31 A- 3 ID illustrate the aforementioned contact insert 1416, which has a projection 1476 on one side, a recess 1478 on the opposite side, a projection 1494 on its top surface, and a ridge 1495 and a groove 1496 on its lower surface. As shown in FIG. 31C, when one contact insert 1416 is oriented as shown in FIG. 31 A, and another identical contact insert 1416 is inverted to the orientation shown in FIG. 3 IB, the two contact inserts 1416 can be joined, with the ridge 1495 of each contact insert fitting within the groove 1496 of the other contactAttorney Docket No. 1729.40001.WOinsert 1416. The resulting 2x1 arrangement can then be used as is, or can be combined with a 2x1 contact insert 1316 to form a 2x2 arrangement (see FIG. 30C). In addition, two contact inserts 1416 in the same orientation (e.g., the orientation of FIG. 31A) can be joined horizontally to form a 1x2 arrangement (FIG. 3 ID), which can be used as is or in combination with two more contact inserts 1416 to form a 2x2 arrangement.[000143] FIGS. 32A and 32B illustrate a grommet 1420 that has the same peripheral arrangement of projections and recesses as the contact insert 1316. As such, the grommet 1420 can be used in a connector whose shell is configured to receive the contact inserts 1316, 1416. The grommet 1420 includes four lips 1510 that follow similar paths to those of the grommet 20 discussed above, such that two grommets 1420 can be brought together to form a 2x2 grommet structure.[000144] FIGS. 33-37 illustrate grommets and contact inserts that take configurations that can be used with the shells 12, 512 discussed above. FIGS. 33A-33C show a grommet 1520 that has the same pattern of projections 1502, 1504, 1506, 1508 that are present in the grommet 20. However, the grommet 1520 has a lip 1510a that is positioned on the “front” side of the grommet 1520 as shown in FIG. 33A, and also has a lip 1510c that is positioned just toward to the “rear” side of the gromet 1520; these lips are continuous around the periphery of the gromet 1520 and are not offset from front to back at any point. As shown in FIG. 33B, the grommet 1520 may be inverted (rotated about a horizontal axis that bisects the middle projection 1608) and, as shown in FIG. 33C, two grommets 1520 can be joined to form a composite 2x2 grommet, with the lips 1510a and 1510c interdigitating to provide a seal at the junction between the two grommets 1520.[000145] FIGS. 34A-34C illustrate a grommet 1620 that can also be used with the shells 12, 512 illustrated and discussed above. The grommet 1620 has the same pattern of projections 1602, 1604, 1606, 1608 as the grommet 20; however, the grommet 1620 has two continuous lips 1610a, 1610c that are both positioned on the “rear” half of the grommet 1620 from the vantage point of FIG. 34A. As can be seen in FIG. 34C, the grommet 1620 can be inverted (i.e., rotated 180 degrees about a horizontal axis though the middle of the grommet that bisects the middle projection 108), such that the lips 1620a, 1620c are on the front half of the grommet 1620 from the vantage point of FIG. 34C. As such, two identical grommets 1620 can be joined as shown in FIG. 34A, with the lips 1620a, 1610c of one grommet sealing against flat surfaces of the otherAttorney Docket No. 1729.40001.WOgrommet 1620 (and, importantly, not interfering with the lips 1610a, 1610c of the other grommet 1620). This configuration can allow the user to employ the same grommet 1620 in both positions of a 2x2-sized connector. This approach can also minimize the tooling required as the main core and cavity can be used for multiple grommets that have interchangeable cores for the different contact configurations as previously provided.[000146] FIGS. 35A-35D illustrate two 1x1 grommets 1720, 1720’ that can be used with the shells 12, 512. Each grommet 1720, 1720’ has the same pattern of projections and recesses as the contact inserts 416a, 416b shown in FIGS. 15A and 15B, with the exception that the projections 485 and recesses 487 are absent. The grommet 1720 (FIGS. 35A and 35B) has two lips 1710a, 1710c on its front half that are routed around the full periphery of the grommet 1720. The forwardmost of the lips 1710a is offset rearwardly from the front surface of the grommet 1720. As shown in FIG. 35B, the grommet 1720 can be inverted and used with another grommet 1720 to form a composite 2x1 grommet, with the flat sides of the grommets 1720 mating in the center. As such, sealing is provided by the lips 1710a, 1710c around the periphery and between the two grommets 1720 without the lips 1710a, 1710c of the two grommets interfering with each other.[000147] FIG. 35C illustrates a grommet 1720’ that is identical to the grommet 1720 with the exception that its lips 1710b, 171 Od are located in the rear half of the grommet 1720’, and the lip 171 Od is located at the rear surface of the grommet 1720’. As shown in FIG. 35D, two grommets 1720’ can be bought together to form a composite 2x1 grommet by inverting one of the grommets 1720’ relative to the other.[000148] FIG. 36 shows that the grommets 1720 of FIG. 35B and the grommets 1720’ of FIG. 35D can be brought together to form a composite 2x2 grommet in which none of the lips 1710a-1710d interfere with each other and the junction between the grommets 1720 and the grommets 1720’ . The lips do not interfere with each other because they are on opposite sides (front vs. rear) at the joining surfaces. FIG. 37 illustrates the grommets 1720 of FIG. 35B can be joined with the grommet 1620 of FIG. 34A to form a composite 2x2 grommet in which none of the lips interfere; the lips 1710a, 1710c of the grommets interdigitate with the lips 1610a, 1610c of the grommet 1620 because the lips 1710a, 1710c of the grommets 1720 are offset from the front (or rear) surface of the grommet 1720. FIGS. 38A and 38B illustrate that a 4x2 composite grommet can be formed by combining the 2x2 composite grommet of FIGS. 34C with the 2x2Attorney Docket No. 1729.40001.WOcomposite grommet of FIG. 36, with the resulting 4x2 composite grommet being sealing completely around its periphery and at all of its junctions without any interference of the lips of adjoining grommets. Notably, the lips can be designed to mate to a flat surface or to one or two adjacent lips or a complimentary recess (not shown) on the grommets.[000149] Those of skill in this art will recognize that, by using only the grommets 1620, 1720, and 1720’, a user can make any size and combination of composite grommet desired. This degree of flexibility can be valuable during manufacturing and assembly.[000150] FIGS. 39-45 illustrate another arrangement for grommets, contact inserts and shells that can be employed for connectors according to additional embodiments of the invention. The grommets, contact inserts and inner surface of the shells rely on each having 180 degree radial symmetry about the periphery (i.e., if each is rotated 180 degrees, it is identical to the original component). FIG. 39A shows a 2x1 grommet 1820 that includes two projections 1806 on each long edge, two recesses 1808 on each long edge, a projection 1802 and a recess 1803 on each lower edge, and a projection 1804 and a recess 1805 on each upper edge. The projections 1806 and recesses 1808 are sized and positioned to be complementary with each other, as are the projections 1802, 1804 with the recesses 1803, 1805. Two lips 1810a, 1810c are routed continuously about the periphery of the grommet 1820, with the lip 1810a being positioned at the rear face and the lip 1810c being spaced from the lip 1810a but still in the rear half of the grommet 1820. FIG. 39B shows a grommet 1820’ that is identical to the grommet 1820, with the exception that its lips 1810b, 18 lOd are offset from the rear face of the grommet 1820’ (but still located in the rear half of the grommet 1820’).[000151] FIGS. 39C and 39D illustrate 1x1 grommets 1920, 1920’ that are similarly shaped about their peripheries to the grommets 1820, 1820’, with a similar pattern for the projections and recess, with the exception that each of the grommets 1920, 1920’ has only one projection 1906 and one recess 1908 on each side edge. The grommet 1920 has continuous lips 1910a, 1910c positioned in its forward half, with the lip 1910a being at the front face of the grommet 1920. The grommet 1920’ has lips 1910b, 191 Od that are located in its forward half, but the lip 1910b is offset rearwardly from the front face.[000152] FIG. 40 illustrates how these four grommets 1820, 1820’, 1920, 1920’ can be used to form a composite grommet of any size. FIG. 40 shows a 2x2 grommet 1820’ joined to a 1x1 grommet 1920 and a 1x1 grommet 1920’, with the grommet 1920 positioned above theAttorney Docket No. 1729.40001.WOgrommet 1920’. The junction between the grommet 1820’ and the grommets 1920, 1920’ is sealed because the lips of the grommet 1820’ are toward the rear of the structure, and the lips of the grommets 1920, 1920’ are toward the front of the structure. The grommets 1920, 1920’ seal with each other because the lips 1910a, 1910c of the grommet 1920 interdigitate with the lips 1920b, 1920d of the grommet 1920’. The grommets 1920, 1920’ are joined with two more grommets 1920, 1920’, but with the grommet 1920’ on top of the grommet 1920 so that the lips of the grommets 1920, 1920’ on the left in FIG. 40 will interdigitate with the lips of the grommets 1920’, 1920 on the right in FIG. 40. A 2x2 grommet 1820 joins the grommets 1920’, 1920 and seals at the junction because its lips 1810a, 1810c are located at the rear half of the grommet 1820, whereas the lips of the grommets 1920’, 1920 are at the front of the grommets. Finally, another 2x2 grommet 1820’ joins the grommet 1820 and seals because the lips 1810b, 181 Od of the grommet 1820’ are offset from the rear surface of the grommet 1820’ and therefore can interdigitate with the lips 1810a, 1810c of the grommet 1820. Thus, with these four components, the user can create any composite grommet configuration desired. FIG. 41 shows how the lips of the various grommets are arranged, and illustrates that none of the lips interfere with any of the other lips in a manner that might impact sealing. As noted above, the lips can be designed to mate to a flat surface or to one or two adjacent lips or a complimentary recess (not shown) on the grommets.[000153] FIGS. 42A-42D show a 2x2 shell 2012 that can be used with the grommets of FIGS. 39-41. The shell 2012 has two projections 2046 on each side wall, two recesses 2048 on each side wall, two recesses 2050 and two projections 2051 in the floor, and two recesses 2052 and two projections 2053 in the ceiling. These projections and recesses are sized and positioned to be complementary to the projections and recesses described above for the various grommets. In this embodiment, the shell 2012 has no grooves to receive the lips of the grommets.[000154] FIGS. 43A and 43B illustrate a 2x1 contact insert 2016 that has a similar pattern of projections and recesses to that of the grommet 1820. As can be seen in FIG. 43C, the contact insert 2016 can be mated with a similar contact insert 2016 to form a 2x2 arrangement. Notably; as discussed earlier any combination of contacts can be designed into these insert and any wire to the grommets. FIGS. 44A and 44B show a 1x1 contact insert 2116 that has a similar pattern of projections and recesses to that of the grommets 1920, 1920’. FIG. 45 shows that two contact inserts 2116 can be joined and interlocked together, and can also be joined with the 2x1 contactAttorney Docket No. 1729.40001.WOinsert 2016 to form a 2x2 arrangement. FIG. 46 shows how the 2x2 arrangement of FIG. 45 can be inserted into the shell 2012 to form a connector 2010.[000155] Referring now to FIG. 47, another embodiment of a contact insert, designated broadly at 2116, is shown therein. The contact insert 2116 is a 2x1 contact insert that has two clips 2160, one each on the top and bottom sides of the contact insert 2116. Each of the clips 2160 is attached to the contact insert 2116 via a living hinge 2162. Each clip 2160 has a grip panel 2164 that can be pressed to force the free end of the clip 2160, which includes a hook 2166, to deflect away from the contact insert 2116. The hooks 2166 are configured to engage a feature within a shell of the type described above; squeezing the grip panels 2164 toward each other deflects the hooks 2166 away from the engagement feature of the shell, thereby enabling the contact insert 2116 to be removed easily from the shell.[000156] Referring now to FIGS. 48A-48C, another embodiment of a contact insert, designated broadly at 2216, is shown therein. The contact insert 2216 has an upper projection 2292 with a dovetail profile, but unlike other dovetail-profile projections shown herein, the projection 2216 includes a clip 2294 with an upwardly-facing hook 2295. As shown in FIG. 48C, the clip 2294 can deflect during installation, then recover to engage a feature in the shell 2212.[000157] Referring now to FIGS. 49A and 49B, a connector 2310 has a shell 2312 that holds two 2x3 contact inserts 2316, 2318. However, rather than the contact inserts 2316, 2318 being installed directly in the shell 2312, a retention frame 2340 is used to house and retain the contact inserts 2316, 2318. The retention frame 2340 has nubs 2342 on its side walls that are received in slots 2344 in the shell 2312 to hold the retention frame 2340 in place. By using the retention frame 2340 to hold the contact inserts 2316, 2318, this design eliminates the need for specialized retention features on the contact inserts 2316, 2318 themselves, and instead requires only basic alignment geometry. Because the retention frame 2340 handles the retention of the contact inserts 2316, 2318 and is not required to have any specific orientation (unlike the inserts), it can allow for significantly more design freedom. Additionally, since the retention frame 2340 may be a standardized molded part (like the shell 2312), it can offer higher reliability for any clip-style mechanisms.[000158] FIG. 50A shows a blade 2400 that can be employed to remove a contact insert that is clipped into place in a shell. In essence, the blade 2400 can be slid along a channel thatAttorney Docket No. 1729.40001.WOleads from the exterior of the shell to the clip, then the beveled edge 2402 of the blade 2400 can contact the clip and cause it to deflect and thereby disengage from the shell to enable the contact insert to be removed from the shell. FIG. 50B shows a tool 2450 that includes four contact blades 2400 located at positions that align with clip locations within the shell.[000159] It should be apparent to those of skill in this art that the afore-described connectors can be arranged in a large variety of configurations, and therefore and provide specialized arrangements for whatever connector configuration is desired. Different contact inserts of whatever type may be desired can easily be inserted into a shell, and the different shells themselves are capable of receiving any of the different contact inserts irrespective of their configuration. This provides the manufacturer, a distributor or even an end user with tremendous flexibility in providing specialized connectors for specific applications.[000160] The components discussed above may be manufactured in any manner known to be suitable for such parts. For example, the shell 12, rear shell 22, latch 14, contact inserts 16, 18, grommets 20 and secondary lacking tab 24 may all be formed of polymeric materials and therefore may be formed by injection molding, 3-D printing, machining, and the like. The contacts themselves are typically metallic components and may be formed by machining, casting, stamping, forming or the like.[000161] The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention.

Claims

Attorney Docket No. 1729.40001.WOThat Which is Claimed is:

1. A modular connector, comprising:a shell having a floor, opposing first and second side walls, and a ceiling;a plurality of contact inserts, each of the contact inserts including a generally rectangular main body and one or more contacts contained therein, each of the contact inserts including:at least one first attachment feature mounted on a first wall;at least one second attachment extending mounted a second wall opposite the first wall, the at least one second attachment feature being of a different configuration than the first attachment feature;wherein the shell includes at least one third attachment feature on an inner surface of the first side wall, the at least one third attachment feature configured to complement the at least one first attachment feature; andwherein the shell includes at least one fourth attachment feature on an inner surface of the second side wall, the at least one fourth attachment feature configured to complement the at least second attachment feature.

2. The modular connector defined in Claim 1, wherein the first attachment feature comprises at least one first projection extending from the first wall, the second attachment feature comprises at least one second projection extending from the second wall, the third attachment feature comprises a first recess configured to complement the at least one first projection, and the fourth attachment feature comprises at least one second recess on an inner surface of the second side wall, the at least one second recess configured to complement the at least one second projection.

3. The modular connector defined in Claim 2, wherein a first of the plurality of contact inserts includes a third projection on a third wall and a fourth projection on a fourth wall that is opposite the third wall, and wherein the floor of the shell includes a third recess configured to complement the third projection, and the ceiling of the shell includes a fourth recess configured to complement the fourth projection.Attorney Docket No. 1729.40001.WO4. The modular connector defined in Claim 3, wherein a second of the plurality of contact inserts includes a third projection on a third wall and a fourth projection on a fourth wall that is opposite the third wall, and wherein the floor of the shell includes a third recess configured to complement the third projection, and the ceiling of the shell includes a fourth recess configured to complement the fourth projection.

5. The modular connector defined in Claim 2, wherein the at least one first projection is a plurality of first projections.

6. The modular connector defined in Claim 5, wherein the at least one second projection is a plurality of second projections.

7. The modular connector defined in Claim 1, further comprising a latch pivotally connected with the shell, the latch configured to engage a mating connector and secured a mated condition between the connector and the mating connector.

8. The modular connector defined in Claim 1, further comprising a rear shell mounted to the shell.

9. The modular connector defined in Claim 1, wherein the one or more contacts of the contact inserts are selected from the group consisting of signal contacts, power contacts, data contacts, high speed contact, and combinations thereof.

10. The modular connector defined in Claim 1, wherein a first of the contact inserts includes a contact of a first type, and a second of the contact inserts includes a contact of a second type that differs from the first type.

11. The modular connector defined in Claim 1, wherein a first of the contact inserts includes a plurality of contacts.

12. The modular connector defined in Claim 1, wherein the shell defines a 2x2 connector.Attorney Docket No. 1729.40001.WO13. A modular connector, comprising:a shell having a floor, opposing first and second side walls, and a ceiling;a plurality of contact inserts, each of the contact inserts including a generally rectangular main body and one or more contacts contained therein, each of the contact inserts including:at least one first projection extending from a first wall;two second projections extending from a second wall opposite the first wall, the at second projections being of a different configuration than the first projection;wherein the shell includes at least one first recess on an inner surface of the first side wall, the at least one first recess configured to complement the at least one first projection; and wherein the shell includes two second recesses on an inner surface of the second side wall, the second recesses configured to complement the at least one second projection.

14. The modular connector defined in Claim 13, wherein a first of the plurality of contact inserts includes a third projection on a third wall and a fourth projection on a fourth wall that is opposite the third wall, and wherein the floor of the shell includes a third recess configured to complement the third projection, and the ceiling of the shell includes a fourth recess configured to complement the fourth projection.

15. The modular connector defined in Claim 14, wherein a second of the plurality of contact inserts includes a third projection on a third wall and a fourth projection on a fourth wall that is opposite the third wall, and wherein the floor of the shell includes a third recess configured to complement the third projection, and the ceiling of the shell includes a fourth recess configured to complement the fourth projection.

16. The modular connector defined in Claim 13, wherein the at least one first projection is a plurality of first projections.

17. The modular connector defined in Claim 13, further comprising a latch pivotally connected with the shell, the latch configured to engage a mating connector and secured a mated condition between the connector and the mating connector.Attorney Docket No. 1729.40001.WO18. The modular connector defined in Claim 13, further comprising a rear shell mounted to the shell.

19. The modular connector defined in Claim 13, wherein the one or more contacts of the contact inserts are selected from the group consisting of: signal contacts, power contacts, data contacts, high speed contact, and combinations thereof.

20. The modular connector defined in Claim 13, wherein a first of the contact inserts includes a contact of a first type, and a second of the contact inserts includes a contact of a second type that differs from the first type.

21. The modular connector defined in Claim 13, wherein a first of the contact inserts includes a plurality of contacts.

22. A grommet for a modular connector, comprising:a generally rectangular main body;a plurality of first projections extending from a first edge of the main body; a plurality of second projections extending from a second edge of the main body, the second edge being opposed to the first edge the second projections being complementary to the first projections;a third projection extending from a third edge of the main body; and a fourth projection extending from a fourth edge of the main body that is opposite the third edge;a lip extending around the periphery of the grommet, the lip including discontinuities, such that a first portion of the lip is offset from a second portion of the lip in a thickness dimension of the main body; andwherein the first and second portions of the lip form a double seal when the second edge of a first grommet are interdigitated with the first edge of a second identical grommet.

23. A modular connector, comprising:a shell having a floor, opposing first and second side walls, and a ceiling;Attorney Docket No. 1729.40001.WOa plurality of contact inserts, each of the contact inserts including a generally rectangular main body and one or more contacts contained therein, each of the contact inserts including:at least one first alignment feature mounted on a first wall;at least one first alignment feature mounted on a second wall opposite the first wall; wherein the first alignment feature of the first wall and the first alignment feature of the second wall are configured so that each of the contact inserts has 180 degree radial symmetry;wherein the shell includes at least one third alignment feature on an inner surface of the first side wall, the at least one third alignment feature configured to complement the at least one first alignment feature; andwherein the shell includes at least one third alignment feature on an inner surface of the second side wall, the at least one third alignment feature is configured to complement the at least one first alignment feature.

24. The modular connector defined in Claim 23, wherein each of the contact inserts includes at least one second alignment feature on an upper surface and at least one second alignment feature on a lower surface, wherein the second alignment feature of the lower surface and the second alignment feature of the lower surface are configured so that each of the contact inserts has 180 degree radial symmetry.

25. The modular connector defined in Claim 24, wherein the shell includes at least one fourth alignment feature on an inner surface of the ceiling and at least one fourth alignment feature on the floor, and wherein the at least one fourth alignment feature is configured to complement the at least one second alignment feature.

26. The modular connector defined in Claim 23, further comprising a grommet that has a periphery that matches a periphery of the contact insert.

27. The modular connector defined in Claim 23, wherein the first alignment feature includes a deflectable clip.

28. A modular connector, comprising:Attorney Docket No. 1729.40001.WOa shell having a floor, opposing first and second side walls, and a ceiling;a plurality of contact inserts, each of the contact inserts including a generally rectangular main body and one or more contacts contained therein, each of the contact inserts including:at least one first alignment feature mounted on a first wall;at least one first alignment feature mounted on a second wall opposite the first wall; wherein the first alignment feature of the first wall and the first alignment feature of the second wall;a retention frame, wherein the retention frame is interposed between the plurality of contact inserts and the shell, and wherein the retention frame includes first engagement features that engage with second engagement features on the shell to secure the retention frame in the shell.

29. The modular connector defined in Claim 28, wherein the first and second alignment features are configured so that each of the contact inserts has 180 degree radial symmetry.

30. The modular connector defined in Claim 28, wherein the retention frame includes at least one third alignment feature on an inner surface of the first side wall, the at least one third alignment feature configured to complement the at least one first alignment feature.

31. The modular connector defined in Claim 30, wherein the retention frame includes at least one third alignment feature on an inner surface of the second side wall, the at least one third alignment feature being configured to complement the at least one first alignment feature.

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