Abstract:
A connector, method of connecting, and connector assembly preventing potting from disrupting the physical and electrical connection of a mated electrical connector assembly that can be connected and/or disconnected without cutting wires and with a single hand.

Description:
FIELD OF THE INVENTION 
   The present invention is directed to an electrical connector assembly. In particular, the present invention is directed to an electrical connector and conductor connecting method that prevents potting from disrupting the physical and electrical connection of a mated electrical connector assembly. 
   BACKGROUND OF THE INVENTION 
   Connector assemblies typically include a plug connector having a plug housing containing pin contacts mated to a receptacle connector having a receptacle housing containing socket contacts. The plug housing and the receptacle housing are physically mated, which physically and electrically connect the pin and socket contacts to form an electrical connection. 
   Such connectors are used for fluorescent ballast light applications. In these application, a plug connector and a receptacle connector are mated by use of tools and/or require more than one hand. The use of tools and/or multiple hands is inconvenient and undesirable. 
   Upon being mated, these connectors may be contained within a ballast box. Often, a fluid which converts into a foam or solid is introduced into these boxes as potting. This foam or solid prevents the mated connectors from being separated without cutting the wires. 
   Therefore, there is an unmet need to provide a connector and connecting method that allows the physical and electrical connection of a mated electrical connector assembly to occur outside of the potting region and can be connected and/or disconnected without cutting wires that does not require tools and may be connected and/or disconnected with a single hand. 
   SUMMARY OF THE INVENTION 
   This invention provides a connector and method of connecting that prevents potting from disrupting the physical and electrical connection of a mated electrical connector assembly but can be connected and/or disconnected without cutting wires and with a single hand. 
   According to an embodiment, a connector including a housing including a potting shield, at least one conductor configured to extend through the housing, and wherein the housing is configured to be mounted to a PCB, the PCB being configured to be positioned in a ballast, thereby permitting the at least one conductor to extend through the PCB and through the ballast is disclosed. 
   According to another embodiment, a conductor connecting method including providing a connector including a housing with a potting shield, at least one conductor configured to extend through the housing, and wherein the housing is configured to be mounted to a PCB which is configured to be positioned in a ballast thereby permitting the at least one conductor to extend through the PCB and through the ballast is disclosed. 
   According to another embodiment, a connector assembly including a housing including a potting shield, at least one conductor configured to extend through the housing, a corresponding connector, and a PCB configured to be positioned in a ballast, wherein the housing is configured to be mounted to the PCB thereby permitting the at least one conductor to extend through the PCB and through the ballast is disclosed. 
   An advantage of the present invention is a connector and connecting method that can be connected and/or disconnected without cutting wires. 
   A further advantage of the present invention is a connector and connecting method that does not require tools and may be connected and/or disconnected with a single hand. 
   A further advantage of the present invention is a connector and connecting method that prevents fluid and/or foam from disrupting the physical and electrical connection of a mated electrical connector assembly. 
   A further advantage of the present invention is a connector and connecting method that provides a safe means of replacing florescent ballasts in the event of a failure. 
   Further aspects of the method and system are disclosed herein. The features as discussed above, as well as other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates a top perspective view of an exemplary embodiment of a connector mounted in a ballast. 
       FIG. 2  illustrates a top reverse perspective view of the embodiment illustrated in  FIG. 1 . 
       FIG. 3  illustrates a bottom perspective view of an exemplary embodiment of a connector mounted to a PCB. 
       FIG. 4  illustrates a perspective view of an exemplary embodiment of a connector. 
       FIG. 5  illustrates a reverse perspective view of the other side of the embodiment in  FIG. 4 . 
       FIG. 6  illustrates an exploded perspective view of an exemplary embodiment of a connector. 
       FIG. 7  illustrates a sectioned view of an exemplary embodiment of a connector. 
       FIG. 8  illustrates a top perspective view of an exemplary embodiment of a connector. 
       FIG. 9  illustrates a top reverse perspective view of an exemplary embodiment of a connector. 
   

   Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts. 
   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the invention is 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. 
     FIGS. 1 and 2  illustrate an exemplary embodiment of a connector  102  positioned in a ballast  104 . As shown in  FIG. 1 , the connector  102  includes a receptacle end  106 , a housing  108 , and a latching mechanism  110 . As shown in  FIG. 2 , the connector  102  further includes a potting shield  112 , at least one conductor  114 , and a stabilizing member  116 . The embodiment illustrated in  FIGS. 1 and 2  also depicts the connector  102  being mounted to a printed circuit board (“PCB”)  118 . 
   In the embodiment illustrated in  FIGS. 1 and 2 , the connector  102  is positioned within the ballast  104  on top of a PCB  118 . The receptacle end  106  of the connector  102  extends from within the ballast  104  to outside of the ballast  104 . This receptacle end  106  of the connector  102  is specifically configured to mate with existing connectors. Specifically, this connector is configured to mate with a connector such as the connector disclosed in U.S. patent application Ser. No. 11/555,941, filed Nov. 2, 2006, which is incorporated by reference in its entirety. 
   The housing  108  of the connector  102  is depicted in the embodiments illustrated by  FIGS. 1 and 2  as a polyamide molded housing. In other embodiments, other hard and non-conductive plastics, as would be understood by those skilled in the art, are used to create the housing  108 . In the embodiment illustrated in  FIGS. 1 and 2 , the housing  108  is one integral piece but, in other embodiments, includes multiple pieces affixed to each other. 
   The potting shield  112  is a flange-like structure extending around the exterior portion of the housing  108  of the connector  102 . The potting shield  112  is specifically configured to abut the wall  120  of the ballast  104 . As seen in  FIG. 3 , the potting shield  112  includes a substantially planar bottom surface  304  acting as an aligning edge and as a guiding means. In the embodiment illustrated in  FIGS. 1 and 2 , the potting shield  112  is depicted as having a semi-circular top surface  122 . In another embodiment, a grommet may be included to seal any openings where potting could escape. In other embodiments, the potting shield  112  includes a substantially planar top surface. In one embodiment, the potting shield  112  includes a top surface that becomes flush with the top surface of the ballast  124  when the connector  102  is fully inserted in the ballast  104 . 
   The potting shield  112  is configured to act as a physical barrier preventing potting inserted into the ballast  104  from exiting out of the ballast  104 . Potting is a substance used in a process of filling a complete electronic assembly with a compound that is solid or becomes solid. The potting is used for resistance to shock, resistance to vibration, and exclusion of moisture and corrosive agents. Often, thermosetting plastics are used as potting. The potting shield  112  is further configured to serve as a locating device for the ballast  104  and the PCB  118 . 
   The embodiment illustrated in  FIG. 2  depicts the at least one conductor  114 . The embodiment depicted includes a second conductor  114  housed between the stabilizing members  116  beneath the housing  108  of the connector  102 . The at least one conductor  114  extends through the PCB  118  on one end and through the housing  108  to the receptacle end  106  of the connector  102  where the conductor  114  is in electrical communication with the at least one contact  302  which is configured to mate with a corresponding connector. 
   As depicted in the embodiment illustrated in  FIGS. 1 and 2 , the stabilizing member  116  is a horizontal member of cuboid geometry configured to abut the PCB  118  and act as a means of preventing the connector  102  from becoming dislodged. In the embodiment illustrated by  FIGS. 1 and 2 , there are two stabilizing members  116  located on opposite sides of the connector  102  within the ballast  104 . The stabilizing members  116  are depicted as integral with the housing  108  of the connector  102 . In other embodiments, the stabilizing members  116  are separate from the connector  102  and attached to the connector  102 . In  FIGS. 1 and 2 , the stabilizing members  116  are depicted as the same material as the connector  102 . In other embodiments, the stabilizing member  116  are comprised of different materials. Another function of the stabilizing member  116  is that the stabilizing members  116  partially protect the conductor  114  from being damaged. The stabilizing members  116  provide this protection by acting as a physical barrier between the conductor  114  and the areas surrounding the connector  102 . The stabilizing members  116  also provide features permitting board locks  602  to be inserted into the stabilizing member  116  thereby securing the connector to the PCB  118  prior to soldering or other affixing. 
     FIG. 3  illustrates an exemplary embodiment of a connector  102  mounted to a PCB  118 . As depicted in  FIG. 3 , the receptacle end  106  of the connector  102  is specifically configured to mate with corresponding connectors by means of the latching mechanism  110 . The receptacle end  106  includes at least one opening arranged and disposed within the receptacle end  106  to permit a contact  302  to be housed within the housing  108 . In the embodiment illustrated in  FIG. 3 , the receptacle end  106  includes two contacts  302 . In other embodiments, more or fewer contacts  302  are included. The contact  302  in the embodiment illustrated in  FIG. 3  is comprised of copper alloy tin plating over a nickel inside. As will be understood by those skilled in the art, in other embodiments, the contact  302  material may be comprised of other conductive materials. 
   The embodiment illustrated in  FIG. 3  also depicts the substantially planar bottom surface  304  of the potting shield  112 . The substantially planar back surface  304  is an embodiment of the aligning edge providing location for proper placement of the connector  102  in relation to the PCB  118 . In the embodiment illustrated in  FIG. 3 , the flat bottom surface  304  is integral with the potting shield  112 . In another embodiment the potting shield  112  is a separate piece that is configured to be attached to the housing  108 . In yet another embodiment, the potting shield  112  is directly attached to the ballast  104  thereby permitting the connector  102  to be inserted into the potting shield  112 . 
   As illustrated in the embodiment of the connector  102  in  FIG. 3 , the connector  102  further includes surface mounted hold-downs  306 . The surface mounted hold-downs  306  extend from the stabilizing members  116  of the housing  108  of the connector  102  through the PCB  118 . As illustrated in  FIG. 3 , in one embodiment, the surface mounted hold-downs  306  protrude through the PCB  118  permitting the surface mounted hold-downs to be soldered, welded, or flattened thereby affixing the connector  102  to the PCB  118 . 
     FIGS. 4 and 5  illustrate an exemplary embodiment of a connector  102 . In  FIGS. 4 and 5 , the latching mechanism  110  is depicted as separate from the potting shield  112 . The distance of a slot  402  between the latching mechanism  110  and the potting shield  112  corresponds to the thickness of the wall  120  on the ballast  104  (shown in  FIG. 1 ). In the embodiment illustrated in  FIGS. 4 and 5 , the slot  402  is slightly larger than the thickness of the wall  120  (shown in  FIG. 1 ). In another embodiment, the latching mechanism  110  is attached to the potting shield  112  but the potting shield  112  extends further from the housing  108  than the latching mechanism  110  thereby permitting the latching mechanism  110  to abut the wall  120  of the ballast  104  (shown in  FIG. 1 ) while permitting the potting shield  112  to act as a physical barrier surrounding the interface between the ballast  104  and the connector  102 . 
     FIG. 6  illustrates an exploded perspective view of an exemplary embodiment of a connector  102 . In  FIG. 6 , the stabilizing member  116  is depicted as configured to permit a board lock  602  to be inserted into the stabilizing member  116 . The board lock  602  is configured to be inserted into the PCB  118  (not shown in  FIG. 6 ). The board lock  602  permits the connector  102  to be secured upon being positioned in the ballast  104  and/or on the PCB  118 . The board locks  602  also act as a guide for positioning the connector  102  properly on the PCB  118 . In the embodiment illustrated in  FIG. 6 , the board locks  602  also act as the surface mounted hold-downs  306 . In other embodiments, the board locks  602  are separate from the surface mounted hold-downs  306 . 
   The embodiment illustrated in  FIG. 6  also depicts the contacts  302  removed from the receptacle end  106 . In the embodiment illustrated, the contacts  302  are in electrical communication with the conductor  114 . The conductor  114  illustrated in  FIG. 6  are the same conductor  114  that extend through the housing  108  of the connector  102  where they bend and then extend between the stabilizing members  116  and through the PCB  118 . Those skilled in the art will understand that the contacts  302  can be replaced with sockets corresponding to contacts on another connector. 
     FIG. 7  illustrates a sectioned view of an exemplary embodiment of a connector  102  along a central axis. The sectioned view illustrates the conductor  114  extending through the housing  108 . As a sectioned view along a central axis,  FIG. 7  only shows one stabilizing member  116 ; however, in the embodiment depicted in  FIG. 7 , two stabilizing members  116  are included. 
     FIGS. 8 and 9  illustrate an exemplary embodiment of the connector  102 . As shown in  FIG. 8 , the connector  102  includes the receptacle end  106 , the housing  108 , the latching mechanism  110 , the potting shield  112 , the at least one conductor  114 , and the stabilizing member  116 . In the embodiment illustrated in  FIGS. 8 and 9 , the connector  102  may be positioned within the ballast  104  (not shown in  FIGS. 8 and 9 ) on top of a PCB  118  (not shown in  FIGS. 8 and 9 ). The receptacle end  106  of the connector  102  is specifically configured to mate with existing connectors. The potting shield  112  includes the substantially planar bottom surface  304  acting as an aligning edge and as a guiding means. 
   The embodiment illustrated in  FIGS. 8 and 9  depicts the at least one conductor  114  including three conductors  114  extending from the receptacle end  106  through the housing  108  to beneath the housing  108  of the connector  102 . In other embodiments, any number of conductors  114  may be included. As depicted in the embodiment illustrated in  FIGS. 8 and 9 , the stabilizing member  116  is a horizontal member of cuboid geometry configured to abut the PCB  118  and act as a means of preventing the connector  102  from becoming dislodged. In the embodiment illustrated by  FIGS. 8 and 9 , there is one stabilizing members  116  located at the bottom of the housing  108  configured to abut the ballast  104 . In the embodiment illustrated by  FIGS. 8 and 9 , the stabilizing member  116  houses two of the conductors  114  and is integral with the housing  108  of the connector  102 . As mentioned above, another function of the stabilizing member  116  is that the stabilizing member  116  partially protects the conductors  114  from being damaged. The stabilizing member  116  depicted in  FIGS. 8 and 9 , provides this protection by acting as a physical barrier housing two of the three conductors  114 . In the embodiment depicted in  FIGS. 8 and 9 , the stabilizing member  116  does not provide the same protection of the third conductor  114 . Although not further described, other embodiments including features and elements described above may be included in the embodiment illustrated in  FIGS. 8 and 9 . 
   While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.