Electrical connector with an anti-splay ferrule

An electrical connector includes a female housing configured to include a first mating interface adapted to receive a second mating interface; a male housing configured to include the second mating interface; and at least one first anti-splay ferrule positioned at least one of the female housing and the male housing. An electrical connection is achieved when the first mating interface receives the second mating interface.

BACKGROUND OF THE INVENTION

The present invention is directed to an electrical connector. In the past, electrical connectors, sometimes referred to as FAKRA connectors, have been used to connect multiple coaxial cables. One such connector is illustrated inFIGS. 1(A)-1(F).

As illustrated inFIGS. 1(A)-1(F), the connectors include a male housing108and a female housing100. Ferrules102are positioned adjacent to the male housing108and the female housing100, respectively. Protrusion106on the male housing is adapted to engage latch104in the female housing100.

By way of explanation,FIGS. 1(B) and 1(C)illustrate the connector assembly110in a state of pre-engagement and engagement, respectively.FIGS. 1(D) and 1(F)provide perspective views of the connector assembly110in a state of connection.FIGS. 1(A) and 1(C)illustrate cross-sectional views of the connector assembly110as taken along a midsection, where lines A-A throughoutFIGS. 1(A)-1(F)correspond to each other.

However, several problems exist with the configurations illustrated inFIGS. 1(A)-1(F). For example, it is difficult to guarantee proper alignment of the male housing108and the female housing100. Typically, these electrical connectors are installed on assembly lines, which tend to have limited lighting. Because the connectors illustrated inFIGS. 1(A)-1(F)do not include adequate alignment features, misalignment may often occur, which can result in electrical and mechanical damage to the connector assembly110.

For example, elements112and114(FIG. 1(F)) may be used to provide a visual indication of alignment. However, elements112and114are not easily distinguished on a dimly lit assembly line, and simply provide a visual (not physical) aid to alignment. Although protrusion118may be used by an operator to identify the relative alignment of the female housing100, there is no corresponding alignment feature on the male housing108. As a result, inadequate alignment may occur.

Additionally, ferrules102cause undesirable wear and tear on the coaxial (or other) cables positioned therein. For example, throughout the life of the connector assembly110, the coaxial cables experience friction against the ends of ferrules102. Consequently, the insulation on the coaxial cables may deteriorate and may result in a short circuit, fire, or the like.

As can be seen inFIGS. 1(B),1(C),1(E), and1(F) particularly, space exists between the ferrules102. During normal use, it is quite likely that a user will grasp the end of the ferrules102. Pressure applied at the ends of the ferrules causes the ends to become compressed together. This pressure also causes a corresponding splay of the opposite ends of the ferrules (e.g., at ports140). This corresponding splay often results in misalignment between the ports140of the female housing100and the ports140of the male housing108.

Another problem with the configurations illustrated inFIGS. 1(A)-1(F)is that the latch104is provided at the female housing100. As a result, it is difficult to achieve secure engagement between the female housing100and the male housing108. In the event that the latches104do engage protrusions106, it becomes very difficult to disengage the connection. Effectively, the latch is a “lazy latch,” which means that the latch often fails to return to its original position after disengagement.

Latches104are also subject to significant pressure during normal use. Due to the fragility of the configuration of latches104, they frequently shatter during use. The latches104also fail to properly engage protrusions106, which can result in failed electrical connections.

As illustrated inFIGS. 1(B) and 1(E), male housing108includes pin120, which creates an electrical connection when received in socket126of the female housing100. Conductive body138provides a second area of electrical connection when mated with conductive body142of the male housing108for electrically connecting the outer conductors in the coaxial cables being connected. Insulators124and128prevent undesired electrical contact between the inner and outer conductor.

Female housing100further includes retaining ring134, which applies a resilient force at the mating end of ferrule102. In more detail, when the pin120is received by receptacle126, an outward stress is applied to the ferrule102. Retaining ring134provides a spring-like force at the end of the ferrule102of the female housing100that strengthens the engagement between the female housing100and the male housing108.

SUMMARY OF THE INVENTION

In light of the difficulties described above, the Applicants developed the present invention. To this end, a first non-limiting aspect of the invention provides an electrical connector, including: a female housing configured to include a first mating interface adapted to receive a second mating interface; a male housing configured to include the second mating interface; and at least one first anti-splay ferrule positioned at least one of the female housing and the male housing, wherein an electrical connection is achieved when the first mating interface receives the second mating interface.

Another aspect of the invention provides an electrical connector, including a female housing configured to include a first mating interface adapted to receive a second mating interface; a male housing configured to include the second mating interface; and at least one means for preventing electrical contact positioned at least one of the female housing and the male housing, wherein an electrical connection is achieved when the first mating interface receives the second mating interface.

DESCRIPTION OF THE EMBODIMENTS

In the following description of the exemplary embodiments, like reference numerals refer to like elements throughout.

FIGS. 2(A)-2(F)illustrate several views of the electrical connector according to a first non-limiting embodiment of the present invention. According to the configurations illustrated inFIGS. 2(A)-2(F), it is possible to improve the mating characteristics between coaxial cables. In each of the embodiments described herein, it is possible that the ferrules (e.g., ferrules202) may have different diameters as desired to accommodate different sized coaxial cables. InFIGS. 2(A)-2(F), lines A-A correspond throughout.

To this end, as illustrated inFIGS. 2(A) through 2(F), the connector assembly210includes a male housing208and a female housing200. Ferrules202, which may be made of any suitable material, are positioned adjacent to the male housing208and the female housing200, respectively, coaxial with the end portion of conductive bodies238and222. Ferrules202may be made of a metal, a polymer, or any combination thereof, and preferably include wider anti-splay portions (e.g., flanges)202A. By including these wider portions202A, wear and tear (e.g., wear and tear caused by bending stress) on the coaxial cables (not shown) fed therethrough may be significantly reduced.

As illustrated inFIGS. 2(B) and 2(F), anti-splay portions202A may include beveled inner diameters202B to further reduce bending stress and wear and tear on the coaxial cables. However, other configurations, such as rounded edges on inner diameters202B, are within the scope of the present invention. In addition to reducing damage to the coaxial cables, anti-splay portions202A also reduce the risk that ports280may become misaligned due to pressure applied at the ends of ferrules202. Because anti-splay portions202A generally abut each other, the relative positioning of the ferrules202does not change if a force is applied at or near anti-splay portions202A (for example, when a user grasps either the female housing200or the male housing208).

The connector assemblies210further include protrusion206, which is adapted to engage latch204. As shown inFIGS. 2(B) and 2(E), the latch204is mounted to an outer surface of the female housing200. In other words, the latch204is mounted upside down as compared to the latch104of the background art.

By configuring the female housing to include the latch204as illustrated, the lazy latch problem of the background art is eliminated because the latch may more freely return to its original position. Additionally, fracture of the assembly210during use is reduced. Fewer fractures occur because inverting the positioning of the latch204enables the latch204to be lengthened and widened. This, in turn, reduces the stress on the latch itself. By including gripper portion204A on latch204, secure engagement with protrusion206may be achieved.

Connector assembly210includes keying features212and214, shown inFIGS. 2(D) and 2(F). Because the connector assembly210is often assembled on a dimly lit assembly line, the keying features212and214enable improved alignment between the male housing208and the female housing200. In more detail, keying feature214of the female housing can be divided into two subparts (214A and214B). Subpart214B includes a slot into which keying feature212may be guided. Subpart214A provides a visual indication of alignment, for example with a colored stripe. Thus, as shown inFIGS. 2(D) and 2(F), keying feature212, when engaged, may be contained at least partially within subpart214B and may be visually aligned with keying feature214A.

Additionally, alignment protrusion258may be used to determine the relative alignment of female housing200. It is also possible to include a visual indicator on the keying feature (or elsewhere on the connector assembly210), such as an alignment stripe. Preferably, the alignment stripe may be colored differently than the connector assembly210to enable easier recognition of alignment.

As a further modification, electrical isolation elements may be included in the anti-splay ferrules202. By including an electrical isolation element (e.g., elements202A and202B), it is possible to prevent accidental and/or undesirable electrical contact between elements of the connector assembly210. Although all of the ports280inFIGS. 2(A)-2(F)are illustrated as populated by ferrules202, it is possible to leave one or more ports280unpopulated, as desired.

As shown inFIGS. 2(B) and 2(C), male housing208includes pin220that provides an electrical connection when received by receptacle226. Conductive body222provides an additional electrical connection when engaged with conductive body238for the outer conductors of coaxial cable, and insulators228,230, and242prevent undesired electrical contact between the inner and outer conductive elements.

Retaining ring234may also be provided, as illustrated inFIG. 2(B). Like retaining ring134, retaining ring234provides a more secure engagement between female housing200and male housing208.

FIG. 3provides an enlarged illustration of a male housing according to an aspect of the present invention. The male housing308of this embodiment may be incorporated into any other embodiment of the present invention.

As shown in detail inFIG. 3, the end portions302A of anti-splay ferrules302have larger diameters than the body portions302B. The keying feature320enables improved alignment, as described above with respect to elements212and214ofFIG. 2(E). Keying feature320provides early engagement with the female housing (not shown), and may optionally include an alignment stripe of a desired color to provide a visual indication of engagement. Protrusions306are adapted to engage the latch elements of the female housing (see, e.g.,FIG. 5).

FIG. 4provides another illustration of an exemplary male housing of the present invention. Like the male housing ofFIG. 3, the male housing ofFIG. 4may be incorporated into the connector assemblies of any of the embodiments of the present invention.

As shown inFIG. 4, protrusions406and408may be positioned on both sides of keying feature420. However, alternative configurations of the protrusions406and408are also within the scope of the present invention. For example, it may be desirable to include a third protrusion (not shown), or only one protrusion406or408. Additionally, it is possible not to include any protrusions, if that is desirable for the intended use of the connector assembly.

FIG. 5provides a more detailed illustration of an exemplary female housing500according to the present invention. As shown inFIG. 5, the latch534may be wider than the latches of the background art. This wider latch geometry enables improved alignment and engagement between the female housing500and a corresponding male housing (not shown). As described with respect to the other embodiments, flanges502A (anti-splay portions502A) are configured to reduce wear and tear on coaxial cables, which are provided therein (not shown).

Additionally, the female housing500includes a shrouded mating face526, which enables early alignment between the female housing500and a male housing. Similarly, the enlarged lead chamfer provides a larger target for a corresponding male housing. Finally, tighter interface criteria in the electrical engagement modules532(e.g., the mating ends of ferrules502) enable secure engagement between the female housing500and a male housing. Due to the tighter interface criteria, less force is required to achieve a secure electrical engagement.

The male housing shown inFIG. 3and the female housing shown inFIG. 5, respectively, also include lengthened ferrules302and502. By increasing the length of the ferrules302and502, it may be possible to further reduce strain and wear and tear on the connector assemblies when in use.

FIG. 6provides another illustration of a connector assembly according to the present invention. As shown inFIG. 6, female housing600is configured to mate with male housing610. To enable a secure engagement of the housings, female housing600is provided with shrouded mating face618, as well as alignment guides612and614. The alignment guide616, which may be configured to protrude from the male housing610, is adapted to engage alignment guide614. Alignment guides612and616also provide a visual indication of alignment due to their different coloring relative to the female housing600and the male housing610.

Ferrules602, as described above with respect to other embodiments, are shown as being of different sizes. However, it is possible to provide ferrules having identical sizes, if desired. Additionally, it is possible to have the ferrules of the female housing be of different sizes with respect to each other while the ferrules of the male housing may be of the same size relative to each other and/or relative to at least one of the ferrules of the female housing. Of course, other configurations of the ferrule sizes are also within the scope of the present invention. Ferrules602also include beveled edges602B on the inner diameters of the flanges602A.

If separation of the female housing600and the male housing610is desired after the housings have been connected, it is possible to press latch releases620and/or622. Once the latch releases have been pressed, the latches disengage from protrusions624on the male housing610. While two latch releases and two protrusions are illustrated inFIG. 6, other quantities and/or positions of the latch releases and protrusions are within the scope of the present invention.

FIG. 7(A)provides a detailed view of the insulator230, which may be added to improve axial alignment to reduce the concentricity of the center contact due to errors in cable preparation, variations in dielectric diameters, and component tolerances.FIG. 7(B)provides a schematic illustration of the ferrule202, which more clearly illustrates the relationships between insulator230, conductive body222, and pin220.

Of course, the location of insulator230is not limited to the location shown inFIGS. 7(A) and 7(B). Preferably, the insulator is coaxial to the pin. However, the insulator is not limited in axial position.

FIGS. 8(A)-8(C)provide additional illustrations of the female housing latch geometry. As these figures illustrate, latch804is mounted to an exterior surface of the female housing. Like the other embodiments described above, alignment features858and860enable improved alignment of the female housing with a male housing (not shown) during connection of the assemblies.

FIG. 9(A)provides a more detailed illustration of ferrule202in female housing200. As shown inFIG. 9(A), retaining ring234is positioned at or near an end of the mating end of the ferrule202. However, other suitable positions of the retaining ring are within the scope of this invention.

Additionally, conductive body238provides an electrical connection between the coaxial cables (not shown) when the female housing200is mated with a corresponding male housing. Receptacle226, made of a conductive material, provides a second electrical connection between the coaxial cables.

As shown inFIG. 9(B), the mating end290of ferrule202may be flexible. This flexibility may be achieved, for example, by making mating end290of a non-contiguous material.

FIG. 10(A)provides yet another illustration of the connection elements of male housing208. Because the elements ofFIG. 10(A)were described in detail above, a detailed description herein is omitted.FIG. 10(B)provides a perspective view of ferrule202of the male housing208.

FIGS. 11(A)-11(D)illustrate yet another embodiment of the present invention. The female housing of this non-limiting embodiment may be equally substituted into any of the other embodiments described herein.

As shown inFIG. 11(A), which shows a rear view of the female housing1100, the female housing1100includes latches1104, as well as alignment guides1114A and1158. Alignment feature1114A is also illustrated inFIG. 11(D), as is alignment groove1114B.

It is important to note that any of the ports may be populated or not populated, as desired. For example, port1184is shown unpopulated, while port1180(e.g., where the mating end of ferrule1102is positioned) is shown populated.

As shown inFIG. 11(C), an additional alignment feature may be provided in the female housing. Alignment feature1192is adapted to prevent misalignment of the ferrules1102during mating with a male housing. In more detail, the alignment feature1192may be a plastic protrusion or configuration in the interior of the female housing1100. Because the protrusion must be properly aligned with the corresponding surface of the male housing, it is not possible to improperly mate the female housing1100with a male housing. In other words, if the female housing1100is not in proper alignment with the male housing during mating, the alignment feature1192will prohibit the female housing1100from connecting to the male housing.

Additionally, the height and/or width of the alignment feature1192may be set such that the mating ends of ferrules1102do not accidentally contact an improperly aligned ferrule from a corresponding male housing. In this way, it is possible to prevent damage to the connection elements.

FIGS. 12(A)-12(E)provide additional partial views of an exemplary male housing1208according to the present invention. The male housing1208may be incorporated into any other embodiment discussed herein.

As shown inFIG. 12(A), the female housing includes three ports,1280,1282, and1284. A view from the opposite end of the ports is shown inFIG. 12(C). Of course, more or less ports may be included, as desired, and any combination of ports may be populated or unpopulated. In this non-limiting example, port1282is shown unpopulated.

Male housing1208may also include alignment guide1212, which provides a visual indication of successful alignment when mated with a corresponding female housing (not shown). Alignment feature1292may also be included, as illustrated inFIG. 12(C). Alignment feature1292may include, for example, a plastic protrusion on the male housing1208. Of course, other materials and methods of implementing alignment feature1292are also within the scope of this invention. The height and other dimensions of the alignment feature1292may be selected such that the mating end1270of the ferrules1202is not damaged if improper alignment occurs. In other words, alignment feature1292prevents engagement of the male housing1208with a female housing, even if excessive force is applied.

Like the embodiments described above, ferrules1202preferably include flanges1202A and beveled inner diameters1202B, as shown inFIG. 12(B). Mating end1270of ferrule1202is illustrated inFIG. 12(E). Additional alignment features1210provide a tactile and visual indication of proper alignment of the male housing1208.

Pin1220provides a first electrical connection between male housing1208and a female housing. Conductive body1222provides a second electrical connection between male housing1208and a female housing. Insulators1230and1224prevent undesired electrical contact between elements of the male housing.

FIGS. 13(A)-13(D)provide illustrations of exemplary key codes according to the background art. In more detail,FIGS. 13(A) and 13(B)depicted female housings1342and1340, respectively. As shown inFIGS. 13(A) and 13(B), the female housings include latches1326, alignment guides1312and1318, and ports1324. Ports1324may be populated or unpopulated, as desired. Additionally, keys1320and1322are present to prevent misalignment with male housings1344and1346, respectively. However, keys1332and1330in male housings1344and1346(shown inFIGS. 13(C) and 13(D)) may be overcome by brute force and misalignment may occur. In other words, it is possible to improperly mate key1320with key1330and to improperly mate key1332with key1322. Male housings1344and1346each include ports1324(which may be populated or unpopulated as desired), protrusions1306adapted to engage latches1326, and alignment guides1304.

FIGS. 14(A)-14(D)illustrate male and female housings according to a non-limiting example of the present invention. As shown inFIGS. 14(A) and 14(B), female housings1442and1440include keys1420and1422, respectively. Male housings1444and1446include corresponding keys1432and1430, respectively. Through the improved configurations ofFIGS. 14(A)-14(D), misalignment achieved by brute force is prevented.

Male housings1444and1446further include ports1424(populated or unpopulated as desired), protrusions1406, and alignment guides1412. Female housings1442and1440each include ports1424(also populated or unpopulated as desired), latches1426, which are adapted to engage protrusions1406of the male housings1444and1446(respectively), and alignment guides1418.