Overmolded shielded connector

Abstract: The shield covers (22,24) of an overmold shielded electrical connector (10) have pivot detents (58,60) stamped into their surfaces to provide a point for the shield halves to rotate on the center dielectric (27) with a lever type action. When fully closed, the lever action assures that the cover tabs (62) of the shield members (22,24) securely contact the connector hell (16,18) and maintain a positive ground.

Description: This invention relates to a shielded electrical connector comprising an insulative housing and a conductive shell according to the preamble of claim 1 and a shield system according to the preamble of claim 9. A shielded electrical connector of this type is already known from US-A-4,689,723. This known electrical connector comprises shield means designed as stamped and formed metal members having hooked gripping tines along the forward edge thereof that engage recesses of a rear shell portion by means of an interference fit, when that shield means are rotated about said tines into engagement with said shield. A similar shielded connector is further disclosed in US-A-4,585,292. Generally, shielded electrical connectors are necessary in the telecommunications and computer industry to provide a means for shielding electrical connections from external electromagnetic signals and to prevent the systems which use the connections from emitting electromagnetic signals. The connectors provide a means for continuing the shielding of a shielded cable either to another shielded cable or to an electronic device. The use and transmission of high frequency electrical signals necessitates the need for shielded electrical connections. High frequency electromagnetic signals are susceptible to interference from other undesirable electromagnetic signals. In addition, these signals also naturally generate unwanted electromagnetic signals of their own which may interfere with other electronic devices. Electromagnetic shielding is generally required to satisfy United States Federal Communication Commission standards which place limits on the emission of interfering electromagnetic signals. The use of a grounded continuous metal shield which surrounds the electrical wiring, cable or electronic device is the most effective way to minimize these undesirable effects and satisfy the standards. Furthermore, shielded electrical connectors are necessary to maintain the integrity of a shielded system from one device to another device. It is the object of the present invention to provide an improved shielded electrical connector which assures a positive pressure ground connection between the forward end of the shield halves and the metal shell of the connector. This object is accomplished by means of a connector of the type indicated at the outset and being characterized in that said insulative housing and said shield means include engaging portions which engage to form a fulcrum outboard of said contact portion of said shield means and that said engaging portions forming a fulcrum include protruding portions of said shield means or of said insulative housing, whereby said contact portion of said shield means is rotated upward into contact with said overlying portion of said shell as said shield means is assembled over said insulative housing by such pivotal motion. Thus, the subject matter of the present invention is an overmolded shielded electrical connector which maintains a positive electrical connection between the overmold shield covers and the connector shell. The shielded electrical connector consists of an electrical connector, first and second metal shells and a pair of metal shields. The connector has an insulative housing with a plurality of terminal passages which contain pin or socket contacts. The front shell has an integral metallic shroud which encloses the forward end of the insulative housing. The rear shell also defines a cavity which receives the rear portion of the insulative housing and has a flange with recesses along the rear edge of the shell. The shield members have a generally planar primary wall with integral side walls. The forward edge of each shield member has engagement lip means designed to engage beneath an edge or lip of the rear shell. The rear of the shield terminates in a cable exit passage configuration. Fulcrum means are provided to serve as pivots for the shield members to rotate on the dielectric housing with a lever type action as these members are mated. When the shield members are fully closed, the lever action assures that the lips of the shield halves securely contact overlying portions of the connector shell and provide a positive electrical connection. In a preferred embodiment pivot detents are formed in the shield members and rest on the center dielectric housing to establish a fulcrum for these shield members which thereby act as simple levers. When the shield members are rotated into their seated positions, slightly before the shield members reach a fully closed position the pivot detents engage the center dielectric housing in resilient interference such that a small force must be applied on the rear of the shield members to overcome the interference. When this force is applied, the forward edge and lips of the shield members securely engage overlying portions of the connector shell. Once the shield members are fully seated and mated, the loaded condition of the simple lever action assures the electrical continuity between the shield members and the connector shell. For ease of manufacturing, the shield members may be complementary mateable halves and may be held closed by a set of complementary interlocking detents and protuberances to form the shield cover. It is an advantage of this invention that it provides overmolded shielded electrical connectors with a solderless positive electrical connection which is achieved by pivoting the shield members on the dielectric housing and into forceful engagement with a shell of the connector in the course of assembly. It is a further advantage that the invention provides an improved interlocking shield assembly on electrical connectors which biases the dielectric, the connector shells and the shield member into fixed predetermined relationships between one another. It is a specific advantage of this invention that it achieves the solderless positive electrical connection by placing pivot detents on the surfaces of mating shield members so that the cover members rotate on the dielectric housing with a lever type action as the cover members are moved to their assembled positions. Other objects, advantages and features of the present invention will become apparent upon reading the following detailed description and appended claims, and upon reference to the accompanying drawings. For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings, and described below by way of examples of the invention. In the drawings: FIG. 1 is an exploded perspective view of one embodiment of a shielded connector assembly employing the invention showing two mateable cover halves. FIG. 2 is a view similar to FIG. 1 showing the subject connector in a partially assembled condition with only one shield member exploded therefrom. FIG. 3 is an illustration of an assembled connector. FIG. 4 is a partially schematic sectional view of the shielded electrical connector taken along line 4-4 of FIG. 3. FIG. 5 is a perspective view of a second embodiment of a shielded connector assembly employing teachings of the invention, showing the connector in a partially assembled condition with only one shield member exploded therefrom. FIG. 6 is a partially schematic sectional view of the shielded connector taken along line 6-6 of FIG. 5. FIG.7 is a perspective view of the shielded electrical connector after the overmolding operation. It should be understood that the drawings are not necessarily to scale and that an embodiment is sometimes illustrated in part by schematic and fragmentary views. In certain instances, details of the actual structure which are not necessary for an understanding of the present invention may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. Referring to FIGS. 1-4, an overmolded shielded electrical connector is indicated generally by the reference numeral 10. The shielded electrical connector 10 consists of an electrical connector 14, first and second metal shells 16, 18 and a metal shield formed by a pair of metal shield members 22, 24. As shown in FIG. 4, the connector 14 has an insulative or dielectric housing 27 with an integral peripheral flange 29 and a front mating portion 30A presenting a front face 31A and a rear or tail portion 30B presenting a rear face 31B with a plurality of terminal passages 32 therethrough. Each passage 32 has a suitable pin socket contact 33 mounted therein, used to terminate the respective conductors of cable 38. (See FIG. 2) The only differences between the illustrated female connector version of the present invention and a male version are that the conductors of cable 38 would terminate to pin contacts rather than socket contacts and the contacts would include pins protruding from front face 31A for mating with the socket contacts and a surrounding front shell portion for sliding over and contacting the front shell 16 in a conventional manner. The metal shells 16 and 18 are each integral stamped and formed metal members. The front shell 16 has mounting apertures 40 and gripping lugs 42 and is received against the front surface of flange 29. The front shell 16 has an integral metallic shroud enclosing the forward end of the housing 27. The metallic shroud provides a continuation of the metal shell shielding and conductive contact from one connector to another when two connectors are mated as noted above. The rear shell 18 has matching apertures 43 which align with apertures 40 of front shell 16 and recesses which receive lugs 42 to secure the front and rear shells together. The rear shell 18 also defines a cavity which receives the flange portion 29 of the housing 27 and has a flange 44 with an opening 44A through which the tail portion 30B is received. The inner edge of the flange opening provides access spaces or slots 44B along the outer wall of tail portion 30B and is formed with a plurality of inwardly opening edge recesses 45. The connector portion 14 is assembled in the usual manner by combining shells 16 and 18 and connecting terminals to their respective wires from the cable 38. The shield members 22 and 24 are complementary to one another and will be referred to herein as top and bottom members solely for convenience. The top shield member or cover 22 is an integral stamped and formed metal member having a generally planar wall 46 with side walls 48 and 50. These side walls extend along the forward as well as the end portions and the angled portion of the connector, see, e.g., the complementary walls of the lower connector shown in FIG. 1. The planar wall 46 has a transverse embossment 52 and diverging embossments 54 and 56 with stamped inwardly protruding fulcrum detents 58 and 60. The forward edge of each shield member has engagement lips 62 while the rear of the shield terminates in a semicircular cable exit portion 66. Additionally, the shield member 22 may contain at least one pressure relief means 68 and at least one overmold grip means 72. In this embodiment, the pressure relief means 68 is a hole or aperture in the shield. Furthermore, the angled portions of the side walls have latching apertures (not shown). In this particular embodiment, the latching apertures are square in configuration. The latching apertures will engage latching lugs on the bottom shield member to hold the shield halves together after the shields are assembled, in a known manner. The overmold grip means 72 are located on the planar wall 46 near the engagement lips 62. The grip means 72 are upwardly protruding embossments which are formed so that a majority of their peripheral surface is free from the adjacent wall 46 except for the connecting or hinge portion of the grip means 72. The purpose of the grip means 72 is to allow a small amount of overmold material to flow into the shield cavity. After the overmold material has hardened, the grip means will prevent the overmold material from being pulled away from the shield members. The bottom shield member 24 is similar to shield 22 and includes the inwardly protruding stamped pivot detents 74 and 76, a pressure relief means 78, a first transverse embossment 79, and a second embossment 80 located on planar surface 82. Latching lugs 84 are located on side walls 86. The latching lugs 84 are formed so that they protrude outwards away from the side wall of the shield. In another embodiment, the latching lugs are formed so that a majority of their peripheral surface is free from the adjacent side wall except for the connecting or hinge portion of the latching lug. The operation of the shields 22 and 24 will be discussed by describing the operation of shield 22 since both shields operate in a similar manner. Referring to FIGS. 1 and 4, the lips 62 of the shield 22 are extended through the slot space within opening 44A, between the inner edge of the flange 44 and the tail portion of the dielectric housing 30B. In particular, the sectioned lips or tines may be hooked into the recesses 45 of the rear shell 18. This initial insertion typically occurs with the shield member tilted outward relative to the adjacent surface of tail portion 30B and the cable 38 to facilitate the insertion. Thereafter, the shield member is rotated inward, towards the cable 38, until the pivot detents 58 and 60 contact the dielectric housing 27. Further inward movement of the outer or distal end portion of the shield member results in pivotal movement of the shield about the fulcrum established by the engagement of the detents with the dielectric housing. Thereby, the further inward movement of the distal end portion causes concomitant outward movement of the lip portions beneath the edge of opening 44A. The relevant dimensions, including the height of the insertion space, the effective thickness of the shield metal and the height of the protruding fulcrum detents is such that the pivot detents cause the tines 62 of the shield 22 to contact the shell 18 and oppose further downward rotation of the shield 22, preferably before the shield member reaches its fully seated or closed position of FIG. 3. One particular embodiment of this invention has the following dimensions: the height of each insertion space 44B, i.e., the distance between tail portion of the dielectric housing 30B and the inwardly facing surface 87 of recess 45 is at least 0.76 mm (.030 inches); the thickness 88 of the shield members 22,24 is 0.5 mm (.020 inches) and the height 89 of the fulcrum detents 58,74 is at least 0.254 mm (.010 inches). The forward edge and cover tabs of the shield halves thus normally engage the shell in resilient interference such that a downward force must be applied to the distal portion of the shield 22 to completely close the shield. The shield member 22 acts as a lever and the pivot detents 58 and 60 act as a fulcrum to provide a lever type action. When the downward force is applied, the pivot detents force the engagement lips upwards against the engaged shell and provide positive engagement between the shield and the shell. This positive engagement assures an electrical connection between the shield and the shell. When fully closed, the shield 22 is in a loaded condition which assures that the shield 22 securely contacts the shell 18 at all times under all circumstances. The resulting clamping action also fixes the connector housing 27 against being easily shifted or moved relative to the shell or the shield. A second embodiment of the shielded connector is shown in FIGS. 5 and 6. In this particular embodiment, the shielded connector is similar to the shielded connector in FIGS. 1-4 except that a fulcrum or pivot means 90 are located on the upper and lower surfaces 98 and 100 of the tail portion of the dielectric housing 30B. In addition, the shield members 122, 124 do not have the fulcrum detents 58, 60, 74 and 76 as shown in the shielded connectors in FIGS. 1-4. The fulcrum means 90 are outwardly protruding embossments which extend upwardly away from the upper and lower surfaces 98 and 100 of the dielectric housing. In this particular embodiment, the upper surface 98 has two embossments and the lower surface 100 has two additional embossments. Referring to FIG. 6, the embossments are located on the dielectric housing 30B between the flange 29 and the rear face 31B of the housing. However, the number and location of the embossments can vary depending upon the particular connector design. For example, in a small electrical connector which only has nine electrical contacts 33, a single fulcrum embossment 90 may be located in the center of both the upper and lower surfaces 98 and 100 of the dielectric housing. The operation of the shields 122 and 124 will be discussed by describing the operation of shield 122 since both shields operate in a similar manner. Referring to FIGS. 5 and 6, the lips 162 of the shield 122 are extended through the slot space within opening 44A, between the inner edge of the flange 44 and the tail portion of the dielectric housing 30B. In particular, the sectioned lips or tines may be hooked into the recesses 45 of the rear shell 18. This initial insertion typically occurs with the shield member tilted outward relative to the adjacent surface of tail portion 30B and the cable 38 to facilitate the insertion. Thereafter, the shield member 122 is rotated inward, towards the cable 38, until the shield member 122 contacts the fulcrum means 90 on the dielectric housing 27. Further inward movement of the outer or distal end portion of the shield member 122 results in pivotal movement of the shield about the fulcrum established by the engagement of the shield with the fulcrum means 90 on the dielectric housing. Thereby, the further inward movement of the distal end portion causes concomitant outward movement of the lip portions beneath the edge of opening 44A. The relevant dimensions, including the height of the insertion space, the effective thickness of the shield metal and the height of the protruding fulcrum means 90 is such that the fulcrum means 90 cause the tines 62 of the shield 122 to contact the shell 18 and oppose the downward rotation of the shield 122, preferably before the shield member reaches its fully seated or closed position. The forward edge and cover tabs of the shield members thus normally engage the shell in resilient interference such that a downward force must be applied to the distal portion of the shield 122 to completely close the shield. The shield member 122 acts as a lever and the fulcrum means 90 act as a fulcrum to provide a lever type action. When the downward force is applied, the fulcrum means 90 force the engagement lips upwards against the engaged shell and provide positive engagement between the shield 122 and the shell 18. This positive engagement assures an electrical connection between the shield and the shell. When fully closed, the shield 122 is in a loaded condition which assures that the shield 122 securely contacts the shell 18 at all times under all circumstances. The resulting clamping action also fixes the connector housing 27 against being easily shifted or moved relative to the shell or the shield. Referring to FIGS. 1 and 3, when both of the shields are assembled, the latching lugs 84 of shield 24 engage the latching apertures in shield 22 and hold the shields together until a ferrule 290 is crimped onto the annular cable engaging portions of the shields. The shielding 292 of the shielded multiconductor cable 38 is positioned over the cable exit portions 66 of the shields. The connector is now ready for the overmolding operation. As shown in FIG. 7, the shields are covered with the overmold material 296. The overmold material 296 provides an insulative barrier for the shields. The overmolding operation can exert pressure on the metal shields which is sufficient to crush the shields into the cavity formed by the shields. The pressure relief means 68 is provided to relieve the pressure of the overmolding operation. The present invention assures a secure connection between the cover shields and the connector shell. The invention satisfies the need for an overmold shielded electrical connector which maintains a positive ground without the need for soldering during the manufacturing process, and meets the aforestated objects. While specific embodiments of the invention have been shown and described, it will be understood that the invention is not limited to these embodiments. Those skilled in the art to which the invention pertains may make modifications and other embodiments employing the principals of this invention, particularly upon considering the foregoing teachings. Therefore, it is contemplated by the appended claims to cover any such modifications and other embodiments as incorporate the features of this invention within the true spirit and scope of the following claims.

Claims: A shielded electrical connector (10) comprising an insulative housing (27) and a conductive shell (16, 18) surrounding at least a portion of said housing (27), said insulative housing (27) including a portion (30B) projecting from said conductive shell (16, 18), a portion (44) of said conductive shell (16, 18) overlying a proximal portion of said projecting portion (30B) of said insulative housing (27), and shield means (22, 24; 122, 124) for encompassing said projecting portion (30B) of said insulative housing (27) and designed to be assembled thereover by a pivotal motion, said shield means (22, 24) including a contact portion (62; 162) to be positioned beneath said overlying portion (44) of said shell (16, 18) and engaged therewith, characterized in that said insulative housing (27) and said shield means (22, 24; 122, 124) include engaging portions (58, 60, 74, 76; 90) which engage to form a fulcrum outboard of said contact portion (62; 162) of said shield means (22, 24) and that said engaging portions forming a fulcrum include protruding portions (58, 60, 74, 76, 90) of said shield means (22, 24; 122, 124) or of said insulative housing (27), whereby said contact portion (62; 162) of said shield means is rotated upward into contact with said overlying portion (44) of said shell (16, 18) as said shield means (22, 24; 122, 124) is assembled over said insulative housing (27) by such pivotal motion. The electrical connector of claim 1, wherein said insulative housing (27) has a rear face (31B), an upper surface (98), a lower surface (100) and a plurality of terminals mounted therein; wherein said conductive shell comprises metal shell means (16, 18) covering a portion of the periphery of said housing forward of said rear face (31B), said shell means (16, 18) having an aperture (44A) therethrough, and said insulative housing (27) projecting rearward of said aperture (44A) toward said rear face (31B); wherein said shield means comprises a pair of shields (22, 24; 122, 124) enclosing the rear conductor receiving face (31B) of the insulative housing (27) and a cavity extending rearward therefrom, said shields (122, 124) each having electro-mechanical engagement means (62; 162) comprising said contact portion for engaging said shell means (16, 18) proximate said aperture (44A) as said shields (22, 24; 122, 124) are rotated about said engagement means (62; 162) to form said cavity; and wherein said fulcrum forming engaging portions comprise offset portions (58, 60; 74, 76; 90) for pivoting said shields (122, 124) on said housing (27) such that said engagement means (62; 162) positively contact said shell means (16, 18) to assure an electrical connection between said shields (22, 24; 122, 124) and said shell means (16, 18). The electrical connector of claim 1, wherein said protruding portion is defined by at least one inwardly protruding detent (58, 60, 74, 76) on said shield (22, 24). The electrical connector of claim 3, wherein said detent is centrally located along the width of said shield. The electrical connector of claim 1, wherein said protruding portion is defined by at least two inwardly protruding detents (58, 60) on said shield. The electrical connector of claim 1, wherein said protruding portion is at least one protruding embossment positioned on said insulative housing (27) between a front mating face (31) of said housing (27) and a rear conductor receiving face (31B) thereof. The electrical connector of claim 6, wherein said protruding embossment (90) is centrally located between sidewalls of said connector (10). The electrical connector of claim 1, wherein said protruding portion comprises at least two protruding embossments (90) positioned on said insulative housing (27) between a front mating face (31A) of said housing (27) and a rear conductor receiving face (31B) thereof. A shield system for an electrical connector (10), said electrical connector having an insulative housing (27), a conductive shell (16, 18) surrounding at least a portion of said housing (27), said insulative housing (27) including a portion (30B) projecting from said conductive shell (16, 18), a portion (44) of said conductive shell (16, 18) overlying a proximal portion of said projecting portion (30B) of said insulative housing (27) wherein said shield system comprises a shield means (16, 18) for encompassing said projecting portion (30B) of said insulative housing (27) and is designed to be assembled thereover by a pivotal motion, wherein said shield means includes a contact portion (62) to be positioned beneath said overlying portion of said shell (16, 18) and engaged therewith, characterized in that said shield means include engaging portions (58, 60; 74, 76) including a protruding portion (58, 60) of said shield which engage with the insulative housing (27) to form a fulcrum outboard of said contact portion (62) of said shield means whereby said contact portion (62) thereof is rotated upward into contact with said overlying portion of said shell as said shield (16, 18) is assembled thereover by such pivotal motion. The system as in claim 9, wherein said protruding portion is defined by at least one inwardly protruding detent on said shield. The system as in claim 10, wherein said detent is centrally located along the width of said shield. The system as in claim 13, wherein said protruding portion is defined by at least two inwardly protruding detents (58, 60) on said shield.

Inventors: PETERS ROCCO J, PLEGGE RICHARD W, SELLERS GREGORY J, WALSH CHARLES T, PETERS, ROCCO J., PLEGGE, RICHARD W., SELLERS, GREGORY J., WALSH, CHARLES T.
Applicants: LABINAL COMPONENTS & SYSTEMS, LABINAL COMPONENTS AND SYSTEMS, INC.
Application year: 1991
Main classification: H01R13
IPC codes: H01R13