Electrical connector with terminal modules and terminal tail aligning device

Abstract: An electrical connector (20) includes an elongated dielectric housing (22) having a longitudinal cavity (28) for receiving a terminal module (26). The module includes a dielectric insert (30) received in the cavity and mounting a plurality of terminals (32) having tail portions (42) projecting from the housing. An elongated tail aligning device (24) is mountable on the housing and has a plurality of apertures (68) through which the tail portions (42) of the terminals (32) project. The tail aligning device (24) has portions (72) overlying the terminal module (26) for holding the module in the housing in response to mounting the tail aligning device on the housing.

Description: Field of the Invention This invention generally relates to the art of electrical connectors and, particularly, to an electrical connector which includes one or more separate terminal modules and a separate terminal tail aligning device. Background of the Invention A known type of input/output (I/O) electrical connector includes an elongated dielectric housing having a front mating face and rear face with a terminal module-receiving cavity extending therebetween. The faces extend between opposite ends of the elongated housing. One or more terminal modules are mountable within the cavity. Each terminal module includes a dielectric insert surrounding a plurality of terminals, with the terminals of each module often being in a linear array. The dielectric inserts often are overmolded about the array of terminals. Various means normally are employed to hold or lock the terminal modules within the housing cavity of such electrical connectors as described above. Most often, the dielectric inserts of the modules have latches that interengage with corresponding latch means on the connector housing to hold the modules within the housing cavity as seen for ex. in EP-A-0 635 912. These latches cause various problems, including increasing the overall size of the connector. The latch devices are asymmetrical which makes assembly tedious particularly when the assembly operations are carried out by hand. Latches also are often provided between adjacent terminal modules when mounted within the housing cavity. Therefore, connectors using less than a full complement of terminal modules cannot be used. In other words, it may be desirable to provide a system flexible enough to permit the omission of some of the modules. Electrical connectors of the character described above often include terminal tail aligning devices. Specifically, the tail aligning devices are mountable on the connector housings and have a plurality of apertures through which the tail portions of the terminals extend. A tail aligning device typically is provided as a flat plastic member having the tail-receiving apertures therethrough and function to maintain the tail portions of the terminals in proper position and spacing. The present invention is directed to solving the above problems in electrical connectors which utilize terminal modules, by a unique system in which the tail aligning device serves a dual function of providing means to hold the terminal modules within the housing cavity without any extraneous latch means as described above. This reduces the overall size of the connector, allows for easy mounting of one or more terminal modules in the connector without interengaging latch means therebetween, and affords ready use of symmetrical terminal modules. Summary of the Invention An object, therefore, of the invention is to provide an electrical connector of the modular type described above, with a new and improved tail aligning device. In the exemplary embodiment of the invention, the electrical connector includes an elongated dielectric housing having a longitudinal cavity for receiving a terminal module. At least one terminal module is receivable in the cavity and includes a dielectric insert mounting a plurality of terminals having tail portions projecting from the housing. An elongated tail aligning device is mountable on the housing and has a plurality of apertures through which the tail portions of the terminals project. Generally, complementary interengaging retaining means are provided between the tail aligning device and the terminal module for holding the module in the cavity of the housing in response to mounting the tail aligning device on the housing. More particularly, the tail aligning device includes at least one retaining portion engaging a portion of the terminal module insert to hold the module in the cavity. As disclosed herein, the dielectric insert of the terminal module includes opposite end portions engageable by retaining portions of the tail aligning device outwardly beyond the terminals. As disclosed herein, the tail aligning device includes a plurality of mounting portions in the form of guide rails slidably mountable in guide channels on the housing. The guide rails perform a dual function of forming the retaining means which engage portions of the terminal module insert to hold the module in the cavity. The connector is shown herein mounting a plurality of the terminal modules having dielectric inserts received in the cavity of the housing. The mounting/retaining guide rails are effective for holding all of the modules in the housing cavity. Lastly, complementary interengaging snap-latch means are provided between the housing and the tail aligning device for locking the device on the housing in position for holding the terminal module(s) in the cavity of the housing. Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which: FIGURE 1 is an exploded perspective view of an electrical connector embodying the concepts of the invention, looking downwardly toward the rear terminating face of the connector; FIGURE 2 is a vertical section through the connector in assembled condition; FIGURE 3 is an end elevational view of the top terminal module as seen in Figure 2; FIGURE 4 is a perspective view of the terminal module; FIGURE 5 is an elevational view of the front mating face of the connector housing; FIGURE 6 is an elevational view of the rear terminating face of the connector housing; FIGURE 7 is a top plan view of the connector housing; FIGURE 8 is a bottom plan view of the connector housing; FIGURE 9 is a front elevational view of the tail aligning device, as viewed in Figure 1; FIGURE 10 is a rear elevational view of the tail aligning device; FIGURE 11 is a top plan view of the tail aligning device, as viewed in Figure 1; FIGURE 12 is an exploded plan view of an alternate form of electrical connector including the connector housing and tail aligning device; FIGURE 13 is an exploded elevational view of the connector of Figure 12; and FIGURE 14 is a fragmented plan view, on an enlarged scale, of the snap-latch means between the connector housing and the tail aligning device. Detailed Description of the Preferred Embodiments Referring to the drawings in greater detail, and first to Figure 1, the invention is embodied in an electrical connector, generally designated 20. The connector generally is formed of two basic components, namely an elongated dielectric housing, generally designated 22, and an elongated tail aligning device, generally designated 24, along with one or more terminal modules, generally designated 26. Each of the housing and the tail aligning device is formed as a one-piece molded dielectric component, such as of plastic material or the like. Before proceeding with a detailed description of housing 22 and tail aligning device 24, reference is made to Figures 2-4 in conjunction with Figure 1. Figure 2 shows three terminal modules 26 mounted within an elongated cavity 28 of housing 22, the only difference in the modules being the lengths of the tail portions of the terminals described hereinafter. On the other hand, Figure 1 shows only one terminal module 26 mounted within cavity 28. It should be understood that one of the advantages of the invention is that connector 20 can accommodate a plurality of terminal modules or only one, according to the specifications of the connector. Still referring to Figures 2-4 in conjunction with Figure 1, each terminal module 26 includes an elongated dielectric insert 30 shaped in the form of a plastic bar which is overmolded about a linear array of terminals, generally designated 32. The dielectric insert of each terminal module extends at opposite ends beyond the linear array of terminals, as at 34 (Fig. 4), and terminates in a rib 36 at the extreme opposite ends of the insert. As seen in Figure 1, the ribs are positionable into grooves 38 at opposite ends of elongated cavity 28. Each terminal 32 includes a forwardly projecting contact portion 40 and a rearwardly projecting, right angled tail portion 42. Therefore, electrical connector 20 is a right-angle connector as seen best in Figure 2, for mounting on a printed circuit board, with mounting posts 44 of connector housing 22 extending into appropriate mounting holes in the board, and with tail portions 42 of the terminals projecting into circuit holes in the board. Referring to Figures 5-8 in conjunction with Figures 1 and 2, elongated dielectric housing 22 has a front mating face 46 and a rear terminating face 48 with the terminal module-receiving cavity 28 extending generally therebetween. Actually, the front mating face of the housing is defined by a D-shaped mating end 50 of the housing as is conventional with many such I/O electrical connectors. A shield (not shown) may be added to the front mating face 46 if desired. End portions 52 of the housing include apertures 54 for receiving appropriate fastening means to secure the connector to an appropriate complementary mating connector (not shown). Still further, the housing includes a rearwardly opening side cavity 56 (Fig. 1) which communicates through openings 58 (Fig. 5) in front mating end 50 to accommodate various high speed terminal means which do not form part of the invention herein and will not be described further. According to the invention, dielectric housing 22 includes a plurality of guide channels 60a, 60b and 60c (Figs. 1 and 7) for guiding tail aligning device 24 into position, as described hereinafter. It can be seen that the left-hand (as viewed in Figures 1, 7 and 8) guide channel 60a and the center guide channel 60b are narrower than the right-hand guide channel 60c. The guide channels are generally T-shaped. If desired, as shown in Figure 13, the outer portions 60a' and 60c', respectively , of the guide ribs 60a and 60c could extend along generally the entire height of the connector in order to provide additional guiding during assembly and strength after assembly of the connector. According to the invention, dielectric housing 22 further includes a pair of upstanding latch posts 62 near opposite ends 52 of the housing, with chamfered latching ribs 64 facing inwardly of the elongated housing. The latching ribs function to latch tail aligning device 24 in proper position, as described hereinafter. Referring to Figures 9-11 in conjunction with Figure 1, tail aligning device 24 includes an elongated plate portion 66 having a plurality of apertures 68 through which tail portions 42 of terminals 32 project. One function of the tail aligning device, of course, is to maintain the tail portions of the terminals in proper position and spacing. The tail aligning device further includes a plurality of gussets 70a, 70b and 70c having flanges or rails 72 at the front edges thereof. The flanges cooperate with the gussets to form T-shaped guide rails which ride within guide channels 60a and 60c of connector housing 12. Spacers 74 are formed between gussets 70b and 70c for purposes not germane to the invention and will not be further described. Tail aligning device 24 further includes latch grooves 76 (Fig. 11) which face outwardly at opposite ends of plate portion 66 of the device. These latch grooves cooperate with latching ribs 64 of connector housing 22, as described below. In assembly of electrical connector 20, one or more terminal modules 26 are inserted into elongated cavity 28 as shown in Figures 1 and 2. When inserted, ribs 36 at opposite ends of dielectric inserts 34 of the terminal modules ride into grooves 38 at opposite ends of housing cavity 28. No independent latching means are provided between the terminal modules and the connector housing. Although it may be desirable to create an interference fit between the terminal modules and the housing, such interference fit would be sufficient to hold the modules in place during assembly, but not during mating of intermating connectors. Tail aligning device 24 then is assembled to connector housing 22 in the direction of arrow "A" (Fig. 1). During assembly, tail portions 42 of terminals 32 move into apertures 68 in the tail aligning device. The guide rails of the device formed by gussets 70a-70c and flanges 72 ride into guide channels 60a-60c of the connector housing. When the tail aligning device is fully assembled, latching ribs 64 which face inwardly of latch post 62 of the connector housing snappingly latch into latch grooves 76 at opposite ends of the tail aligning device. When the tail aligning device is assembled to the connector housing, a portion of the flanges 72 of gussets 70a and 70b of the tail aligning device engage opposite ends 34 of terminal modules 26 to hold the modules in housing cavity 28 in response to mounting the tail aligning device on the housing. In other words, the tail aligning device performs the dual function of not only aligning the tail portions of the terminal but also holding the terminal modules within the housing without requiring any extraneous latching means between the module and the housing. Figure 14 shows the latched condition of latching ribs 64 on mounting post 62 of the connector housing within latch grooves 76 of the tail aligning device. Terminal modules (not shown) similar to those shown in Figures 3 and 4 may also be inserted into side cavity 56. In such case, flanges 72 of gussets 70b and 70c would hold such modules within cavity 56 in a manner similar to that described above. Figure 10 shows a feature of the invention wherein it can be seen that one row of apertures 68a in tail aligning device 24 are open at a front edge 80 of plate portion 66. When the tail aligning device 24 is in place on the housing, the lower rear edge 48a of rear terminating face 48 of the housing interacts with the open apertures 68a to close the open side and encircle the terminal tails to hold them in place. This allows for the width dimensions of the tail aligning device to be reduced. In addition, open apertures 68a make assembly of the connector less difficult since only some but not all (two-thirds in the embodiments shown) of the terminal tails must be aligned with and inserted into apertures 68. Lastly, Figures 12 and 13 show an alternative, more simplified electrical connector 20' having a dielectric housing 22' and a tail aligning device 24'. In this connector, the tail aligning device has three T-shaped guide rails formed by flanges 72 receivable into three guide channels 60. In other words, a center guide rail and a center guide channel are provided intermediate opposite ends of the housing and tail aligning device. The centermost guide rail and guide channel engages the dielectric insert of the terminal module(s) near the center thereof. This embodiment might be used to further support the dielectric inserts of the terminal modules and prevent them from bowing near the center thereof, such as in electrical connectors that are more elongated than those shown herein. Figure 12 also shows an additional embodiment of the interaction between the tail aligning device and the housing to hold the terminals in place. In that embodiment, the open row of apertures 68a' are moved to the lower edge 48a' of the rear terminating face. The front or leading edge 80' is relatively planar or smooth in order to close the open side of apertures 68a' and encircle the terminals. It will be understood that the invention may be embodied in other specific forms without departing from the scope of the appended claims.

Claims: An electrical connector (20), comprising: an elongated dielectric housing (22) having a longitudinal cavity (28) for receiving a terminal module (26); at least one terminal module (26) including a dielectric insert (30) received in said cavity and mounting a plurality of terminals (32) having tail portions (42) projecting from the insert; an elongated tail aligning device (24) mountable on the housing (22) and having a plurality of apertures (68) through which the tail portions (42) of the terminals (32) project, characterized by complementary interengaging retaining means (72, 34) between the tail aligning device (24) and the terminal module (26) for holding the module in the cavity (28) of the housing (22) in response to mounting the tail aligning device on the housing. The electrical connector of claim 1 wherein said housing includes a rear face (48), said rear face including an opening leading into said cavity and a flange defining said opening, said tail aligning device (24) spans a portion of said cavity between portions of said flange and includes at least one retaining portion (72) engaging a portion (34) of the terminal module insert (30) to hold the module in the cavity (28). The electrical connector of claim 2 wherein the dielectric insert (30) of said terminal module (26) includes opposite end portions (34) engageable by retaining portions (72) of the tail aligning device (24). The electrical connector of anyone of claims 1 to 3 wherein said tail aligning device (24) includes at least one mounting portion (72) adapted for mounting the device on the housing (22), the mounting portion comprising at least part of said retaining means (72,34). The electrical connector of claim 4 wherein said mounting portion (72) is configured for engaging a portion (34) of the terminal module insert (30) to hold the module (26) in the cavity (28). The electrical connector of claim 5 wherein said mounting portion comprises a guide rail (72) slidably mountable in a guide channel (60a-60c) on the housing. The electrical connector of claim 6, engaging a pair of said guide rails (72) near opposite ends of the tail aligning device (24) and adapted for engaging opposite end portions (34) of the terminal module insert (30) outwardly beyond the terminals (32). The electrical connector of claim 7, including a third guide rail (72) intermediate said opposite ends of the tail aligning device (24'). The electrical connector of anyone of claims 1 to 8, including a plurality of said terminal modules (26) having dielectric inserts (30) received in the cavity (28) of the housing (22), said retaining means (72,34) being adapted for holding all of the modules in the cavity of the housing. The electrical connector of anyone of claims 1 to 9, including complementary interengaging snap-latch means (64, 76) between the housing (22) and the tail aligning device (24) for locking the device on the housing in position for holding the terminal module (26) in the cavity (28) of the housing. The electrical connector of anyone of claims 1 to 10 wherein at least some of the apertures (68) in the tail aligning device (24) are open along an edge (80) thereof adjacent said housing. The electrical connector of anyone of claims 1 to 11 wherein said housing, terminals and tail aligning device are configured to position contact portions of said terminals generally at a right angle to said tail portions of said terminals. The electrical connector of anyone of claims 1 to 12 wherein said cavity is dimensioned to receive more than one terminal module therein.

Inventors: HARWATH FRANK A, MCFARLANE WALTER G, HARWATH, FRANK A., MCFARLANE, WALTER G.
Applicants: MOLEX INC, MOLEX INCORPORATED
Application year: 1997
Main classification: H01R12
IPC codes: H01R13, H01R12, H01R4