Patent Publication Number: US-9425531-B2

Title: Stage pin connector

Description:
RELATED APPLICATIONS 
     This application claims priority to and benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61/654,570, filed Jun. 1, 2012 and U.S. Design patent application Ser. No. 29/423,569, filed Jun. 1, 2012, the contents of both of which are incorporated by reference herein in their entireties. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to an electrical connector and more particularly to a stage pin connector which is configurable to have a retractable shroud. 
     BACKGROUND OF THE INVENTION 
     Stage pin connector assemblies are well known in the art and are mainly used in the entertainment industry, such as for studio and theatrical lighting applications. Because these stage pin assemblies are used in all different types of environments they are typically constructed from high-temperature, high impact resistant thermoset and phenolic materials. Referring to  FIG. 1A , a typical stage pin connector assembly  100  in accordance with the prior art is shown. As can be seen, the stage pin connector assembly  100  typically includes a stage pin male connector  102  and a stage pin female connector  104  connected via conductor cable(s)  106 , which includes a first power conductor cable, a second power conductor cable and a ground conductor cable. The stage pin male connector  102  may include two circuit conductor pins  108  and  112  and a ground pin  110 . The stage pin female connector  104  may include two circuit conductor pin sockets  114  and  118 , and a ground pin socket  116 . The two circuit conductor pins  108  and  112  are connected to the two circuit conductor pin sockets  114  and  118 , respectively via the first and second power conductor cables and the ground pin  110  is connected to the ground pin socket  116  via the ground conductor cable. 
     Unfortunately however, current stage pin connector designs have a number of disadvantages. One such disadvantage is that the pins on the stage pin male connector  102  extend away from the end of the connector body and are thereby exposed. This is undesirable for at least two reasons. First, cables such as these are typically used in areas and conditions where they can come into contact with heavy equipment, such as forklifts, sound equipment, etc. Accordingly, because the pins are exposed they are prone to damage, such as bending or scraping of the pins. If the pins are bent, or if the pins become scraped, then the damage to the pin may prevent the pin from securely and correctly making contact with a corresponding pin socket. Moreover, the pins used on the stage pin male connector  102  typically include a slot  103  that bisects the pin (See  FIG. 1B ) and that extends down at least a portion of the pin. If the pin gets compressed under a heavy weight, one (or both) sides of the bisected portion of the pin slot may be bent inwards. Thus, the diameter of the pin may be decreased affecting the ‘fit’ of the pin into a corresponding pin socket. Second, the exposed nature of the pins used on the stage pin male connector  102  also presents a safety issue in that if the stage pin connector assembly is energized, a person touching (or becoming exposed to the pins via water or other conductant) the pins can be electrocuted (at worst) or shocked (at best). This also presents an issue regarding damaging of sensitive electrical equipment by presenting as a short circuit hazard. 
     Another disadvantage is that when the stage pin male connector  102  is connected to a female connector/device female inlet  104 , the exposed nature of the pins present a different safety issue. Referring to  FIG. 2 , this is because if the stage pin male connector  102  is not completely pressed up against the stage pin female connector/inlet, a portion of the energized pins may be exposed. This presents an electrocution hazard to workers who may inadvertently touch the exposed portion directly or through other cabling. Furthermore, another disadvantage involves the wide body design of both the stage pin male connector  102  and the stage pin female connector  104  which are configured to fit securely and snugly together. This wide body design coupled with the secure and snug fit makes it physically difficult to separate the connectors when paired together. In order to separate the stage pin male connector  102  and the stage pin female connector  104 , a person has to grab each connector with one hand and pull them apart. Unfortunately, the wide body design of the connectors (both male and female) makes it difficult for the average person to get a suitable handhold and pull the connectors with sufficient force to separate them. Accordingly, users typically then try to pull the connectors apart by the cables or try to pry the ends of the connectors apart. Pulling the connectors apart using the cables is undesirable because this puts stress on the wiring device terminations. Additionally, prying the ends of the connectors apart is undesirable because the pins and sockets are located on the ends of the connector and any inadvertent touching of an energized pin/socket could kill or hurt a user. 
     SUMMARY OF THE INVENTION 
     A Stage Pin connector having a connector top and a connector base is provided and includes a contact carrier module, wherein the contact carrier module defines a first module cavity, a second module cavity and a third module cavity and includes a first module top opening communicated with a first module bottom opening via the first module cavity, a second module top opening communicated with a second module bottom opening via the second module cavity and a third module top opening communicated with a third module bottom opening via the third module cavity. The Stage Pin connector also includes a first electrical conductor, a second electrical conductor and a third electrical conductor, wherein the first electrical conductor is located within the first module cavity to be communicated with the first module top opening and the first module bottom opening, the second electrical conductor is located within the second module cavity to be communicated with the second module top opening and the second module bottom opening and the third electrical conductor is located within the third module cavity to be communicated with the third module top opening and the third module bottom opening. Additionally, the Stage Pin connector includes a plurality of electrical cables each having a cable conductor, wherein each of the cable conductors is in electrical communication with at least one of the first electrical conductor, second electrical conductor and third electrical conductor via at least one of the first module bottom opening, second module bottom opening and third module bottom opening and a connector housing, wherein the connector housing includes a pre-mold material and an outer-mold material, wherein the pre-mold material covers at least a portion of the contact carrier module and at least a portion of the plurality of electrical cables, and the outer-mold material covers at least a portion of the plurality of electrical cables, the pre-mold material and the contact carrier module, such that the first module top opening, second module top opening and third module top opening are uncovered, wherein at least one of the pre-mold material and the outer-mold material forms a connector knob proximate the connector base and the plurality of electrical cables. 
     A Stage Pin connector is provided, wherein the stage pin connector includes a connector top and a connector base. The stage pin connector includes a contact carrier module, wherein the contact carrier module defines a first module cavity, a second module cavity and a third module cavity and includes a first module top opening communicated with a first module bottom opening via the first module cavity, a second module top opening communicated with a second module bottom opening via the second module cavity and a third module top opening communicated with a third module bottom opening via the third module cavity. Additionally, a first electrical conductor, a second electrical conductor and a third electrical conductor are provided, wherein the first electrical conductor is located within the first module cavity to be communicated with the first module top opening and the first module bottom opening, the second electrical conductor is located within the second module cavity to be communicated with the second module top opening and the second module bottom opening and the third electrical conductor is located within the third module cavity to be communicated with the third module top opening and the third module bottom opening. Moreover, a plurality of electrical cables each having a cable conductor may be provided, wherein each of the cable conductors is in electrical communication with at least one of the first electrical conductor, second electrical conductor and third electrical conductor via at least one of the first module bottom opening, second module bottom opening and third module bottom opening. Also, a connector housing is provided, wherein the connector housing includes an outer-mold material, wherein the outer-mold material covers at least a portion of the plurality of electrical cables and the contact carrier module, such that the first module top opening, second module top opening and third module top opening are uncovered. 
     In another embodiment an electrical connector is provided, wherein the electrical connector includes a connector top and a connector base. The electrical connector further includes a contact carrier module, wherein the contact carrier module defines a module cavity and includes a module top opening communicated with a module bottom opening via the module cavity. Additionally, the electrical connector includes a electrical conductor located within the module cavity to be communicated with the module top opening and the module bottom opening and a connector housing, wherein the connector housing includes a pre-mold material and an outer-mold material, wherein the pre-mold material covers at least a portion of the contact carrier module and at least a portion of the electrical cable, and the outer-mold material covers the pre-mold material and the contact carrier module, such that the module top opening is uncovered, wherein the connector housing forms a connector knob located proximate the connector base. 
     In still yet another embodiment, an electrical connector is provided wherein the electrical connector includes a connector top and a connector base, the electrical connector comprising, a contact carrier module, wherein the contact carrier module defines a module cavity and includes a module top opening communicated with a module bottom opening via the module cavity. The connector also includes an electrical conductor located within the module cavity to be communicated with the module top opening and the module bottom opening and a connector housing, wherein the connector housing includes an outer-mold material, wherein the outer-mold material covers the contact carrier module, such that the module top opening is uncovered, wherein the connector housing forms a handle portion located proximate the connector base. 
     In still yet another embodiment, a Stage Pin connector is provided and includes a contact carrier module, wherein the contact carrier module defines a module cavity and includes a module top opening communicated with a module bottom opening via the module cavity. The Stage Pin connector further includes a electrical conductor located within the module cavity to be communicated with the module top opening and the module bottom opening and an electrical cable having a cable conductor, wherein the cable conductor is in electrical contact with the electrical conductor via the module bottom opening. Furthermore, the Stage Pin connector includes a connector housing, wherein the connector housing includes a pre-mold material and an outer-mold material, wherein the pre-mold material covers at least a portion of the contact carrier module and at least a portion of the electrical cable, and the outer-mold material covers the pre-mold material and the contact carrier module, such that the module top opening is uncovered, wherein the connector housing forms a connector knob located proximate the electrical cable. 
     In still yet another embodiment, an electrical connector is provided and includes a contact carrier module, wherein the contact carrier module defines a module cavity and includes a module top opening communicated with a module bottom opening via the module cavity. The connector further includes a electrical conductor located within the module cavity to be communicated with the module top opening and the module bottom opening, an electrical cable having a cable conductor, wherein the cable conductor is in electrical contact with the electrical conductor via the module bottom opening and a connector housing, wherein the connector housing includes a pre-mold material and an outer-mold material, wherein the pre-mold material covers at least a portion of the contact carrier module and at least a portion of the electrical cable, and the outer-mold material covers the pre-mold material and the contact carrier module, such that the module top opening is uncovered, wherein the connector housing forms a connector knob located proximate the electrical cable. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other features and advantages of the present invention will be better understood from the following detailed description of illustrative embodiments, taken in conjunction with the accompanying drawings in which: 
         FIG. 1A  is a top down perspective view of a stage pin connector assembly, in accordance with the prior art. 
         FIG. 1B  is a side perspective view of a contact pin showing the slot that bisects the end of the pin. 
         FIG. 2  is a top down view of a male stage pin plug associated with a female stage pin connector, in accordance with the prior art. 
         FIG. 3A  is a side view of one embodiment a stage pin connector assembly without a retractable shroud, in accordance with the present invention. 
         FIG. 3B  is a side view of the stage pin connector assembly of  FIG. 3A  with a retractable shroud, in accordance with the present invention. 
         FIG. 4A  is a side view of a male stage pin connector of the stage pin connector assembly of  FIG. 3A . 
         FIG. 4B  is a front view of the male stage pin connector of  FIG. 4A . 
         FIG. 4C  is a side view of the male stage pin plug of  FIG. 4A  without the outer-mold component. 
         FIG. 5A  is a side view of the male contact carrier module of the male stage pin connector of  FIG. 4A . 
         FIG. 5B  is a top view of the male contact carrier module of  FIG. 5A . 
         FIG. 5C  is a bottom view of the male contact carrier module of  FIG. 5A . 
         FIG. 5D  is a side perspective view of the male contact carrier module of  FIG. 5A . 
         FIG. 5E  is a side perspective view of a contact pin for use with the male connector housing of  FIG. 5A . 
         FIG. 5F  is a side perspective view of a male contact carrier module, in accordance with another embodiment. 
         FIG. 5G  is a side view of the male contact carrier module of  FIG. 5E . 
         FIG. 5H  is a bottom view of the male contact carrier module of  FIG. 5E . 
         FIG. 5J  is a top down sectional view of the male contact carrier module of  FIG. 5E . 
         FIG. 6  is a side view of a male stage pin connector of the stage pin connector assembly of  FIG. 3A . 
         FIG. 7A  is a front view of a male stage pin plug shroud of the stage pin connector assembly of  FIG. 3B . 
         FIG. 7B  is a rear view of the male stage pin plug shroud of  FIG. 7A . 
         FIG. 7C  is a top view of a male stage pin plug shroud of  FIG. 7A . 
         FIG. 7D  is a bottom view of a male stage pin plug shroud of  FIG. 7A . 
         FIG. 8A  is a side view of the male stage pin plug of the stage pin connector assembly of  FIG. 3B . 
         FIG. 8B  is a top view of the male stage pin plug of  FIG. 8A . 
         FIG. 9A  is a side view of the female stage pin connector of the stage pin connector assembly of  FIG. 3A . 
         FIG. 9B  is a top view of the female stage pin connector of  FIG. 9A . 
         FIG. 9C  is a side view of the female stage pin connector of  FIG. 9A . 
         FIG. 9D  is a side view of the female stage pin connector of  FIG. 9A  without the outer-mold component. 
         FIG. 10A  is a side perspective view of a contact socket for use with the female connector housing of  FIG. 9A . 
         FIG. 10B  is a side view of the female contact carrier module of the female stage pin connector of  FIG. 9A . 
         FIG. 10C  is a top view of the female contact carrier module of  FIG. 10A . 
         FIG. 10D  is a bottom view of the female contact carrier module of  FIG. 10A . 
         FIG. 10E  is a side perspective view of the female contact carrier module of  FIG. 10A . 
         FIG. 11  is a side view of the stage pin connector assembly of  FIG. 3A  with a retractable shroud. 
         FIG. 12  is a side view of a stage pin connector showing the handle portion. 
         FIG. 13  is a top view of the stage pin connector of  FIG. 12  with a retractable shroud. 
         FIG. 14A  is a side view of a stage pin connector of  FIG. 12 . 
         FIG. 14B  is a bottom view of the stage pin connector of  FIG. 12 . 
         FIG. 14C  is a top view of the stage pin assembly of  FIG. 12 . 
         FIG. 15A  is a side view of an electrical connector without a knob, in accordance with still yet another embodiment of the invention. 
         FIG. 15B  is a side view of an electrical connector without finger grooves/grip, in accordance with still yet another embodiment of the invention. 
         FIG. 15C  is a side view of an electrical connector without finger grooves/grip or a knob, in accordance with still yet another embodiment of the invention. 
         FIG. 15D  is a side view of an electrical connector having a contoured portion that is contoured outward, in accordance with still yet another embodiment of the invention. 
         FIG. 15E  is a side view of an electrical connector having a contoured portion that is contoured inward, in accordance with still yet another embodiment of the invention 
         FIG. 16  is an exploded side sectional view of an electrical connector module having outer-mold material illustrating interaction of lip with over-mold material, in accordance with an embodiment of the invention. 
         FIG. 17  is an operational block diagram illustrating one embodiment of a method  500  for assembling the stage pin connector assembly  200 , in accordance with one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In accordance with the present invention, a stage pin connector assembly is disclosed herein, wherein the stage pin connector assembly includes a male stage pin connector conductively connected to a female stage pin connector via at least one cable. Referring to  FIG. 3A  and  FIG. 3B , a stage pin connector assembly  200  is illustrated in accordance with an exemplary embodiment and includes a male stage pin connector  202  associated with a female stage pin connector  204  via a cable assembly  206 , where the cable assembly  206  may include one or more conductors. The stage pin connectors  202 ,  204  include a handle portion  201  having a connector grip  205  and connector base  199  having a connector knob  207  It should be appreciated that the stage pin connector assembly  200  may or may not include a shroud  203  that may be fixed or retractable.  FIG. 3A  illustrates the stage pin connector assembly  200  without a shroud  203  and  FIG. 3B  illustrates the stage pin connector assembly  200  with a shroud  203 . 
     Referring to  FIG. 4A ,  FIG. 4B  and  FIG. 4C , a male stage pin connector  202  is shown without a retractable shroud, wherein the male stage pin connector  202  includes a male connector housing  208 , a male contact carrier module  210  and a plurality of contact pins  212 . The male plug housing  208  is constructed from a pre-mold material  214  and a outer-mold material  216 , where the pre-mold material  214  is configured to cover a portion of the male contact carrier module  210  (including ‘cored out’ regions  253 ) and a portion of the cable assembly  206 , as shown in  FIG. 4C . The male outer-mold material  216  is configured to cover the male pre-mold material  214  and the male contact carrier module  210 , where the end of the male contact carrier module  210  from which the contact pins  212  extend may or may not be left uncovered by the male outer-mold material  216 , as shown in  FIG. 4B . It should be appreciated that although the male pre-mold material  214  and the male outer-mold material  216  are discussed herein as being molded materials, the male pre-mold material  214  and/or the male outer-mold material  216  may be replaced by a cover/material that is mechanically held together, such as by screws, clips, etc. 
     Referring to  FIG. 5A ,  FIG. 5B ,  FIG. 5C  and  FIG. 5D , a male contact carrier module  210  which is configured for use with a connector having a shroud  203  in accordance with one embodiment of the invention, is shown and includes a male module body  218  having a male body top  220 , a male body bottom  222 , a male body front  224 , a male body rear  226  and male body sides  228 . The male body top  220  includes a male first top opening  230 , a male second top opening  232  and a male third top opening  234 . The male body bottom  222  includes a male first bottom opening  236 , a male second bottom opening  238  and a male third bottom opening  240 . The male module body  218  defines at least one module cavity which may include a male first cavity  242 , a male second cavity  244  and a male third cavity  246 , wherein the male first cavity  242  communicates the male first top opening  230  with the male first bottom opening  236 , the male second cavity  244  communicates the male second top opening  232  with the male second bottom opening  238  and the male third cavity  246  communicates the male third top opening  234  with the male third bottom opening  240 . 
     Additionally, in accordance with one embodiment of the invention the male body front  224  includes a plurality of first body openings  250  and a plurality of second body openings  251  which are located proximate the male body bottom  22  and which are communicated with the male first cavity  242 , male second cavity  244  and male third cavity  246 , wherein the plurality of first and second body openings  250 ,  251  are not threaded. Referring to  FIG. 5E , one embodiment of a contact pin  212  is shown and includes a contact pin body  600  and a contact pin socket interface  602 , wherein the contact pin socket interface  602  extends from the male connector to make electrical contact with a socket of a female connector or output/input port. The contact pin body  600  defines a contact pin body cavity  604  and includes a contact pin body bottom opening  606  which is communicated with the contact pin body cavity  604 . Additionally, the contact pin body  600  further includes a first contact pin side opening  608  and a second contact pin side opening  610 , each of which is communicated with the contact pin body cavity  604 , wherein the first and second contact pin side openings  608 ,  610  are threaded. 
     Accordingly, when a contact pin  212  is inserted into the male first cavity  242 , male second cavity  244  and male third cavity  246 , the contact pin  212  can be securely contained therein by aligning the first body opening  250  with the first contact pin side opening  608  and the second body opening  251  with the second contact pin side opening  610  and inserting screws into the openings  250 ,  251  to engage the threaded portion of the first contact pin side opening  608  and/or second contact pin side opening  610 . A cable may be associated with the contact pin body  600  by inserting the cable into the contact pin body cavity  604  via the contact pin body bottom opening  606  and rotating the screws contained in the first contact pin side opening  608  and/or second contact pin side opening  610  such that the screws extend into the contact pin body cavity  604  and compressingly interact with the cable to secure the cable therein. It should be appreciated that a conductive sleeve (such as a ferrule sleeve) may be used as an interface between the screw and the cable, wherein the screw compresses the sleeve onto the cable. This would allow the compressing force from the screw to be distributed over a larger portion of the cable to eliminate and/or reduce breaking of the individual wire strands of cable. It should be further appreciated that the sleeve may be associated directly with the cable prior to inserting the cable into the contact pin body cavity  604  or the sleeve may be located within the contact pin body cavity  604  prior to insertion of the cable. It should be appreciated that in accordance with the invention, other ways of securely containing the contact pins  212  and/or cables within the cavities  242 ,  244  and  246  are contemplated, such as using set screws and/or press fitting (i.e. friction fit) the contact pins  212  and/or cables into the cavities  242 ,  244  and  246 . Moreover, the first and second body opening  250 ,  251  may be threaded and the first contact pin side opening  608  and a second contact pin side opening  610  may be unthreaded (or they both may be threaded). 
     Moreover, the male body front  224  and the male body rear  226  include a shroud guide structure  252  which extends from the surface of the male body front  224  and the male body rear  226  and which defines a shroud guide channel  254  which extends at least partially along the male body front  224  and the male body rear  226  between the male body top  220  and the male body bottom  222 . Furthermore, it should be appreciated that the male module body  218  may also include one or more ‘cored out’ regions  253 , cavities  255  and/or protrusions  256  located on the male body front  224 , male body rear  226  and/or male body sides  228  to aid the male pre-mold material  214  and/or male outer-mold material  216  to more securely associate with the male module body  218 . It should be appreciated that the openings  250 ,  251  may be threaded or unthreaded. 
     It is contemplated that the connector  202 ,  204  of the present invention may or may not include a shroud  203 . Referring to  FIG. 5F ,  FIG. 5G ,  FIG. 5H  and  FIG. 5J , a male contact carrier module  400  which is configured for use with a connector without a shroud  203 , is shown in accordance with another embodiment of the invention. 
     Thus, as briefly described hereinabove, a contact pin  212  may be associated with the male contact carrier module  210  by locating the male contact pin  212  within the male first cavity  242  such that the contact pin socket interface  602  extends from the male body top  220  of the contact carrier module  210  and such that the first contact pin body side opening  608  and second contact pin body side opening  610  are aligned with the first and second body openings  250 ,  251 , respectively. A first threaded mounting screw may be inserted into the first body opening  250  and the first contact pin body side opening  608  to engage with the threads on one (or both if both are threaded) of the first body opening  250  or the first contact pin body side opening  608 . This secures the contact pin  212  within the male first cavity  242 . 
     A conductor is inserted into the contact pin body bottom opening  606  such that the conductor is located within the contact pin body cavity  604  and a second threaded mounting screw may be inserted into the second body opening  251  and the second contact pin body side opening  610  to engage with the threads on one (or both if both are threaded) of the second body opening  251  and the second contact pin body side opening  610 . In this embodiment, the second threaded mounted screw preferably extends into the contact pin body cavity  604  to compressingly engage a conductive sleeve which compresses against the conductor such that the conductor is securely contained within the contact pin body cavity  604 . It is contemplated that one or both of the first and second mounting screws may be used to secure the conductor within the contact pin body cavity  604 . This may repeated for each of the conductors that will be associated with the male contact carrier module  210 . Moreover, although the connectors  202 ,  204  are shown as having only three conductors, other additional embodiments of the connector  202 ,  204  may include more or less conductors. 
     Referring to  FIG. 6  and again to  FIG. 4A  and  FIG. 4B , the male outer-mold material  216  includes a male outer-mold material front  258  and a male outer-mold material rear  260 , where the male outer-mold component front includes a shroud lock guide channel  261  having a first lock channel  263  located proximate one end of the shroud lock guide channel  261  and a second lock channel  265  located proximate the other end of the shroud lock guide channel  261 . It should be appreciated that the male outer-mold component rear  260  also includes a shroud pin  267  which extends from the surface of the male outer-mold component rear  260  to interact with a shroud as discussed hereinafter. 
     Referring to  FIG. 7A ,  FIG. 7B ,  FIG. 7C  and  FIG. 7D , it should be appreciated that a male stage pin connector shroud  203  may also be provided as desired and is sized and shaped to cover the end portion of the male stage pin connector  202  and at least a portion of the plurality of contact pins  212  extending therefrom. The male stage pin connector shroud  203  is resiliently and movably associated with the male stage pin connector  202  and includes a shroud body  266  defining a shroud cavity  268  and having a shroud front  270 , a shroud rear  272  and shroud sides  274 , wherein the shroud front  270  includes a shroud front outer surface  278  and a shroud front inner surface  280  and wherein the shroud rear  272  includes a shroud rear outer surface  282  and a shroud rear inner surface  284 . The shroud front  270  includes a shroud front tab  285  located on the shroud front inner surface  280  and the shroud rear  272  includes a shroud rear tab  286  located on the shroud rear inner surface  278 . Additionally, the shroud rear  272  defines a guide pin cavity  288  which communicates the shroud rear outer surface  282  with the shroud rear inner surface  284  and which extends vertically along a portion of the shroud rear  272 . The shroud front  270  includes a shroud locking switch opening, a shroud locking switch  290 , a connector locking member opening and a connector locking member  292 . The shroud locking switch  290  includes a locking switch finger actuator  291  and a shroud lock tab  294 . The shroud locking switch  290  is movably associated with the shroud front  270  via the shroud locking switch opening such that the locking switch finger actuator  291  is extending away from the shroud front outer surface  278  and the shroud lock tab  294  is extending away from the shroud front inner surface  280  into the shroud cavity  268 . The shroud locking switch  290  is slidably configurable between a shroud lock first configuration and a shroud lock second configuration. 
     The connector locking member  292  includes a connector lock actuator  296  and a connector lock protrusion or tab  298 , wherein the connector locking member  292  is movably associated with the shroud front  270  via the connector locking member opening such that the connector lock actuator  296  is configurable between an extended configuration (See  FIG. 7C ) and a compressed configuration (See  FIG. 7D ). When configured in the decompressed configuration, the connector lock actuator  296  is located away from the shroud front outer surface  270  and the connector lock tab  298  is not protruding into the shroud cavity  268  from (or protruding only slightly) the shroud front inner surface  280 . When configured in the compressed configuration, the connector lock actuator  296  is located adjacent the shroud front outer surface  270  and the connector lock tab  298  is protruding away from the shroud front inner surface  280  into the shroud cavity  268 .  FIG. 8A  and  FIG. 8B  show the male stage pin connector shroud  203  associated with the male stage pin connector  202 . It should be appreciated that the connector shroud  203  may or may not be used. Moreover, it is also contemplated that the connector shroud  203  may be located on the female connector  204  rather than the male connector  202 , as desired. 
     Referring to  FIG. 9A ,  FIG. 9B ,  FIG. 9C  and  FIG. 9D , the female stage pin connector  204  is shown and may include a female connector housing  300  and a female contact carrier module  302  having a plurality of contact sockets  304 . It should be appreciated that the female connector housing  300  may be constructed from a female pre-mold material  306  and a female outer-mold material  308 , where the female pre-mold material  306  is configured to cover at least a portion of the female contact carrier module  302  and a portion of the cable assembly  206 . The female outer-mold material  308  is configured to cover the female pre-mold material  306  and the female contact carrier module  302 , where the end of the female contact carrier module  302  which includes the plurality of contact sockets  304  may be left uncovered by the female outer-mold material  308 . It should be appreciated that although the female pre-mold material  306  and the female outer-mold material  308  are discussed herein as being molded materials, the female pre-mold material  306  and/or the female outer-mold material  308  may be replaced by covers/materials that are mechanically held together, such as by screws, clips, etc. 
     Referring to  FIG. 10A , one embodiment of a contact socket  304  is shown and includes a contact socket body  700 , wherein the contact socket body  700  defines a contact socket body cavity  702  and includes a contact socket body bottom opening  704  and a contact socket body top opening  706 , both of which are communicated with the contact socket body cavity  702 . The contact socket body  700  further includes a first contact socket side opening  708  and a second contact socket side opening  710 , each of which may be communicated with the contact socket body cavity  702 , wherein the first and second contact socket side openings  708 ,  710  are threaded. 
     Referring to  FIG. 10B ,  FIG. 10C ,  FIG. 10D  and  FIG. 10E , the female contact carrier module  302 , in accordance with one embodiment of the invention, is shown and includes a female module body  310  having a female body top  312 , a female body bottom  314 , a female body front  316 , a female body rear  318  and female body sides  320 . The female body top  312  includes a female first top opening  322 , a female second top opening  324  and a female third top opening  326 . The female body bottom  314  includes a female first bottom opening  328 , a female second bottom opening  330  and a female third bottom opening  332 . The female module body  310  defines a female first cavity  334 , a female second cavity  336  and a female third cavity  338 , wherein the female first cavity  334  communicates the female first top opening  322  with the female first bottom opening  328 , the female second cavity  336  communicates the female second top opening  324  with the female second bottom opening  330  and the female third cavity  338  communicates the female third top opening  326  with the female third bottom opening  332 . 
     Additionally, the female body front  316  includes a plurality of first female body side openings  340  and second female body side openings  341 . Referring to  FIG. 10B , one of the first female body side openings  340  and second female body side openings  341  is communicated with the female first cavity  334 , another of the first female body side openings  340  and second female body side openings  341  is communicated with the female second cavity  336  and still yet another of the first female body side openings  340  and second female body side openings  341  is communicated with the female third cavity  338 . As discussed further herein, the first and second female body side openings  340 ,  341  are located such that when a contact socket  304  is inserted into the female first cavity  334 , female second cavity  336  and female third cavity  338 , the first contact socket body side opening  708  and second contact socket body side opening  710  are aligned with the first and second female body side openings  340 ,  341 , respectively. When a contact socket  304  is located within the female first cavity  334  such that the first contact socket body side opening  708  and second contact socket body side opening  710  is aligned with the first and second female body side openings  340 ,  341 , the contact socket  304  is securely contained within the female first cavities  334  by inserting a screw into the first female body side opening  340  to engage the threaded portion of the first contact socket side opening  708 . 
     Additionally, a screw is inserted into second female body side opening  341  to engage a threaded portion of the second contact socket body side opening  710 . A conductor may be secured to the contact socket  304  by inserting the conductor into the contact socket body cavity  702  via the contact socket body bottom opening  704  to be aligned with at least one of the first contact socket body side opening  708  and second contact socket body side opening  710  and configuring the screw to extend into the contact socket body cavity  702  to compressingly engage a sleeve (such as a ferrule sleeve) which compresses against the conductor to contain the conductor within the contact socket body cavity  702 . This is repeated for the remaining conductors. It should be appreciated that in accordance with the invention, other ways of securely containing the contact sockets  304  and/or cables/conductors within the cavities  334 ,  336  and  338  are contemplated, such as using set screws and/or press fitting (i.e. friction fit or threading the cavities) the contact sockets  304  and/or cables/conductors into the cavities  334 ,  336  and  338 . Moreover, the first and second female body side openings  250 ,  251  may be threaded and the first contact socket body side opening  708  and a second contact socket body side opening  710  may be unthreaded (or they both may be threaded). 
     Referring again to  FIG. 10D , it should be appreciated that the female module body  310  may also include one or more ‘cored out’ regions  253 , cavities  342  and/or protrusions  344  located on the female body front  316 , female body rear  318  and/or female body sides  320  to aid the female pre-mold material  306  and female outer-mold material  308  to more securely associate with the female module body  310 . Furthermore, referring again to  FIG. 9A , the female outer-mold material  308  includes a connector lock cavity  346  for interacting with the connector lock tab  298  when mated with a male stage pin connector  202  incorporating the male stage pin connector shroud  203 . 
     Additionally, referring to  FIG. 11 , the cable conductor assembly  206  typically includes at least two circuit conductor cables  348  and  350 , and a ground cable  352 . However, it should be appreciated that the stage pin connector assembly  200  may be used for applications that use any amperes and may be modified and used for cable conductor assemblies  206  that include more or less cables/conductors, such as for example two cables or 4 cables. It is contemplated that the present invention may also be used with fiber optic cables as well. Accordingly, the number of contact pins  212  and contact sockets  304  may also be modified as the application requires and/or as desired. 
     It should be further appreciated that although the pre-mold material and/or the outer-mold material may be constructed from a, thermoset, thermoplastic and/or a thermoplastic elastomer (TPE) material, such as Santoprene® or some other synthetic rubber/polypropylene combination, it is contemplated that any material suitable to the desired end purpose may be used, such as a material that has an ergonomic, electrically insulating and/or structurally supporting property. For example, the outer-mold material  308  may be constructed using a hard plastic material. Moreover, the male contact carrier module  210 , female contact carrier module  302  and/or male stage pin connector shroud  203  may be constructed from a thermoset material, a polycarbonate material and/or any other material or composite suitable to the desired end purpose. Moreover, it should be appreciated that although the connector assembly is disclosed herein with regards to stage pin connectors, it is contemplated that the invention may be applied to any type of connector assemblies that have protruding contacts or that are capable of being locked together. 
     Referring to  FIGS. 3A-4A ,  FIG. 12  and  FIG. 13 , in one embodiment the male connector  202  and/or female connector  204  includes a handle portion  201  having a connector grip  205  and a connector knob  207 , where the connector grip  205  is sized, shaped includes a contoured surface that has finger grooves/grip  209  to allow a user to better grip the connector during use and during connection and disconnection from an electrical component and/or a reciprocal connector. The connector knob  207  is located proximate the base of the connector where the outer-mold material  216  and/or the pre-mold material  214  meet the cable/conductors  206 . The connector knob  207  is sized relative to the connector grip  205  such that a portion of the connector knob  207  forms a knob lip  211  of which a portion extends outward past the connector grip  205 . As such, when a user is holding the connector  202 ,  204  by the connector grip  205 , at least a portion of the side of the hand that is located between the pinky finger and the wrist contacts the knob lip  211 . When a user pulls the connector  202 ,  204  in the direction of the connector knob  207  to disconnect the connector  202 ,  204  from a component or reciprocal connector, the users hand advantageously contacts and presses against the knob lip  211  thereby assisting with the disconnection of the connector  202 ,  204 . Additionally, because the width of the connector knob  207  is greater than the base of the connector grip  205 , the tendency of the pre-mold material and outer-mold material to peel is reduced or eliminated. 
     Although the male connect  202  and the female connector  204  may be of any size depending on desired application and/or design,  FIG. 14A ,  FIG. 14B  and  FIG. 14C  illustrates one embodiment of the size of the male connector  202  and the female connector  204  for use with 100 Amp, 125 Volt applications. The connector  202 ,  204  includes a Connector Length (CL), a Connector End First Width (CEFW), a Connector Base Width (CBW), a Handle Portion Length (HPL), a Connector End Second Width (CESW) and a Connector Knob (CKD). In this embodiment, appropriate sizes may be CL is about 7.72 inches (±10%), CEFW is about 4.19 inches (±10%), CBW is about 1.46 inches (±10%), HPL is about 4.33 inches (±10%), CESW is about 1.45 inches (±10%) and CKD is about 1.94 inches (±10%). 
     It should be appreciated that in other embodiments, the finger grooves/grip  209  and/or the connector knob  207  may not be included. For example, in one embodiment the handle portion on the male connector  202  and/or female connector  207  may only include the finger grooves/grip  209  and not the connector knob  207  (See  FIG. 15A ). In another embodiment, the handle portion on the male connector  202  and/or female connector  207  may only include the connector knob  207  and not the finger grooves/grip  209  (See  FIG. 15B ). And in still yet another embodiment, the handle portion may not include either of the finger grooves/grip  209  and the connector knob  207  (See  FIG. 15C ). In still yet another embodiment, it is contemplated that the handle portion on the male connector  202  and/or female connector  207  may include a contoured portion to assist with gripping and pulling the connectors  202 ,  207 . For example, the contoured portion may be contoured outward (See  FIG. 15D ) or inward (See  FIG. 15E ). 
     Furthermore, it is contemplated that modules  210 ,  302 ,  400  may be molded or non-molded articles and may include ‘cored out’ regions  253  and cavities  255 ,  342  which may be created by and/or during the molding process (for molded modules), which may be part of the design or which may be created after the module is made (such as for non-molded modules). The pre-mold material  214  may then fill these ‘cored out’ regions  253  of the module  210 ,  302 ,  400 . It should be appreciated that the filling of the ‘cored out’ regions  253  advantageously assists with the adherence of the pre-mold material to the module  210  and may help to increase the structural integrity of the module. Moreover, referring to  FIG. 16  and again to  FIGS. 5A-5H  and  FIGS. 10B-10E , the modules  210 ,  302 ,  400  may include a module top (and/or bottom) lip  402  and at least one module pullback hole  403 , wherein the module top lip  402  acts as a relief by providing the outer-mold material  216  a lip or shelf to adhere to and to finish substantially flush with the exposed contact carrier surface (i.e. body top  220 ,  312 ). It should be further appreciated that as the outer-mold material  216  is molded to the connector  202 ,  204 , the outer-mold material  216  fills (at least partially) the at least one module pullback hole  403 . This provides support to the outer-mold material  216  and advantageously helps the outer-mold material  216  to better bond to the module  210 ,  302 ,  400  and limit any “pullback” of the outer-mold material  216  from the module top lip  402  due to shrinking of the outer-mold material  216  during cooling. 
     Referring to  FIG. 17 , an operational block diagram illustrating one embodiment of a method  500  for assembling the stage pin connector assembly  200  is provided and includes assembling the male stage pin connector  202  and the female stage pin connector  204 , as shown in operational block  502 . This may be accomplished as described herein above and/or as follows. The male stage pin connector  202  may be assembled by inserting a contact pin  212  into each of the male first cavity  242 , the male second cavity  244  and the male third cavity  246 . The contact pins  212  are then secured within the male first cavity  242 , the male second cavity  244  and the male third cavity  246  by inserting screws into the openings  250  and tightening the screws so that they securingly engage the first contact pin body side opening  608  of the contact pins  212  contained in the male first cavity  242 , the male second cavity  244  and the male third cavity  246 . The female stage pin connector  204  may be assembled by inserting a contact socket  302  into each of the female first cavity  334 , the female second cavity  336  and the female third cavity  338 . The contact sockets  302  are then secured within the female first cavity  334 , the female second cavity  336  and the female third cavity  338  by inserting screws into the openings  340  and tightening the screws so that they securingly engage the first contact socket body side opening  708  of the contact sockets  302  contained in the female first cavity  334 , the female second cavity  336  and the female third cavity  338 . 
     The cable assembly  206  is connected to the assembled male stage pin connector  202  and the assembled female stage pin connector  204 , as shown in operational block  504 . This may be accomplished by exposing the metal conductors on the ends of the power cable  348 , the neutral cable  350  and the ground cable  352  of the cable assembly  206 . A sleeve is associated with the metal conductor on one end of the circuit conductor cables  348  and  350  and the ground cable  352 , which are then inserted into and secured within the male first cavity  242 , the male second cavity  244  and the male third cavity  246 , respectively. This may be accomplished by inserting screws into the openings  251  and the second contact pin body side opening  610  of the contact pins  212  and tightening the screws so that they securingly engage the metal conductors contained within the male first cavity  242 , the male second cavity  244  and the male third cavity  246 . The metal conductors on the other end of the power cable  348 , the neutral cable  350  and the ground cable  352  are prepared as above and inserted into and secured within the female first cavity  334 , the female second cavity  336  and the female third cavity  338 , respectively. This may be accomplished by inserting screws into the openings  341  and the second contact socket body side opening  710  of the contact sockets  302  and tightening the screws so that they securingly engage the metal conductors contained within the female first cavity  334 , the female second cavity  336  and the female third cavity  338 . 
     When the cable assembly is connected to the assembled male stage pin connector  202  and the assembled female stage pin connector  204 , a pre-mold material  214  is molded onto/into the assembled male stage pin connector  202  and the assembled female stage pin connector  204  assemblies, as shown in operational block  506 . This may be accomplished by placing the assembled male stage pin connector  202  with the cables connected into a mold and associating a pre-mold component material with the assembled male stage pin connector  202  to cover a portion of the assembled male stage pin connector  202 , the cable-pin connections and the cable proximate the male stage pin connector  202 . Also, the assembled female stage pin connector  204  with the cables connected are also placed into a mold and a pre-mold component material is associated with the assembled female stage pin connector  204  to cover a portion of the assembled female stage pin connector  204 , the cable-socket connections and the cable proximate the female stage pin connector  204 . 
     When the pre-mold material  214  is associated with the male stage pin connector  202  and the assembled female stage pin connector  204 , the molding process is repeated for the outer-mold material  216  to associate the outer-mold material  216  with the male stage pin connector  202  and the female stage pin connector  204 , as shown in operational block  508 . If desired, the male stage pin connector shroud  203  may then be associated with the male stage pin connector  202  as shown in operational block  510 . This may be accomplished by placing the male stage pin connector shroud  203  over the male stage pin connector  202  such that the shroud front  270  is proximate the male body front  224  and the shroud rear  272  is proximate the male body rear  226  and such that front tab  285  is located in the shroud channel guide  254  on the male body front  224  and the rear tab  286  is located in the shroud channel guide  254  on the male body rear  226 . Prior to locating the front and rear tabs  285 ,  286 , a spring (or other resilient article) is placed in each of the shroud channel guides  254  to be located between the front and rear tabs  285 ,  286  and the bottom of the shroud channel guides  254 . This advantageously bias&#39;s the male stage pin connector shroud  203  to be springingly associated with the male stage pin connector  202  such that when you push down on the male stage pin connector shroud  203 , it springs back up to protect the contact pins  212 . It should be appreciated that although the shroud channel guide  254  is discloses herein as being part of the contact carrier module, in yet another embodiment, the shroud channel guide  254  may be defined/formed by the outer-mold material or may be an add-on to the connector  202 ,  204 . 
     Additionally, the male stage pin connector shroud  203  is associated with the male stage pin connector  202  such that the shroud pin  267  is located within the guide pin cavity  288  and the shroud lock tab  294  is located within the shroud lock guide channel  261 . It should be appreciated that the connector locking member  292  is located such that when the male stage pin connector  202  is connected to a female stage pin connector  204 , the connector lock tab  298  on the male stage pin connector shroud  203  is located proximate the connector lock cavity  346  on the female stage pin connector  204 . Thus, when the connector locking member  292  is compressed (i.e. the compressed configuration) the connector lock tab  298  extends into the connector lock cavity  346  and the connectors are locked together. The connector locking member  292  is configured into the decompressed configuration by pulling the connector lock actuator away from the shroud front outer surface  270 . This causes the connector lock tab  298  to be located away from the connector lock cavity  346  and the connectors may be separated. 
     It should also be appreciated that the male stage pin connector shroud  203  may be unlocked so that it freely moves or the male stage pin connector shroud  203  can be locked between a shroud lock first configuration and a shroud lock second configuration. The male stage pin connector shroud  203  can be locked in a shroud lock first configuration by compressing the male stage pin connector shroud  203  and sliding the locking switch finger actuator  291  such that the shroud lock tab  294  is located within the second lock channel  265 . This locks the male stage pin connector shroud  203  so that the contact pins  212  are exposed. The male stage pin connector shroud  203  can be locked in a shroud lock second configuration by allowing the male stage pin connector shroud  203  to cover the contact pins and sliding the locking switch finger actuator  291  such that the shroud lock tab  294  is located within the first lock channel  263 . This locks the male stage pin connector shroud  203  so that the contact pins  212  are covered by the male stage pin connector shroud  203 . 
     It is contemplated that, if desired, the connectors  202 ,  204  of the present invention may also be constructed without using a pre-mold material. In this case, only the over-mold material would be used to construct the connectors  202 ,  204 . As such, the construction of the connectors  202 ,  204  would be the same as above, but without the pre-mold step. 
     Moreover, the connectors  202 ,  204  may be constructed from any materials or combination of materials as desired and suitable to the desired end purpose. For example, in one embodiment the male contact carrier module  210  and female contact carrier module  302  may be constructed from a thermoset Bulk Molding Compound (BMC) which is resistant to charring and burning and the pre-mold material may be constructed from a thermoplastic material and the over-mold material may be constructed from a thermoplastic elastomer (TPE), such as Santoprene® which is a mixture of in-situ cross linking of EPDM rubber and polypropylene. 
     It should be appreciated that while the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes, omissions and/or additions may be made and equivalents may be substituted for elements thereof without departing from the spirit and 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 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. Moreover, unless specifically stated any use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another.