Patent Publication Number: US-2022216646-A1

Title: Housing for an Electrical Connector

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of PCT International Application No. PCT/EP2020/076599, filed on Sep. 23, 2020, which claims priority under 35 U.S.C. § 119 to European Patent Application No. 19200239.2, filed on Sep. 27, 2019. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to an electrical connector and, more particularly, to a housing for an electrical connector. 
     BACKGROUND 
     Electrical connectors, such as network connectors, usually comprise a cable outlet arranged at a rear side of the electrical connector. For physical and electrical protection, a housing is provided for receiving the electrical connector. As the cable exits the cable outlet, sufficient space is necessary to install the cable, which is a rare commodity in various applications. Therefore, there is a demand for space-saving housings, which redirect the cable in such a way that minimal space is occupied when installed. However, depending on the application, the cable must be redirected in different directions, resulting in a large stock of different housings, which increases production costs and storage costs. 
     SUMMARY 
     A housing for an electrical connector includes a housing body having an opening receiving a cable in an insertion direction and a pair of cable covers hinged to the housing body at a proximal end of each cable cover of the pair of cable covers. The pair of cable covers extend away from the opening. Each of the cable covers is pivoted away from the other cable cover in a cable mounting position and each cable cover is pivoted toward the other cable cover to form a cable support sleeve supporting the cable in an operating position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described by way of example with reference to the accompanying Figures, of which: 
         FIG. 1  is an exploded perspective view of a housing according to an embodiment; 
         FIG. 2  is a perspective view of the housing in a mounting position; 
         FIG. 3  is a perspective view of the housing in an operating position with different pairs of cable covers; 
         FIG. 4  is a perspective view of a cable cover of the housing; and 
         FIG. 5  is a perspective view of a locking nut of the housing. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENT(S) 
     In the following, the housing, according to the invention, is explained in greater detail with reference to the accompanying drawings in which exemplary embodiments are shown. 
     In the figures, the same reference numerals are used for elements which correspond to one another in terms of their function and/or structure. 
     According to the description of the various aspects and embodiments, elements shown in the drawings can be omitted if the technical effects of those elements are not needed for a particular application, and vice versa: i.e. elements that are not shown or described with reference to the figures can be added if the technical effect of those particular elements is advantageous in a specific application. 
     First, the inventive housing  1  is explained with reference to  FIGS. 1 and 2 .  FIG. 1  shows a schematic exploded view of an exemplary embodiment of the housing  1  according to the invention, and  FIG. 2  shows a schematic perspective view of the housing  1  in a mounting position  2 . 
     The housing  1  is adapted for an electrical connector  4 , having a housing body  6  and an opening  8  configured to receive an electrical cable  10  in an insertion direction I. A pair of cable covers  12  is hinged to the housing body  6  at a proximal end  14  of the respective cable cover  16  of the pair of cable covers  12  extending away from the opening  8 . In the cable mounting position  2  as shown in  FIG. 2 , each cable cover  16  of the pair of cable covers  12  is pivoted away from the other cable cover  16  of the pair of cable covers  12  allowing the insertion of the electrical cable  10  into the opening  8  in the insertion direction I. 
     The housing body  6  may be provided with a polarization element  9 , shown in  FIGS. 1 and 2 . In this exemplary embodiment, the polarization element  9  is formed by two guiding notches  11  extending from the entrance of the opening  8  in the insertion direction I. The electrical connector  4 , shown in  FIG. 2 , may comprise protrusions adapted to be received in the respective notches  11 . Therefore, the electrical connector  4  can only be inserted into the opening  8  in the insertion direction I, when the protrusions are aligned with the guiding notches  11 . The guiding notches  11  are, in an embodiment, arranged opposite to one another and spaced apart from a middle axis essentially perpendicular to the insertion direction I, so that the opening  8  comprises an asymmetrical cross section in a plane essentially perpendicular to the insertion direction I. Due to the asymmetrical cross section, the orientation of the electrical connector  4  in which it can be inserted into the opening  8  is predetermined. This may further fool-proof the connection system. Of course, different embodiments of the polarization element  9  may be envisioned, such as guiding rails or ribs. The housing body  6  may be formed of an electrically insulating material. The housing body  6  may be formed by injection molding allowing for a cost-efficient production, particularly for mass scale. 
     The cable  10  may comprise an insulation  18  and a cable braid  20  arranged coaxially under the insulation  18 , as shown in  FIG. 2 . The cable  10  may further be comprised of multiple wires  22 , which are terminated in a wire organizer  24  that is inserted in the opening  8  of the housing body  6 . In an embodiment, the cable  10  has a predetermined cable diameter  26 , so that the pair of cable covers  12  may provide a strain relief in an operating position, shown in  FIG. 3 . 
     The electrical connector  4  may be a termination unit in which the wires  22  of the cable  10  may be terminated. The termination unit may be inserted into the opening  8  of the housing body  6  and may be connected to a further connector element, such as a plug terminal. 
     The housing body  6  comprises a bearing  28  in the form of two holes  30  arranged on opposing sides of the opening  8 , as shown in  FIG. 1 . The holes  30  are arranged coaxially to one another forming a pivoting axis  32  essentially perpendicular to the insertion direction I. A second bearing  28  is provided on the other side of the opening  8  forming a second pivoting axis  32  extending essentially parallel to the first pivoting axis  32 . 
     Each cable cover  16  of the pair of cable covers  12  comprises pins  34  adapted to be fittingly inserted into the respective holes  30  formed on opposing latches  36 . Therefore, a cable cover  16  of the pair of cable covers  12  may be hinged to either of the bearings  28  and the other cable cover  16  of the pair of cable covers  12  to the other bearing  28 . 
     The holes  30  may be closed towards the opening  8 . At the closed hole  30  on the side facing the opening  8 , an electrically conductive element  37  may be provided, as shown in  FIG. 1 , the conductive element  37  forming a bulge and being adapted to contact the electrical connector  4 , when the connector  4  is inserted. Thus, the electrically conductive element  37  may act as a further shielding for the connector  4 . The electrically conductive element  37  may be formed onto the closed hole  30  or may close the hole  30  itself. 
     The bearings  28  are formed in a depression  38  of the housing body  6  forming a blocking surface  40 , which may block the cable cover  16  from pivoting too far away from the other cable cover  16 , as shown in  FIG. 1 . In an embodiment, the hinged cable cover  16  may be pivotable at an angle of about 90° from the mounting position  2  shown in  FIG. 2  to the operating position as shown in  FIG. 3 . Thus, in the mounting position  2 , the pair of cable covers  16  do not block the insertion of the cable  10  into the opening  8 . 
     As can be seen in  FIG. 2 , each cable cover  16  of the pair of cable covers  12  may comprise a grounding spring  42 , a fixation latch  44 , and a strain relief spring  46  mounted to an interior side  48  facing towards the other cable cover  16  in the operating position. The grounding springs  42 , fixation latch  44 , and strain relief spring  46  are each formed integrally with one another as a monolithic component  50 , for example as a leaf spring. 
     The monolithic component  50  comprises a main spring body  52  which is rigidly mounted to the interior side  48  of the respective cable cover  16 . The main spring body  52  may extend from the proximal end  14  of the respective cable cover  16  of the pair of cable covers  12  to a distal end  55  of the respective cable cover  16 . At the proximal end  14 , the main spring body  52  may be provided with the fixation latch  44 , which may be bent at about 90° from the main spring body  52 . The at least one strain relief spring  46  and at least one grounding spring  42  may be formed as a stamped metal sheet that is bent into a form. The at least one strain relief spring  46  and the at least one grounding spring  42  may be formed as bent latches from the main spring body  52  that may be fastened to the respective cable cover  16 . 
     The fixation latch  44  is adapted to extend into the opening  8  such that the fixation latch  44  overlaps with a cross section  54  of the opening  8  in a plane perpendicular to the insertion direction I. Therefore, the electrical connector  4 , e.g. a cable organizer  56 , can be secured in the opening  8  by the fixation latch  44  during operation blocking a disengagement of the electrical connector  4  and the housing  1  due to vibrations or similar. 
     The at least one strain relief spring  46  and the at least one fixation latch  44  may be formed integrally with one another as a monolithic component. The at least one strain relief spring  46  and the at least one fixation latch  44  may be formed as a stamped metal sheet that is bent into form. The at least one strain relief spring  46  and the at least one fixation latch  44  may be formed as bent latches from a main spring body  52 . The at least one strain relief spring  46  and the at least one fixation latch  44  may be formed on opposing ends of the main spring body  52 , whereby the at least one fixation latch  44  may be arranged at the proximal end  14  of the respective cable cover  16 . 
     The fixation latch  44  may be adapted to be pivoted away from the opening  8  in the mounting position  2 , shown in  FIG. 2 , allowing a free passage of the cable  10  and/or electrical connector  4  into the opening  8 . In an operating position  64 , shown in  FIG. 3 , in which the pair of cable covers  12  are pivoted towards one another, the fixation latch  44  may abut the electrical connector  4 , pushing the electrical connector  4  further into the opening  8  along the insertion direction I. Consequently, the fixation latch  44  is pressed against the electrical connector  4  with a normal force, which may be transferred via the cable cover  16  to the pins  34  pressing into the bearings  28 . Therefore, the electrically conductive element  37  is pressed towards the electrical connector  4  with said normal force providing a further shielding feature for the connector  4 . 
     For grounding the electrical cable  10 , grounding springs  42  are provided at each cable cover  16  of the pair of cable covers  12 , as shown in  FIG. 2 . The grounding springs  42  may extend from the main spring body  52  as wings from the lateral sides of the main spring body  52  at the proximal end  14  of the respective cable cover  16 . In this exemplary embodiment, each cable cover  16  is provided with two grounding springs  42  that are arranged along an inner circumference so that each grounding spring  42  can be pushed under the cable braid  20  of the cable  10  for grounding. The grounding springs  42  may extend from the proximal end  14  towards the distal end  55  projecting obliquely towards the other cable cover  16  of the pair of cable covers  12  at least in the operating position so that the grounding springs  42  are biased towards the cable  10  when inserted. Consequently, the grounding springs  42  may be resiliently deflected by the cable  10  adapting to the cable diameter  26 . This allows for grounding of a wider range of cable diameters  26 , such as from about 3.8 mm to about 8.0 mm. 
     At the distal end  55 , the main spring body  52  may be arched back towards the proximal end  14  forming the strain relief spring  46 , as shown in  FIG. 2 . The main spring body  52  may be arched at about 120° so that the strain relief spring  46  may be formed as a spring tongue that extends obliquely towards the opposing cable cover  16  of the pair of cable covers  12 . Thus, the strain relief spring  46  may be adapted to be biased towards the cable  10  providing a strain relief for a wider range of cable diameters, such as from about 3.8 mm to about 8.0 mm. A compact design may be achieved by providing a recess or cutout  58  in the respective cable cover  16 , so that the arch  60  forming a deflection section  62  of the strain relief spring  46  is arranged in the cutout  58 . In this formation, the space is provided for the strain relief spring  46  to be deflected without increasing the overall dimensions of the housing  1 , particularly the pair of cable covers  12 . Consequently, the greater the cable diameter, the further the strain relief spring  46  is deflected radially outwards through the cutout  58 . 
     The strain relief spring  46  is adapted to provide a strain relief for a wider range of cables  10 , increasing the applicability of the housing  1 , preventing mechanical force applied to the exterior of the cable  10  from being transferred to the electrical terminations within the housing  1 , which could lead to failure. 
     To ensure the correct position of the electrical cable  10  within the housing  1 , the cable cover  16  may comprise at least one positioning rib  63  protruding from the interior side  48  of the cable cover  16 , as shown in  FIG. 2 . In an embodiment, each cable cover  16  of the pair of cable covers  12  comprises two positioning ribs  63  arranged opposite to one another, whereby the positioning ribs  63  reduce the inner diameter of the pair of cable covers  16 , at least when they are pivoted towards one another. The at least one positioning rib  63  may provide an abutment surface  65  facing away from the opening  8 , which may be abutted by the insulation  18  of the electrical cable  10 , limiting the insertion depth of the cable  10  and ensuring that the grounding springs  42  contact the cable braid  20  in the operating position  64 . 
     In  FIG. 3 , two exemplary embodiments of the housing  1  according to the invention are shown in the operating position  64 . In the first embodiment shown with solid lines, the pair of cable covers  12  form a cable support sleeve  66  having a cable outlet  67  that opens parallel to the insertion direction I and the opening  8 . For guiding the movement of the cable covers  16  towards each other, a guiding protrusion  68  is provided circumferentially extending from one cable cover  16  of the pair of cable covers  12 . The guiding protrusion  68  may be adapted to be guided into a, in an embodiment complementary formed, receiving notch  70  on the other cable cover  16  of the pair of cable covers  12 . 
     The second embodiment depicted with the dotted lines in  FIG. 3  shows the pair of cable covers  12  forming a cable support sleeve  66  that is angled at about 90° having a cable outlet  67  oriented essentially perpendicular to the insertion direction I and the opening  8 . Alternatively, the pair of cable covers  12  may be adapted to form the cable support sleeve  66  having cable outlets  67  oriented at a 90° angle, a 45° angle or anything in between 45° to 90°. Depending on the orientation relative to the insertion direction I in which the cable  10  should enter the cable support sleeve  66 , a respective pair of cable covers  12  may be provided. 
     The cable covers  12  may be adapted for the predetermined cable diameter  26 , meaning that in the operating position, the formed cable support sleeve  66  is adapted to receive the cable  10  in an essentially precise fit. 
     The housing body  6  may remain structurally identical in each embodiment, allowing for an easy and cost efficient production of the housing  1  in mass scale. By having identically structured hinges, i.e. the bearings  28  of the housing body  6  and the pins  34  of the respective cable covers  16 , each cable cover  16  may be attached on either side of the housing body  6  changing the orientation of angled pairs of cable covers  16 . The cable covers  16  may also be formed structurally identically. Consequently, by switching the position of each cable cover  16  of the second embodiment shown in  FIG. 3  the cable support sleeve  66  may be oriented in the opposite direction with respect to the second embodiment shown in  FIG. 3 . Thus, by providing a pair of cable covers  12  wherein each cable cover  16  of the pair of cable covers  12  may be hinged to the housing  1 , multiple degrees of freedom are provided for adapting the housing  1  to the application surroundings. By simply choosing a specific pair of cable covers  12 , the direction and/or angular orientation of the cable support sleeve  66  cable outlet  67  relative to the insertion direction I may be determined. 
     According to a further advantageous embodiment, a set may be provided, the set comprising at least two housings  1  according to the invention, wherein the at least two housings  1  may comprise identically structured housing bodies  6  and different pairs of cable covers  12 , the cable covers  12  forming the cable support sleeve  66 . The cable outlets  67  of the different pairs of cable covers  12  may be oriented differently with respect to the insertion direction I. 
     For maintaining the pair of cable covers  12  in the operating position  64 , a locking nut  72  may be provided, as shown in the embodiment of  FIG. 3 . The locking nut  72  may be adapted to receive the pair of cable covers  12  at least partially in the operating position  64 , blocking the cable covers  16  from pivoting away from one another. 
     In order to further increase the retention-withstanding force of the housing  1 , the locking nut  72  may be adapted to extend parallel to the cable  10 , meaning that the locking nut  72  does not bend the cable  10 . In other words, the locking nut  72  may extend coaxially with the cable  10  at the position of the locking nut  72 . 
     In an embodiment, the locking nut  72  and the pair of cable covers  12  comprise a bayonet locking assembly  74  shown in  FIG. 3  for locking the locking nut  72  to the pair of cable covers  12 . The bayonet locking assembly  74  may ensure an easy locking with a simple twist and an exact orientation of the final position of the locking nut  72 , which ensures not exceeding the offered space in an existing application. In particular, in comparison to a threaded locking assembly, the bayonet locking assembly  74  allows for an easier locking, especially in tight spaces. In the threaded locking assembly  74 , the pair of cable covers  12  must be perfectly aligned for the locking nut  72  to be able to engage the threads of the cable covers  12 . Thus, the pair of cable covers  12  must be pushed and held together in exact alignment with one hand while screwing on the locking nut  72 . 
     The bayonet locking assembly  74  is further explained in detail with reference to  FIGS. 3, 4 and 5 .  FIG. 4  shows a perspective view of a cable cover  16  of the pair of cable covers  12  and  FIG. 5  shows a perspective view of a locking nut  72  according to the invention. 
     As can be seen in  FIGS. 3 and 4 , the cable cover  16  may have a tapered distal end  55  allowing the locking nut  72  to slide over the distal end  55 , even when the cable covers  16  of the pair of cable covers  12  are not completely pushed together. By pushing the locking nut  72  over the pair of cable covers  12 , the cable covers  16  of the pair of cable covers  16  may automatically be pushed together, further facilitating the locking of the housing  1  in the operating position  64 . Consequently, an easy single-handed installation is possible, which further decreases the space requirements for installation. 
     Each cable cover  16  of the pair of cable covers  12  may have a guiding groove  76  on their respective outer surface facing away from each other at least in the operating position  64 , as shown in  FIG. 4 . The guiding groove  76  may extend from the distal end  55  of the respective cable cover  16  towards the proximal end  14  and may taper circumferentially towards the proximal end  14 . Therefore, the guiding groove  76  may form a mouth at the distal end  55  to catch a respective locking protrusion  78 , allowing for an easy insertion of the respective cable cover  16  into the locking nut  72 , even when the respective cable cover  16  and the locking nut  72  are not perfectly rotationally aligned. By pushing the locking nut  72  over the respective cable cover, the locking protrusion  78  slides along the tapering guiding groove  76 , resulting in an automatic realignment of the cable cover  16  relative to the locking nut  72 . 
     The cable cover  16  may further comprise a locking recess  80  arranged circumferentially adjoining to the guiding groove  76  at its end closer to the proximal end  14  of the cable cover  16 , as shown in  FIG. 4 , forming an L-shape. Therefore, the locking protrusion  78  of the locking nut  72  may be pushed along the guiding groove  76  until abutment, and then by a simple twist movement, be brought into the locking recess  80 . The locking protrusion  78  and the locking recess  80  may form a positive fit locking movement in a direction parallel to the insertion direction I. 
     As shown in  FIG. 4 , a locking rib  82  protruding radially from the respective cable cover  16  may be provided between the guiding groove  76  and the locking recess  80 . The locking rib  82  may prevent the locking protrusion  78  from unintentionally exiting the locking recess  80  due to movements such as vibrations. Thus, the locking rib  82  may further secure the locking engagement of the locking nut  72  to the respective cable cover  16 . The locking rib  82  may be beveled towards the guiding groove  76 , forming a ramp allowing for an easy movement of the locking protrusion  78  from the guiding groove  76  over the locking rib  82  to the locking recess  80 . The locking rib  82  may comprise an abutment surface  84  extending radially form the cable cover  16 , i.e. extending essentially perpendicular to the locking recess  80 , facing the locking recess  80 . Therefore, the locking protrusion  78  abuts the abutment surface  84  when moving from the locking recess  80  towards the guiding groove  76 , restricting any further movement. 
     The locking nut  72 , in the embodiment shown in  FIG. 5 , has two locking protrusions  78  protruding from an inner surface of the locking nut  72  radially inwards. The locking protrusions  78  and the locking nut  72  may be formed integrally with one another. Thus, the locking protrusions  78  and the locking nut  72  may be produced cost efficiently in a single production step, such as injection molding. 
     The two locking protrusions  78  are arranged diametrically to one another and each locking protrusion  78  may be adapted to be inserted in the locking recess  80  of different cable covers  16  of the pair of cable covers  12 . In other words, each cable cover  16  of the pair of cable covers  12  may be adapted to receive one of the two locking protrusions  78 . Thus, both cable covers  16  of the pair of cable covers  12  may be locked to the locking nut  72 . 
     The locking nut  72  and/or the pair of cable covers  12  may be formed from an insulating material, for example by an injection molding process. 
     The locking nut  72  may comprise a polygonal outer contour such as an octagon as shown in  FIGS. 3 and 5  or a hexagon. Alternatively or additionally, the locking nut  72  may comprise handlebars, i.e. ribs protruding from the outer surfaces of the locking nut  72  having a gripping function for easier handling of the locking nut  72 . With the polygonal outer contour, an easy handling of the locking nut  72  is possible, for example with a tool such as a complementary wrench. Thus, enabling locking and/or unlocking of the locking nut  72  when the locking nut  72  is not reachable by hand, for example due to space constraints. 
     In order to determine the relative rotational position of the locking nut  72  relative to the pair of cable covers  12 , the locking nut  72  may comprise a marking  86  on the outer surface of the locking nut  72 . Hence, the state, i.e. locked or unlocked, of the locking nut  72  and the pair of cable covers  12  may be easily determined. Furthermore, the locking nut  72  may be arranged in a correct rotational position relative to the pair of cable covers  12  for the locking protrusion  78  to be sliding along the guiding groove  76 . 
     The pair of cable covers  12  can be adapted to the application requirements, so that the cable  10  can be redirected as desired. The cable installation may vary depending on the available space. Thus, by having a pair of cable covers  12 , which can be hinged to the housing body  6 , the orientation of the cable cover  12  can be adapted to the application surroundings. Furthermore, the pair of cable covers  12  form the cable support sleeve  66  in the operating position  64  configured to support the cable  10 , in an embodiment directly. Hence, the pair of cable covers  12  further provides a strain relief for the cable  10 , securing the electrical and mechanical integrity and overall performance of the electric connector  4 . The cable covers  12  directly prevent mechanical force applied to the exterior part of the cable  10  from being transferred to the electrical terminations of the cable  10  within the electrical connector  4 . The housing  1  provides a two-part cable support sleeve  66  for strain relief, which can easily be adapted to be oriented in different directions relative to the opening  8 .