Patent Publication Number: US-10770846-B2

Title: Electric connector with wire holder

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a Continuation of U.S. patent application Ser. No. 15/942,758, filed on Apr. 2, 2018, now U.S. Pat. No. 10,103,504 which is a Continuation of U.S. patent application Ser. No. 15/542,016, filed on Jul. 6, 2017, now U.S. Pat. No. 9,935,411, which is a National Stage of Application of PCT/EP2016/050189, filed on Jan. 7, 2016, which claims the benefit of U.S. Patent Application Ser. No. 62/100,766, filed on Jan. 7, 2015, the disclosures of which are incorporated herein by reference in their entireties. To the extent appropriate, a claim of priority is made to each of the above disclosed applications. 
    
    
     BACKGROUND 
     Electric connectors, such as modular plugs, are typically used to transmit digital signals in telephonic and other data communication systems where high performance through reduced electromagnetic interference between conductors (i.e., crosstalk) is desirable and necessary. Modular plugs, one type of electric connectors, are typically terminated by technicians in the field, or prepared in assembly lines of a factory. In certain examples, a cable that is to be terminated in the modular plug includes insulated, multi-colored wires wrapped by an insulating cable jacket. The cable typically includes eight wires that are made into a bundle of four twisted pairs. The bundle may optionally include a drain wire or surrounding shield for use in a shielded plug. 
     To prepare the cable for termination in the plug, the cable jacket is first peeled back to expose the insulated pairs. After that, with the several insulated wires exposed, the wires can be untwisted and arranged in the desired order, generally in a side-by-side fashion. The wires can then be individually inserted into a plug housing and terminated by an insulation piercing blade. The wires can be misaligned and unsecured within the plug housing because the wires need to be independently engaged into the plug housing. 
     Some modular plugs employ a load bar or wire holder configured to hold the wires in an array and be inserted into the housing. The wire holder allows the wires to be presented in alignment below insulation piercing contacts when the wire holder is placed into the housing. The wire holder can define a plurality of wire support passages to arrange the wires in a side-by-side manner thereon and provide a lateral alignment of the wires below the insulation piercing contacts when the wire holder is received into the housing. The wire support passages of the wire holder operate to centralize the wires with the insulation piercing contacts so that the insulation piercing contacts properly pierce the wires to make contact with the conductors within the wires. However, the wire support passages are dimensioned to fit wires of a particular size, and thus cannot function to centralize and align wires of different sizes with the insulation piercing contacts. 
     SUMMARY 
     In general terms, this disclosure provides an electric connector that can be easily assembled with cable wires by ensuring proper positioning of the wires during assembly. 
     In certain examples, an electric connector in accordance with the principles of the present disclosure includes a housing, a plurality of contacts, and a wire holder. The housing includes an extension receiving cavity and a plurality of contact insert slots. The plurality of contacts is configured to be at least partially inserted to the plurality of contact insert slots. The wire holder includes a wire support extension configured to be at least partially inserted to the extension receiving cavity. The wire support extension defines a plurality of wire receiving passages configured to be aligned to the plurality of contact insert slots when the wire support extension is inserted to the extension receiving cavity. The plurality of wire receiving passages is configured to arrange wires of a cable thereon and align the wires of the cable with the plurality of contact insert slots. The wire holder may include a plurality of wire support ribs at least partially arranged on the plurality of wire receiving passages. The wire support ribs are configured to arrange wires of a cable on the plurality of wire receiving passages and align the wires of the second cable with the plurality of contact insert slots. 
     In other examples, an electric connector in accordance with the principles of the present disclosure includes a housing, a plurality of contacts, and a wire holder. The housing includes an extension receiving cavity and a plurality of contact insert slots. The plurality of contacts is configured to be at least partially inserted to the plurality of contact insert slots. The wire holder includes a wire support extension configured to be at least partially inserted to the extension receiving cavity. The wire support extension includes a plurality of wire receiving passages configured to be aligned to the plurality of contact insert slots when the wire support extension is inserted to the extension receiving cavity. The extension receiving cavity defines a plurality of wire channels with the plurality of wire receiving passages of the wire holder. The plurality of wire channels is configured to receive wires of a cable and terminate at a plurality of inner mating portions configured to engage forward ends of the wires of the cable. Each of the plurality of inner mating portions being conically tapered. 
     In certain examples, an electric connector includes a housing, a plurality of contacts, and a wire holder. The housing has a cavity and a plurality of contact insert slots being in communication with the cavity. The plurality of contacts is at least partially inserted to the plurality of contact insert slots. The wire holder includes a wire support extension configured to be at least partially inserted into the cavity of the housing and placed below the plurality of contact insert slots. The wire support extension defines a plurality of wire receiving passages configured to arrange a plurality of wires of a first cable thereon and align the wires with the contact insert slots, respectively, when the wire support extension is inserted to the cavity of the housing. The wire holder may further include a plurality of wire support ribs at least partially arranged on the plurality of wire receiving passages to centralize wires of a second cable that has a size (e.g., a diameter) smaller than that of the wires of the first cable. The plurality of wire support ribs may arrange the smaller wires in place of the larger wires on the plurality of wire receiving passages, thereby aligning the smaller wires with the contact insert slots. 
     In addition, or alternatively, the electric connector may include a plurality of inner mating portions formed in the housing adjacent the plurality of wire receiving passages of the wire holder that is fully inserted into the housing. The inner mating portions are configured to engage forward ends of wires of a cable disposed on the plurality of wire receiving passages of the wire holder and align the cable wires with the contact insert slots. In certain examples, the plurality of inner mating portions is conically tapered to engage forward ends of wires having different sizes. 
     In addition, or alternatively, the wire holder may include a first alignment portion, such as an alignment protrusion, and the housing may include a second alignment portion, such as an alignment groove, corresponding to the first alignment portion. The first and second alignment portions are engaged to arrange the wire holder in place within the housing as the wire holder is inserted into the housing so that cable wires disposed on the wire holder are aligned with the contact insert slots of the housing. 
     Accordingly, the electric connector in accordance with the present disclosure may securely arrange and align cable wires of different sizes with the plurality of contacts. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an example electric connector assembly. 
         FIG. 2  is an exploded view of the electric connector of  FIG. 1 . 
         FIG. 3  is a top perspective view of an example wire holder. 
         FIG. 4  illustrates an exploded cross-sectional view of a base portion of the wire holder of  FIG. 3 . 
         FIG. 5  is a bottom perspective view of the wire holder of  FIG. 3 . 
         FIG. 6  is a side cross-sectional view of an assembly of a housing, contacts, and the wire holder engaging a cable. 
         FIG. 7  is a rear cross-sectional view of the assembly of  FIG. 6  without the cable. 
         FIG. 8A  is a rear cross-sectional view of the electric connector, illustrating a first cable disposed therein. 
         FIG. 8B  is an enlarged rear cross-sectional view of the electric connector of  FIG. 8A . 
         FIG. 9A  is a rear cross-sectional view of the electric connector, illustrating a second cable disposed therein. 
         FIG. 9B  is an enlarged rear cross-sectional view of the electric connector of  FIG. 9A . 
         FIG. 10A  is an exploded side cross-sectional view of an example inner mating portion engaging a first cable. 
         FIG. 10B  is an exploded side cross-sectional view of an example inner mating portion engaging a second cable. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims. 
     As described herein, an electric connector in accordance with the principles of the present disclosure includes a housing, a plurality of contacts, and a wire holder. The housing includes an extension receiving cavity and a plurality of contact insert slots. The plurality of contacts is configured to be at least partially inserted to the plurality of contact insert slots. The wire holder includes a wire support extension configured to be at least partially inserted to the extension receiving cavity. The wire support extension defines a plurality of wire receiving passages configured to be aligned to the plurality of contact insert slots when the wire support extension is inserted to the extension receiving cavity. The plurality of wire receiving passages is configured to arrange wires of a cable thereon and align the wires of the cable with the plurality of contact insert slots. The wire holder may include a plurality of wire support ribs at least partially arranged on the plurality of wire receiving passages. The wire support ribs are configured to arrange wires of a cable on the plurality of wire receiving passages and align the wires of the second cable with the plurality of contact insert slots. 
     In other examples, an electric connector in accordance with the principles of the present disclosure includes a housing, a plurality of contacts, and a wire holder. The housing includes an extension receiving cavity and a plurality of contact insert slots. The plurality of contacts is configured to be at least partially inserted to the plurality of contact insert slots. The wire holder includes a wire support extension configured to be at least partially inserted to the extension receiving cavity. The wire support extension includes a plurality of wire receiving passages configured to be aligned to the plurality of contact insert slots when the wire support extension is inserted to the extension receiving cavity. The extension receiving cavity defines a plurality of wire channels with the plurality of wire receiving passages of the wire holder. The plurality of wire channels is configured to receive wires of a cable and terminate at a plurality of inner mating portions configured to engage forward ends of the wires of the cable. Each of the plurality of inner mating portions being conically tapered. 
       FIG. 1  is a perspective view of an example electric connector assembly  100 . The electric connector assembly  100  includes an electric connector  102  and a cable  104 . 
     As used herein, the word “front” or “forward” corresponds to an end of the electric connector assembly  100  where the contacts  114  are arranged, and the word “rear,” “rearward,” or “back” corresponds to the direction opposite to the end of the trigger mechanism where the contacts  114  are located. 
     The electric connector  102  is configured to ensure reliable termination of cable wires having different sizes. The electric connector  102  can receive and arrange a plurality of wires  106  ( FIG. 6 ) of different sizes (e.g., diameters) therein to be aligned with a plurality of contacts. An example electric connector  102  is illustrated and described in more detail with reference to  FIG. 2 . 
     The cable  104  is terminated in the electric connector  102 . The cable  104  includes a plurality of wires  106  ( FIG. 6 ). In some embodiments, the cable  104  includes eight multi-colored wires that are made into a bundle of four twisted pairs. As shown in  FIG. 6 , each of the wires  106  can include an inner conductive core  108  and an outer insulating layer  110  surrounding the inner conductive core  108 . 
       FIG. 2  is an exploded view of the electric connector  102  of  FIG. 1 . The electric connector  102  may include a housing  112 , a plurality of contacts  114 , a wire holder  116 , a shield cap  118 , and a strain relief boot  120 . 
     The housing  112  is configured to receive the plurality of contacts  114  and the wire holder  116  aligning the wires  106  of the cable  104 . The housing  112  defines a housing cavity  122  and a plurality of contact insert slots  124 . As shown in  FIG. 6 , the housing cavity  122  includes an extension receiving cavity  126 . The housing cavity  122  is configured to receive and support the wire holder  116  with the extension receiving cavity  126  receiving a wire support extension  132  of the wire holder  116 , as described below. The plurality of contact insert slots  124  is configured to at least partially receive the plurality of contacts  114 , respectively. The housing  112  may further include one or more grooves  128  configured to secure the wire holder  116  when the wire holder  116  is received in the housing  112 . 
     The contacts  114  are at least partially inserted into the contact insert slots  124  and adapted to be pressed toward the housing cavity  122  once the wire holder  116  conveying the wires  106  of the cable  104  is inserted into the housing cavity  122  for termination. As described below, when the wires  106  of the cable  104  is received in the wire receiving passages  156  positioned on the wire support extension  132 , the contacts  114  are further pressed into the contact insert slots  124  to pierce through the insulating layers  110  of the wires  106  and engage and terminate to the conductive cores  108  of the wires  106 , respectively. An example of the contacts  114  is illustrated and described in more detail with reference to  FIG. 6 . 
     The conductive cores  108  may be made of copper, aluminum, copper-clad steel, plated copper, or other electrically conductive materials. Some example materials that may be used to manufacture the insulating layer  110  include plastic material, such as polyvinyl chloride (PVC), polyethylene, fluoropolymers (e.g. ethylenechlorotrifluorothylene (ECTF) and Flurothylenepropylene (FEP)), or other electrically insulating materials. 
     The wire holder  116  operates to support and convey the wires  106  of the cable  104  into the housing  112  for termination. The wire holder  116  is configured to centralize and align the wires  106  of the cable  104  with the contacts  114  (and/or the contact insert slots  124 ) when the contacts  114  are pressed onto the wire  106  through the contact insert slots  124 , thereby ensuring an electrical contact between the contacts  114  and the conductive cores  108  of the wires  106 , respectively. As described below, the wire holder  116  is adapted to align wires  106  of different sizes. An example wire holder  116  is illustrated and described in more details with reference to  FIG. 3 . 
     The shield cap  118  is configured to at least partially cover the housing  112 , the wire holder  116 , and/or electrical components contained therein. The shield cap  118  is used to reduce alien crosstalk between adjacent electric connectors  102 . 
     The strain relief boot  120  engages the shield cap  118  and a least a portion of the housing  112  containing the wire holder  116  at the rearward end. The strain relief boot  120  provides strain relief to the cable  104  received within the housing  112 . 
       FIG. 3  is a top perspective view of an example wire holder  116 . The wire holder  116  includes a holder body  130  and a wire support extension  132 . 
     The holder body  130  is configured to be inserted into the housing cavity  122 . In some embodiments, the holder body  130  defines one or more wire insert channels  136  through which the wires  106  of the cable  104  are inserted before the wires  106  are disposed on the wire support extension  132 . In the illustrated example, the holder body  130  has four wire insert channels  136 , each of which receives a twisted pair of wires therethrough. 
     The holder body  130  may include one or more coupling tabs  138  for securing the holder body  130  in the housing cavity  122  of the housing  112 . In some embodiments, the coupling tabs  138  are formed on side walls  140  and  142  and extend further outwardly than the width of the housing cavity  122  such that there is an interference fit between the coupling tabs  138  of the holder body  130  and the grooves  128  ( FIG. 1 ) of the housing  112 . 
     The wire support extension  132  extends from the holder body  130 . For example, the wire support extension  132  extends from a forward end  144  of the holder body  130  and has a wire trimming end  148  opposite to the forward end  144  of the holder body  130 . The wire support extension  132  is configured to be at least partially inserted into the extension receiving cavity  126  ( FIG. 6 ) of the housing  112  and positioned below the contact insert slots  124  of the housing  112 . 
     The wire support extension  132  has a base portion  150  having two opposite surfaces, such as a top surface  152  and a bottom surface  154 . The wire support extension  132  includes a plurality of wire receiving passages  156  formed on the top surface  152  of the base portion  150  and configured to be aligned to the contact insert slots  124  of the housing  112 , respectively, when the wire support extension  132  is inserted into the extension receiving cavity  126 . Cooperating with a plurality of centralizing ribs  160 , the wire receiving passages  156  are configured to centralize wires  106  of different diameters along middle axes A ( FIG. 7 ) that are aligned with the contacts  114 , respectively. 
     The wire receiving passages  156  may be defined by a plurality of base protrusions  158  extending from the top surface  152  of the base portion  150  and arranged in parallel. In the illustrated example, the base protrusions  158  have tapered lateral surfaces  159  to substantially form a triangular cross section (e.g., the wire receiving passages  156  is wider at the top than at the bottom thereof) so that the wires  106  of the cable  104  are abutted onto the tapered lateral surfaces  159 . The base protrusions  158  can thus enable the wires  106  to be easily and securely placed on the wire receiving passages  156 . As described below, the wire receiving passages  156  are shaped and dimensioned to support and align (i.e., centralize) wires  106  having a first diameter. In the illustrated example, the wire support extension  132  has eight wire receiving passages  156  for supporting eight wires  106 . 
     The wire support extension  132  further includes a plurality of centralizing ribs (which is also referred to herein as wire support ribs)  160  at least partially arranged on the wire receiving passages  156  to support wires  106  of a second diameter that is smaller than the first diameter. The centralizing ribs  160  are configured such that a width of the wire receiving passage  156  is defined smaller between adjacent centralizing ribs  160  within the wire receiving passages  156  than between corresponding adjacent base protrusions  158 . As shown in  FIG. 7 , a middle point (or center line) A R2  between adjacent centralizing ribs  160  is in line with the middle axis A that is aligned with a center line of a front side  202  of the associated contact  114 . Thus, the centralizing ribs  160  helps centralizing the wires  106  of the second diameter along the middle axes A. In some embodiments, the centralizing ribs  160  are formed at least partially around the base protrusions  158 , respectively. Further, the centralizing ribs  160  can be shaped to be thin enough to be embedded into the outer insulating layers  110  of the wires  106 . 
     Further, as shown in  FIG. 6 , the centralizing ribs  106  can be aligned with a center line A R1  of a lateral side  204  of the contacts  114 . In addition to aligning a wire of the second diameter, the centralizing ribs  160  can operate to centralize wires of various diameters along the center line of the contacts  114  (i.e., the middle axis A). As described herein, where the twisted pairs of wires are terminated with the connector assembly  100 , an operator or technician at the field will straighten the twisted wires and place them onto the wire support extension  132  of the wire holder  116  for termination. In some occasions, at least one of the twisted wires is not fully flattened and can remain at least partially twisted within the associated wire channel  176  when the wire holder  116  is inserted into the housing  112 . The centralizing ribs  160  that are aligned with the center line A R1  of the lateral side  204  of the contacts  114  ( FIG. 6 ), as well as with the center line A R2  of the front side of the contacts  114  ( FIG. 7 ), operate to align a portion of such at least partially twisted wires with the center of the contacts  114  (at the middle of two opposing insulation piercing tips  186  of each contact  114 ) in both planes (e.g., along the axes A R1  and A R2 ), thereby ensuring the contacts  114  to pierce into the associated wires. 
     In the illustrated example, one centralizing rib  160  is formed around each base protrusion  158 . In other embodiments, a plurality of centralizing ribs  160  can be formed around each base protrusion  158 . For example, two or more centralizing ribs  160  are arranged around each base protrusion  158  and spaced apart from each other along the length of the base protrusion  158 . In some embodiments, such multiple centralizing ribs  160  for each base protrusion  158  can be equally spaced apart along the base protrusion  158 . Other embodiments are also possible. 
       FIG. 4  illustrates an exploded cross-sectional view of the base portion  150 , illustrating example geometry of the wire support extension  132 . As described above, the wire support extension  132  defines the wire receiving passages  156  configured to support and align wires  106  of different dimensions, respectively. 
     In some embodiments, the wire receiving passages  156  defined by the base protrusions  158  can secure wires  106  having a diameter ranging, for example, between D 1  and D 2 . The distance D 1  is a distance between lower edges  162  of adjacent base protrusions  158 , and the distance D 2  is a distance between middle points  164  of the adjacent base protrusions  158 . If the diameter of a wire  106  is larger than the distance D 2 , the wire  106  does not contact the tapered lateral surfaces  159 , but can contact adjacent wires  106 . The adjacent wires  106  thus can interface with each other and do not securely seat on the wire receiving passages  156 . In other embodiments, the wire receiving passages  156  can secure the wire  106  having a diameter slightly larger than the distance D 2  because the outer insulating layers  110  can be compressed without interfering with alignment of the wires  106  when adjacent wires  106  are abutted each other. If the diameter of a wire  106  is smaller than the distance D 1 , the wire  106  does not contact both of the tapered lateral surfaces  159  and can float between the tapered lateral surfaces  159  within the wire receiving passage  156  if there are no centralizing ribs  160 . 
     The centralizing ribs  160  can help securing wires  106  having a diameter ranging, for example, between D 3  and D 1 . The distance D 3  is a distance between lower edges  166  of adjacent centralizing ribs  160 . If the diameter of a wire  106  is smaller than the distance D 3 , the wire  106  does not engage both of opposing sides  168  of the adjacent centralizing ribs  160  and can float between the opposing sides  168  of the adjacent centralizing ribs  160 . 
     Accordingly, the wire receiving passages  156  with the centralizing ribs  160  can support and centralize wires  106  having a diameter, for example, between the distances D 2  (i.e., a distance between the middle points  164  of adjacent base protrusions  158 ) (or slightly larger than D 2 ) and D 3  (i.e., a distance between the lower edges  166  of adjacent centralizing ribs  160 ). 
     In the illustrated example, the centralizing ribs  160  have a cross section that resembles the cross section of the base protrusions  158 . For example, similarly to the base protrusions  158 , the centralizing ribs  160  substantially form a triangular cross-section (e.g., each rib  160  has a width wider at its top than at its bottom). However, in other embodiments, the centralizing ribs  160  can have different shapes. For example, at least one of the centralizing ribs  160  can have a rounded cross section. In other examples, at least one of the centralizing ribs  160  has a polygonal cross section. 
       FIG. 5  is a bottom perspective view of the wire holder  116  of  FIG. 3 . The wire holder  116  includes a first alignment portion  180  configured to correspondingly engage a second alignment portion  182  ( FIG. 6 ) formed in the housing  112  when the wire holder  116  is disposed within the housing  112 . The first and second alignment portions  182  and  182  are configured to align the wire holder  116  in place within the housing cavity  122 . For example, the first and second alignment portions  180  and  182  are engaged with each other when the wire support extension  132  of the wire holder  116  is inserted into the extension receiving cavity  126  of the housing  112  to align the plurality of contact insert slots  124  with the plurality of wire receiving passages  156  of the wire holder  116  along the middle axes A ( FIG. 7 ). 
     In some embodiments, the first alignment portion  180  includes an alignment protrusion, and the second alignment portion  182  includes an alignment groove corresponding to the alignment protrusion. The alignment groove of the housing  112  is configured to engage the alignment protrusion of the wire holder  116  when the wire support extension  132  of the wire holder  116  is inserted into the extension receiving cavity  126  of the housing  112  to align the contact insert slots  124  with the wire receiving passages  156  of the wire holder  116 . The alignment protrusion, as the first alignment portion  180  can be formed on the bottom surface  154  of the base portion  150 . 
     In other embodiments, the first and second alignment portions  180  and  182  have different corresponding shapes. For example, the first alignment portion  180  can include a groove, and the second alignment portion  182  can include a corresponding protrusion. Other embodiments are also possible. 
     In some embodiments, the first and second alignment portions  180  and  182  can be designed to have tolerances such that the first alignment portion  180  slightly interferes with the second alignment portion  182  in engagement, thereby causing the first and second alignment portions  180  and  182  to be always engaged without clearance. This engagement between the first and second alignment portions  180  and  182  without clearance can avoid creating a gap between the first and second alignment portions  180  and  182  and ensure the accurate alignment of the wire holder  116  relative to the housing  112 . 
     Referring to  FIGS. 6 and 7 , an example structure of the extension receiving cavity  126  is described.  FIG. 6  is a side cross-sectional view of an assembly of the housing  112 , the contacts  114 , and the wire holder  116 , which engages the cable  104 .  FIG. 7  is a rear cross-sectional view of the assembly of  FIG. 6  without the cable  104 . 
     As illustrated in  FIG. 6 , the extension receiving cavity  126  is defined by a bottom surface (also referred to herein as a first surface)  170  and a top surface (also referred to herein as a second surface)  172  opposite to the bottom surface  170 . The bottom surface  170  of the extension receiving cavity  126  is configured to receive and support the wire support extension  132  such that the wire support extension  132  seats on the bottom surface  170 . The top surface  172  of the extension receiving cavity  126  can include a plurality of wire grooves  174  that corresponds to the plurality of wire receiving passages  156  to define a plurality of wire channels  176  configured to receive the wires  106 , respectively. 
     The extension receiving cavity  126  further includes a plurality of inner mating portions  190  configured to engage forward ends  192  of the wires  106  and terminate the wires  106 . An example structure of the inner mating portions  190  is illustrated and described in more detail with reference to  FIGS. 10A and 10B . 
     The wires  106  of the cable  104  can be terminated in various manner using the housing  112 , the contacts  114 , and the wire holder  116  of the present disclosure. In some embodiments, the wires  106  of the cable  104  can be first inserted through the wire insert channels  136 . For example, where four wire insert channels  136  are provided as illustrated in  FIG. 3 , eight wires  106  are paired into four groups (e.g., four twisted pairs of wires) that pass through the four wire insert channels  136 , respectively, in various manners. Then, the wires  106  are respectively disposed on the wire receiving passages  156  of the wire support extension  132  of the wire holder  116 . In some embodiments, the wires  106  extend over the wire trimming end  148  of the wire holder  116  when the wires  106  are placed on the wire receiving passages  156 . The wire holder  116  supporting the wires  106  are inserted into the housing cavity  122  until the wire support extension  132  of the wire holder  116  is fully inserted into the extension receiving cavity  126  of the housing  112  and the extended tips (i.e., the forward ends  192 ) of the wires  106  contact the forward mating portions  190  of the extension receiving cavity  126 . 
     Each of the contacts  114  has one or more contact insulation piercing tips  186 . When the wire support extension  132  supporting the wires  106  is completely inserted into the extension receiving cavity  126  of the housing  112 , the contact insulation piercing tips  186  of the contacts  114  are arranged above the wires  106  along the middle axes A ( FIG. 7 ). In some embodiments, each contact  114  can has two contact insulation piercing tips  186  that are opposingly offset from each other with respect to the center line of the contact  114 . As illustrated in  FIGS. 8B and 9B , the contacts  114  can then be depressed through the contact insert slots  124  such that they pierce through the outer insulating layer  110  and make contact with the inner conductive core  108  of the wires  106 . 
       FIGS. 8A and 8B  are rear cross-sectional views of the electric connector  102 , illustrating a first cable  104 A disposed therein. The first cable  104 A is an example of the cable  104  as described above. The first cable  104 A has a plurality of first wires  106 A, each having a first diameter D A . Each of the first wires  106 A includes an inner conductive core  108 A and an outer insulating layer  110 A. As illustrated, the first diameter D A  of the first wire  106 A is greater than a distance defined between the opposing sides  168  of adjacent centralizing ribs  160  at any height from the lowest portions of the centralizing ribs  160 . In this configuration, the centralizing ribs  160  are configured to be embedded at least partially into the outer insulating layers  110 A of the first wire  106 A when the wires  106 A are pressed against the wire receiving passages  156  by the contacts  114  being depressed onto the first wires  106 A. 
       FIGS. 9A and 9B  are rear cross-sectional views of the electric connector  102 , illustrating a second cable  104 B disposed therein. The second cable  104 B is an example of the cable  104  as described above. The second cable  104 B has a plurality of second wires  106 B, each having a second diameter D B . Each of the second wires  106 B includes an inner conductive core  108 B and an outer insulating layer  110 B. The second diameter D B  is smaller than the first diameter D A . The centralizing ribs  160  are configured such that a width of the wire receiving passage  156  is defined smaller between the opposing sides  168  of adjacent centralizing ribs  160  within the wire receiving passages  156  than between the tapered lateral surfaces  159  of adjacent base protrusions  158 . The centralizing ribs  160  are designed to centralize the second wires  106 B of the second diameter D B  along the middle axes A. In some embodiments, similarly to the first wires  106 A, the centralizing ribs  160  can be embedded at least partially into the outer insulating layers  110 B of the second wire  106 B as the second wires  106 B are pressed against the wire receiving passages  156 . 
       FIGS. 10A and 10B  are exploded side cross-sectional views of the extension receiving cavity  126 , illustrating an example structure of the inner mating portions  190  thereof. 
     The plurality of inner mating portions  190  is formed at a forward end of the extension receiving cavity  126  and configured to terminate the forward ends  192  of the wires  106 . The inner mating portions  190  are configured to secure the wires  106  of different diameters at the forward ends  192  thereof, such as the first wires  106 A and the second wires  106 B. 
     Each of the inner mating portions  190  is conically tapered to engage the forward ends  192  of the wires  106 , which have different diameters. In some embodiments, each of the inner mating portions  190  includes a mating end surface  194  and a circumferential side surface  196 . The circumferential side surface  196  can be configured to have a truncated cone shape in a cross-sectional view, such as shown in  FIGS. 10A and 10B . For example, a width We of the circumferential side surface  196  is configured to decrease in a longitudinal direction as it is close to the mating end surface  194  along a corresponding wire channel  176 . 
     The truncated cone shape of the inner mating portions  190  can engage the wires  106  of different diameters and secure them in place. As illustrated in  FIG. 10A , a wider portion of the circumferential side surface  196  away from the mating end surface  194  can engage the forward end  192  of the first wire  106 A having the first diameter D A  as the first wire  106 A is disposed in the wire channel  176 . As illustrated in  FIG. 10B , a narrower portion of the circumferential side surface  196  close to the mating end surface  194  can engage the forward end  192  of the second wire  106 B having the second diameter D B  as the second wire  106 B is disposed in the wire channel  176 . If the forward end  192  of the second wire  106 B is equal to, or smaller than, a size (e.g., a diameter) of the mating end surface  194 , the mating end surface  194  can engage the forward end  192  of the second wire  106 B as the second wire  106 B is disposed in the wire channel  176 . 
     As described herein, the electric connector  100  in accordance with the present disclosure is assembled by inserting wires of the cable into the wire insert channels  136  of the wire holder  116 ; arranging the wires on the wire support extension  132  of the wire holder  116 ; and engaging the wire holder  116  with the housing  112  by inserting the wire support extension  132  of the wire holder  116  into the extension receiving cavity  126  of the housing  112 . As described herein, the wire support extension  132  includes the plurality of wire receiving passages  156  configured to arrange wires of a first cable thereon and centralize the wires of the first cable along middle axes A of the wire receiving passages  156 . The plurality of wire receiving passages  156  is aligned to the plurality of contact insert slots  124  of the housing  112 . The wire holder  116  includes the plurality of wire support ribs  160  at least partially arranged on the plurality of wire receiving passages  156  and configured to arrange wires of a second cable on the plurality of wire receiving passages  156  and centralize the wires of the second cable among the middle axes A of the wire receiving passage  156 . The wires of the second cable have a diameter smaller than a diameter of the wires of the first cable. The method of assembling the electric connector  100  can further include a step of inserting the plurality of contacts  114  into the plurality of contact insert slots  124  until the contact insulation piercing tips  186  pierce through outer insulating layers of the wires to make contact with inner conductive cores of the wires. 
     The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the following claims. 
     LIST OF REFERENCE NUMERALS AND CORRESPONDING FEATURES 
     
         
         
           
               100  electric connector assembly 
               102  electric connector 
               104 A first cable 
               104 B second cable 
               104  cable 
               106 A first wire 
               106 B second wire 
               106  wire 
               108 A inner conductive core 
               108 B inner conductive core 
               108  conductive core 
               110 A outer insulating layer 
               110 B outer insulating layer 
               110  insulating layer 
               112  housing 
               114  contacts 
               116  wire holder 
               118  shield cap 
               120  strain relief boot 
               122  housing cavity 
               124  contact insert slots 
               126  extension receiving cavity 
               128  grooves 
               130  holder body 
               132  wire support extension 
               136  wire insert channels 
               138  coupling tabs 
               140  side walls 
               142  side walls 
               144  forward end 
               148  wire trimming end 
               150  base portion 
               152  top surface 
               154  bottom surface 
               156  wire receiving passages 
               158  base protrusions 
               159  tapered lateral surfaces 
               160  centralizing ribs 
               162  lower edges 
               164  middle points 
               166  lower edges 
               168  opposing sides 
               170  bottom surface 
               172  top surface 
               174  wire grooves 
               176  wire channel 
               180  first alignment portion 
               182  second alignment portion 
               186  contact insulation piercing tips 
               190  inner mating portion 
               192  forward end 
               194  mating end surface 
               196  circumferential side surface 
               202  front side of contact 
               204  lateral side of contact