Patent Description:
This invention relates to the latching of fiber optic and electrical connectors and adapters, and securing the mated connections resulting therefrom.

As data demands have increased, the tendency has been for the overall size of both electrical and fiber optic connectors to get smaller, so as to enable fitting more connectors of a given type into a given physical space. However, given the performance requirements, there is a limit to how small the contacts, whether they are electrical pins or fiber optic ferrules, can realistically be. Any means of reducing the overall size of a given connector would therefore be advantageous.

Latch-type connectors are commonly seen across the industry in both electrical and fiber optic connectors. Examples of electrical connectors include the RJ11 and RJ45 interfaces, while in the realm of fiber optics, the common LC and MPO types both use latches to result in a mechanically secure connection. Latches are usually preferred over electrical press-fit connectors, such as USB-A connector, because they provide visual, audible, and tactile feedback to the user when properly mated. In the case of fiber connectors, a latch is necessary to provide sufficient and secure depth-of-mate to ensure physical contact upon which optical performance of the connection depends.

A major drawback of traditional latch-type designs is that the latch is always placed outside the envelope of the contact pattern. This means that the inclusion of the latch mechanism increases the overall envelope of the connector interface, forcing it to become either wider or taller than the connector would otherwise need to be. As such, a mechanism which utilizes the space between contacts could achieve the advantages of a latch-type connection while simultaneously minimizing the overall size of the connector interface.

<CIT> discloses a fiber optic connector port arrangement including at least one upper receptacle and at least one lower receptacle vertically aligned with the upper receptacle to form a column of receptacles, the column including a center divider that divides the at least one upper receptacle from the at least one lower receptacle. The center divider defines latching shoulders for mating with latches of both a connector to be mounted at the upper receptacle of the column and a connector to be mounted at the lower receptacle of the column.

The present invention relates to a connector assembly as claimed in claim <NUM>, a connector system as claimed in claim <NUM> and a method of connector assembly as claimed in claim <NUM>.

Embodiments of the inventive connectors and connector components described overcome disadvantages of traditional connectors, connector components, and attachment means, and allow more connectors to be used within a given space. In particular, the exemplary connectors discussed herein include a mechanism that does not increase the overall envelope of the connector interface, thereby necessitating less space for a proper connector by minimizing the overall size of the connector interface. Such reduction of the connector interface size allows a greater number of connectors to be used within a given space, as compared to traditional connectors.

According to one embodiment of the invention, there is provided a connector plug comprised of a connector housing at the proximal end, a two-part backshell at the distal end, with a plurality of contacts housed within in a pre-defined contact pattern. Cantilever latching arms extend from the proximal end of the backshell. When mating with the receptacle, these latching arms depress into interstices between contact positions on the plug and snap into latching points located on the receptacle. Touch points are provided to enable the user to depress the latching arms and release the connector plug when required.

According to another embodiment of the invention, the two parts of the backshell are identical and mate to each other hermaphroditically.

According to another embodiment of the invention, an ergonomically-designed decoupler is added encircling the connector plug, which when pulled towards the distal end of the connector, cams over an angled surface on the latching arms, depressing them and releasing the connector plug.

In accordance with embodiments not according to the claimed invention, an exemplary connector assembly is provided. The connector assembly includes a plug housing including contacts. The plug housing defines a proximal end and a distal end. The connector assembly includes a backshell located at or near the distal end of the plug housing. The backshell includes a latching mechanism extending from a proximal end of the backshell. The latching mechanism is at least partially recessed into a complementary space formed in the plug housing.

In some embodiments, the contacts can include an array of <NUM> contacts. In some embodiments, the backshell can include a first backshell half and a second backshell half. In some embodiments, the first and second backshell halves can be identical (or substantially identical) and can be configured to engage relative to each other to form the backshell. In some embodiments, the first and second backshell halves can assemble to one another hermaphroditically.

The complementary space formed in the plug housing can be a recessed groove or an opening formed in a top surface of the plug housing and configured to at least partially receive the latching mechanism of the backshell. The latching mechanism can include a cantilever with at least one latch extending from a proximal end of the cantilever. In the at least partially recessed position of the latching mechanism, the at least one latch of the cantilever can be disposed in an interstitial space between the contacts of the plug housing.

The cantilever can include a press surface extending from the backshell, a ramp extending from the press surface, and the at least one latch extending from the ramp. The press surface can define a broad surface capable of being biased to lower the at least one latch deeper into the complementary space of the plug housing. The at least one latch can be configured to engage with a complementary latch point of a receptacle. Biasing the cantilever to lower the at least one latch deeper into the complementary space of the plug housing can disengage the at least one latch from the complementary latch point of the receptacle.

In some embodiments, the connector assembly can include a decoupler slidably disposed over the plug housing and/or the backshell. Sliding the decoupler over the ramp of the cantilever depresses and biases the at least one latch deeper into the complementary space of the plug housing to disengage the at least one latch from a complementary latch point of a receptacle.

In some embodiments, the contacts can fiber optic ferrules. In some embodiments, the contacts can be electrical contacts. In some embodiments, the contacts can include at least one fiber optic ferrules and at least one electrical contact. In some embodiments, the latching mechanism can include a plurality of cantilevers, each of the cantilevers including at least one latch located at a proximal end of the respective cantilever.

In accordance with embodiments not according to the claimed invention, an exemplary connector system is provided. The connector system includes a connector assembly including a plug housing and a backshell. The plug housing includes contacts, and defines a proximal end and a distal end. The backshell is located at or near the distal end of the plug housing. The connector system includes a receptacle configured to at least partially receive the contacts of the connector assembly. The backshell includes a latching mechanism extending from a proximal end of the backshell. The latching mechanism is at least partially recessed into a complementary space formed in the plug housing.

In accordance with embodiments not according to the claimed invention, an exemplary method of connector assembly is provided. The method includes electrically or optically connecting a connector assembly with a receptacle. The connector assembly includes a plug housing including contacts. The plug housing defines a proximal end and a distal end. The connector assembly includes a backshell located at or near the distal end of the plug housing. The backshell includes a latching mechanism extending from a proximal end of the backshell. The latching mechanism is at least partially recessed into a complementary space formed in the plug housing. The method includes depressing the latching mechanism further into the complementary space formed in the plug housing to disengage the connector assembly from the receptacle.

Additional advantageous functions, features, and applications of the disclosed systems, methods, and assemblies will be apparent from the detailed description which follows, particularly when read in conjunction with the appended figures.

Other aspects and advantages of the invention will be apparent from the following detailed description wherein reference is made to the accompanying drawings. In order that the invention may be more fully understood, the following figures are provided by way of illustration, in which:.

<FIG> illustrates an exemplary plug assembly <NUM>. The contacts, in this case fiber optic ferrules <NUM>, are arrayed in a 4x2 pattern at proximal end <NUM> of the connector, housed within plug housing <NUM>. However, it should be understood that the plug assembly <NUM> can include different types of contacts. The housing <NUM> is assembled between two backshell halves <NUM>, with an elastomeric connector boot <NUM> providing strain relief for a cable <NUM> extending from main body <NUM> in the direction of distal end <NUM>. The two backshell halves <NUM> are identical in structure, and can therefore be interchanged and interlocked relative to each other and the housing <NUM>. Extending from each backshell half <NUM>, in the direction of proximal end <NUM>, is a cantilever <NUM> (e.g., a flange), which fits into opening <NUM> of plug housing <NUM> (see, e.g., <FIG>). Each cantilever <NUM> includes two latches <NUM> at a proximal end, a press surface <NUM> adjacent to and connecting the cantilever <NUM> to the main body portion of the backshell half <NUM>, and a ramp <NUM> between the latches <NUM> and the press surface <NUM>. The cantilever <NUM> acts as a latching means or latching mechanism for the plug assembly <NUM>.

With particular reference to <FIG>, in some embodiments, the bottom surface (e.g., the inwardly facing surface) of the cantilever <NUM> generally extends along the same plane, while the top surface of the cantilever <NUM> defines different profiles at the latches <NUM>, the press surface <NUM>, and the ramp <NUM>. In some embodiments, the bottom or inner surface of the cantilever <NUM> can initially taper inwardly at a tapered section <NUM> before extending along the same plane at planar section <NUM>. The cantilever <NUM> can include a downwardly directed ramp <NUM> at a distal end and connecting the backshell half <NUM> to the press surface <NUM>. The press surface <NUM> can extend from the backshell half <NUM> at a plane below the top surface of the backshell half <NUM>, and generally defines a substantially planar, continuous surface. The ramp <NUM> tapers downwardly to a second plane below the plane of the press surface <NUM>. The latches <NUM> include two spaced flanges <NUM> extending from the proximal end of the ramp <NUM>, with an upwardly directed protrusion <NUM> extending from the proximal end of each flange <NUM>. The top or endpoint of each protrusion <NUM> substantially aligns with or does not extend beyond the plane defined by the press surface <NUM>. The entire structure of the cantilever <NUM> therefore extends below the plane defined by the top surface of the backshell half <NUM>.

At least part of the cantilever <NUM> therefore sits below the top surface <NUM> of plug housing <NUM>. In particular, the top surface <NUM> of the plug housing <NUM> includes an opening or recessed area <NUM> (e.g., a complementary space) formed therein and substantially complementary to the shape of the cantilever <NUM>. During assembly, as illustrated in <FIG>, the cantilever <NUM> at least partially fits within the recessed area <NUM> in the top surface <NUM> of the plug housing <NUM>, resulting in the cantilever <NUM> sitting at least partially below the top surface <NUM> of the plug housing <NUM>. The underside of plug assembly <NUM> is substantially identical to the top side illustrated in <FIG>, aside from the placement of alignment key <NUM> on a side surface of the plug assembly <NUM>, as can be more clearly seen in <FIG>. Therefore, the bottom side or underside of plug assembly <NUM> similarly includes a similar recessed area <NUM> to accommodate the cantilever <NUM> of the other backshell half <NUM>.

Also, as is more easily observed in <FIG>, the latches <NUM> are placed in the interstitial space between fiber optic ferrules <NUM>, affording the maximum distance inside the plug housing <NUM> for the cantilever to depress and release plug assembly <NUM> from a mating receptacle. This can be performed by applying simultaneous inward pressure to press surface <NUM> on both backshell halves <NUM>. During this action, latches <NUM> can retract below top surface <NUM>, enabling the latching mechanism to remain as close to the envelope of plug housing <NUM> as possible. The recessed area <NUM> formed in the top surface <NUM> of the plug housing <NUM> is sufficient to accommodate retraction of the latches <NUM> and at least partially the other structures of the cantilever <NUM> further below the top surface <NUM> when pressure is applied to the press surfaces <NUM>. Therefore, <FIG> illustrates the latches <NUM> in a "normal" position prior to application of inward or downward force to retract the latches <NUM>. When the force is applied to the press surface <NUM>, the latches <NUM> retract below the plane defined by the top surface <NUM>. Therefore, as illustrated in <FIG>, in the "normal" orientation or position, the latches <NUM> extend above the top surface <NUM> of the plug housing <NUM> while remaining below the top surface of the backshell half <NUM>; and in the "retracted" orientation or position, the latches <NUM> can be biased to a position below the top surface <NUM> of the plug housing <NUM>.

Further improvement to the assembly ergonomics is possible with the addition of another component as seen in <FIG>. Here, exemplary plug assembly <NUM> is made using all of the same components as plug assembly <NUM> from <FIG> and <FIG>, with the addition of decoupler <NUM>. The decoupler <NUM> includes a body <NUM> that generally defines a rectangular configuration with an opening <NUM> that is complementary to the outer surface(s) of the plug housing <NUM> and the backshell halves <NUM>. The decoupler <NUM> is slidably positioned at least partially over the plug housing <NUM> and at least partially over the backshell halves <NUM> such that the cantilever <NUM> is capable of being partially covered by the decoupler <NUM>. When decoupler <NUM> is pulled in the direction of distal end <NUM>', the inner surface of the opening <NUM> engages with ramp <NUM>, which is hidden underneath decoupler <NUM> in <FIG>, to bias or force the latches <NUM> downward/inward. This action retracts the latches <NUM> inside of plug housing <NUM>, releasing plug assembly <NUM> from a mating receptacle (e.g., releasing engagement of latches <NUM> from complementary structures within the mating receptacle to allow for removal of the plug assembly <NUM> from the mating receptacle). The decoupler <NUM> may be useful in high-density applications where finger access to the connector may be limited.

Both plug assembly <NUM> from <FIG> and <FIG> and plug assembly <NUM> from <FIG> are designed to mate to the exemplary receptacle <NUM> shown in <FIG>. The receptacle <NUM> provides front opening <NUM> to accept the proximal ends <NUM> and <NUM>' of plug assemblies <NUM> and <NUM>, respectively. Keyway <NUM> aligns with alignment key <NUM> of plug housing <NUM>, ensuring contacts line up when the latches <NUM> snap into latch points <NUM>. In particular, the latch points <NUM> define grooves or openings extending from the inner surface of the opening <NUM> at a position complementary to the latches <NUM> of the plug assembly <NUM>, <NUM>. When the plug assembly <NUM>, <NUM> is inserted into the opening <NUM>, the latches <NUM> snap into and engage with latch points <NUM> to maintain the plug assembly <NUM>, <NUM> properly connected to the receptacle <NUM>. Biasing of the latches <NUM> downward disengages the latches <NUM> from the latch points <NUM>, allowing for removal of the plug assembly <NUM>, <NUM> from the receptacle <NUM>. The top and bottom edges/surfaces of opening <NUM> are completely smooth, as no vertical allowance is required to enable actuation and clearance of the latches <NUM> in that direction. The size of the opening <NUM> and the overall size of the receptacle <NUM> can thereby be kept at a minimum. In contrast, traditional plug assemblies would necessitate additional features for latch clearance, expanding the overall envelope of the connector interface and increasing the overall size of the receptacle.

The simplicity of the latching mechanism is further illustrated by <FIG>, in which the plug assembly <NUM> has been mated to receptacle <NUM>. The contacts have been removed from <FIG> for the sake of clarity. At this particular section point, there would be contacts in front of and behind the section plane, but open clearance inside the assembly where cantilever <NUM> would be depressed when mating and unmating plug assembly <NUM>.

<FIG> shows exemplary backshell half <NUM> in greater detail, with top and bottom perspective views. The backshell half <NUM> is designed to assemble hermaphroditically, so that the exact same component can be used for both the top and bottom half of a given backshell, rather than requiring two different molded parts. This simplifies assembly and/or replacement of parts. Snap extensions <NUM> are mirrored by snap slots <NUM>, as locator post <NUM> is mirrored by locator hole <NUM>. It should be noted that it is not strictly necessary for both backshell halves to be identical, and that a functional connector plug assembly could be constructed with latches on only one side of the backshell. However, using a hermaphroditic design as exemplified in <FIG> reduces the number of different components in the top level assembly, while increasing the production volumes of the backshell half components. This reduces the tooling and unit production costs of the top level assembly, respectively.

Although the above example revolves around a fiber optic connector design, it would be clear to a person skilled in the art that the latch design mechanism and principles of layout and construction would apply to low voltage electrical connectors, as well. At higher voltages, the requisite opening in the connector plug housing may pose a safety risk, limiting the usefulness of the design.

When comparing the present invention to prior art connectors such as the LC type, a duplex version of which is shown in <FIG>, there is an obvious difference in the ratio between the outward size of the latching mechanism as compared to the area occupied by contacts at the proximal end of the connector. With the LC connector, the latch mechanism occupies nearly half of the proximal area, whereas with the present invention, it occupies a negligible part of it. The result is a smaller connector for a given contact pattern, enabling higher contact densities at the panel, and superior ergonomics at equal densities as compared to previous technologies.

Claim 1:
A connector assembly (<NUM>), comprising:
a plug housing (<NUM>) including contacts (<NUM>), the plug housing (<NUM>) defining a proximal end (<NUM>) and a distal end (<NUM>); and
a backshell (<NUM>) located at or near the distal end (<NUM>) of the plug housing (<NUM>);
wherein the backshell (<NUM>) includes a latching mechanism extending from a proximal end of the backshell (<NUM>) and including a cantilever (<NUM>) with at least one latch (<NUM>) extending from the proximal end of the cantilever (<NUM>), and the latching mechanism is at least partially recessed into a complementary space (<NUM>) formed in the plug housing (<NUM>); and
wherein in the at least partially recessed position of the latching mechanism, the at least one latch (<NUM>) of the cantilever (<NUM>) is disposed in an interstitial space between the contacts (<NUM>) of the plug housing (<NUM>).