Patent ID: 12237616

DETAILED DESCRIPTION

The inventors have recognized and appreciated techniques for making a rugged, environmentally sealed connector that may be economically manufactured and simply installed. Such a connector may be mounted in a panel opening in an electronic enclosure installed in a harsh environment. For example, the connector may be used to provide power to a fan inside an electronics enclosure housing portions of a communication system that is installed outdoors. The connector may prevent moisture, dust and other environmental contaminants from contaminating the mating contacts of the connector and/or from entering the enclosure.

The inventors have recognized and appreciated that sealing may be enhanced by appropriate selection of the shape and position of seals inserted between two connectors mounted to a panel. In some embodiments, the seals may be arranged to provide three-way sealing. For instance, a single, integral seal may provide sealing at the interfaces formed when three components are assembled together (e.g., a plug connector, a panel connector, and the panel). The seal may be arranged to form a seal between the panel connector and the panel and between the panel connector and the plug connector. In this way, passageways (through which foreign matter may pass) that may otherwise be formed through the panel opening may be prevented. In some embodiments, the seals may comprise one or more ribs configured to mate with respective recesses formed in one of the connectors and one or more ribs configured to mate with respective recesses formed in the panel. The ribs may be sized and arranged to occupy gaps that may otherwise be formed between the connectors, thus hermetically sealing the interior of the connectors where the mating contacts reside. As a result, passage of foreign matter, such as liquid, gas, and dust particles, through these gaps may be prevented (or at least limited) and the integrity of the electrical connections may be preserved.

The inventors have further recognized and appreciated that the contact force between mating contacts in a mated configuration may be adjusted by adjusting the extent to which the plug's mating contact portions are allowed to flex. In some circumstances, it may be desirable to adjust the contact force depending on the environment in which an interconnection system is intended to be used. For example, environments that tend to have mechanical vibrations, such as certain industrial environments, may call for large contact forces (e.g., 1 N or more) to prevent accidental disconnections of the mating contacts.

In some embodiments, the extent to which a mating contact portion is allowed to flex may be set using a contact cover placed in contact with the mating contact portion, such that the position of an end of the contact cover determines the position of a hinge axis of the mating contact portion (that is, the position of an axis about which the mating contact portion can pivot). A reduction in the distance between the end of the contact cover and the mating contact portion may increase the stiffness of the mating contact portions, since a shorter portion of the mating contact portion is allowed to flex. As a result, the force with which the mating contacts are retained is increased. By contrast, an increase in the distance between the end of the contact cover and the mating contact portion may decrease the contact force.

Accordingly, the contact force may be set as desired by appropriately sizing and positioning the contact cover relative to the mating contact portion.

The inventors have further recognized and appreciated that, in some circumstances, it may be desirable to overmold a plug connector to ensure that the cable to which it is connected is reliably secured to it, and/or to insulate conductors that may be exposed at the cable's termination. In this manner, the assembly may be configure to withstand mechanical vibrations that may arise in the environment in which it is deployed. The overmolding may be performed, at least in some embodiments, by injecting a thermoplastic material heated to a fluid into the opening of the plug connector through which the cable is passed.

The injection may be performed once the cable has been assembled with the plug connector. Subsequently, the fluid may be allowed to solidify, thus retaining the cable and the plug connector together. The inventors have appreciated, however, that injecting fluid in the plug connector as described above may cause part of the fluid to reach the mating contacts, which may create an undesired insulating barrier around the mating contacts. The formation of such a barrier may impair the connector's ability to electrically contact a complementary connector or change the flexure of the mating contact portions so that the desired contact force is not achieved in practice. In some embodiments, passage of the fluid may be prevented by blocking the injected portion of the plug connector from the portion in which the mating contacts are positioned.

In some embodiments, blocking may be accomplished by at least partially filling passageways that may otherwise be formed in the plug connector with ribs. In one example, a combination of three ribs may be used for blocking a passageway. Two of such ribs may be longitudinally aligned with one another. The third rib may be aligned with the region where the first two ribs come together, and may fill the discontinuity that may arise between the first two ribs. Such a discontinuity between the first two ribs may arise, for example, due to non-zero manufacturing tolerances. For example, in a connector in which a contact cover may be mounted in any of a number of positions, there may be a gap between the contact cover and other portions of the connector housing. That gap may be filled by the third rib, preventing fluid molding material from passing through the gap.

The inventors have recognized and appreciate that the lifetime of the seals may be greatly increased by preventing foreign matter, such as dust, moist or other particles, from reaching the region where the seals reside. When foreign matter reaches the region where a seal resides and contacts the seal, damage or wearing off of the seal may occur over time. To prevent damage caused by the contact with foreign matter, in some embodiments, the portion of the panel where the seal contacts the panel may be raised. The raised portion, which may be offset from the base of the panel, may form a block against contact of the foreign matter with the seal. In this manner, the foreign matter would have to climb the raised portion, making it significantly less likely that contact with the seal is established. To further protect the raised portion from foreign matter, in some embodiments, the sidewalls of the plug connector's housing may have slanted ends. The slanted ends may be arranged to protect the seal against passage of foreign matter without interfering with the raised portion. For example, the slanted ends may extend outwardly relative to the plug connector's housing.

In some embodiments, one side of the panel connector may be configured to be mated with a plug connector, and another side of the panel connector may be configured to be mated to a board connector, connected to a board. In this way, the panel connector may allow interconnection between a cable positioned on one side of an electronic enclosure formed by the panel with a board positioned on the inside of the enclosure.

The inventors have recognized and appreciated that the engagement of the panel connector with the board connector may be simplified by using guiding structures. In one example, the guiding structure may be formed using projections in the panel connector and channels in the board connector. Accordingly, engagement may be carried out by allowing the projections to slide into the respective channels, thus guiding the panel connector in the proper position. Using structures as described herein may enable a relatively small guiding distance between the board connector and the panel connector. Such a connector system may enable a more compact electronic assembly.

The inventors have further recognized and appreciated that the cost associated with the manufacturing of panel connectors of the types described herein may be reduced by designing the panel connectors to include an inner housing for supporting the mating contacts during overmold and an outer housing for encasing the inner housing. The inventors have recognized that by including an inner housing, in addition to the outer housing, the material needed for the overmold may be limited, thus reducing manufacturing costs. Furthermore, the use of the inner housing may enable a reduction in the amount of material used in the overmold for the formation of the outer housing. Such reduction in the amount of material may be desirable as it may reduce the number and/or size of shrink holes forming inside the outer housing when the molten plastic solidifies. In this respect, the inventors have appreciated that the more material used in the outer housing's walls, the larger the volume the outer housing loses as it cools during the solidification process, and as a result the higher the likelihood that shrink holes are formed. Shrink holes in the outer housing are not desirable as they create points of weakness and/or pockets in which moisture may be trapped. Accordingly, using the inner housing, in addition to the outer housing, results in a reduction in the material for the outer housing.

As a further benefit, the use of the inner housing may limit the number of cut outs in the outer housing (or even completely eliminate the cut outs), including avoiding cut outs which are often formed to maintain the position of the contacts during an insert molding process. In insert molding, plastic is often injected around the contacts at high speed. Given the high speed, the plastic rushing toward the contact may, due to the pressure, displace the contacts from the desired position. To limit contact displacement, molds having projections are often utilized, where the projections pinch and hold the contacts in place while the plastic is being injected. The projections lead to the formation of cut outs in the outer housing, and the projections reach the contacts, during the injection process, through these cut outs. Because precise tooling of molds having projections is costly, cutouts in a molded part, regardless of why they are present, can lead to high costs, with a higher number of projections leading to higher cost of the molds. To limit the cost associated with the formation of projections in the mold, the inventors have appreciated that an inner housing can be used to hold the contacts in place while the plastic is injected. In this way, the mold projections, and as a result the cut outs, can be reduced in number or even eliminated.

FIG.1illustrates an interconnection system100, in accordance with some embodiments. Interconnection system100may be used to connect two electronic devices to one another. In some embodiments, interconnection system100is used in ruggedized applications (e.g., in industrial applications). Interconnection system100may be mounted to panel102. In some embodiments, panel102may include an opening for allowing electrical signals to be passed through the panel. Panel102may be an interface provided by a user in some embodiments. For example, panel102may be part of (or otherwise be coupled to) the sidewall of an enclosure (e.g., a liquid-containing tank). In this example, interconnection system100may be arranged to allow electrical communication between an electronic device placed inside the tank (e.g., a sensor) and other electronic devices placed outside the tank. Panel102and interconnection system100may be arranged to block passage of foreign matter, such as liquid, gas, or dust particles, from one side of panel102to the other and/or to prevent foreign matter from depositing on the mating contacts.

In the example ofFIG.1, interconnection system100is arranged to deliver signals between cable106, which includes conductive wires108, to circuit board111. Circuit board111may include one or more electronic devices mounted thereon. Of course, interconnection system100is not limited to this arrangement. For example, other embodiments may not use cables and may connect two printed circuit boards (or other type of devices) to one another with conductors that are not part of a cable. In an alternative example, interconnection system100may be used to connect a cable to another cable.

As illustrated, cable106passes through an opening formed in a housing (107) of a plug connector104and is terminated in the plug connector104such that is it in electrically connected to contacts placed in the plug connector. Plug connector104may be mounted to one side of panel102. Positioned at the other side of panel102may be a board connector110. In some embodiments, board connector110may be mounted to panel102via panel connector130(also referred to as “panel adapter” or “adapter connector”). While board connector110is illustrated such that printed circuit board111is substantially perpendicular to panel102, other configurations are also possible. For example, in other embodiments, board connector110may be arranged such that printed circuit board111is parallel to panel102. In yet other embodiments, board connector110may be arranged such that printed circuit board111is neither parallel nor perpendicular to panel102.

FIG.2shows the illustrative plug connector104of the example ofFIG.1when not mounted to panel102, in accordance with some embodiments. Plug connector104includes an opening145, which may be arranged to allow passage of mating contacts therethrough.FIG.2illustrates a plurality of mating contacts105(also referred to herein as “terminals”) passing through the opening145. Mating contacts105may be electrically connected to conductive wires108of cable106(not visible inFIG.2). Opening145may be shaped and sized to receive a mating element therein. The mating element may include mating contacts configured to electrically connect to mating contacts105when the interconnection system100is in the mated configuration. As such, opening145may serve as a receptacle.

An example of such a mating element is depicted inFIGS.3A-3B, which illustrates panel connector130and mating contacts136. As illustrated, in this configuration panel connector130is configured to support mating contacts136. This support may be formed, at least in some embodiments, by overmolding mating contacts136with plastic. In some embodiments, panel connector130includes a projection134extending away from the panel connector's body. Projection134supports the ends of mating contacts136. Projection134may be shaped and size to fit, at least partially, into opening145(shownFIG.2) such that mating contacts136electrically contact mating contacts105. Mating contacts105may be configured as beams and the mating contacts of the panel connector may be configured as pads (though the opposite arrangement is also possible). While in this configuration plug connector104includes a receptacle and panel connector130forms a mating element (through projection134), the opposite configuration is also possible.

In some embodiments, a seal132is used to hermetically seal mating contacts136and105from the external environment. Seal132may be arranged to prevent passage of foreign matter through gaps that may otherwise be formed between plug connector104and panel connector130and/or through gaps that may otherwise be formed between panel102and panel connector130. In some embodiments, seal132may include a portion configured to skirt around the outer border of the panel connector, as will be described further below. Panel connector130may be mounted to panel102via attaching mechanisms141, which may be implemented, at least in some embodiments, using screws. In one example, as illustrated inFIG.3B, four screws are used. The screws may be spaced to provide even pressure on the panel. In at least some of the embodiments in which the attaching mechanisms are screws, panel connector130may include openings138for allowing passage of respective screws. Similarly, seal132may include openings (as shown inFIG.5A) for allowing passage of the screws.

In some embodiments, the top surface of panel connector130's body may include a slanted region arranged to cause dust, moisture or other foreign matter to slide off to the side of the panel connector. In the embodiment ofFIG.3A, for example, an angled surface129is formed at the edge of the top surface of panel connector130's body. In this way, if dust, moisture or other foreign matter inadvertently infiltrates the region where the mating contacts are positioned, the angled surface may cause the foreign matter to slide off the panel connector. Alternatively or additionally, as shown inFIG.3A, the upper edge of seal132is below that top surface such that seal132does not trap foreign matter. In the embodiment illustrated the upper edge of seal132is below angled surface129.

FIG.4Ais a cross sectional view of the illustrative interconnection system100of the example ofFIG.1in the mated configuration (that is, when mating contacts105are connected to mating contacts136), in accordance with some embodiments. As illustrated, in this configuration projection134fits, at least partially, within opening145. Plug connector104and panel connector130may be connected to panel102.FIG.4Billustrates a portion (labeled “A”) ofFIG.4Ain additional detail. As described above, a seal132may be used to prevent passage of foreign matter. Seal132may be made form an elastic material, such as polymer or rubber. Seal132may include one or more sealing elements142for sealing gaps between the plug connector104and the panel connector130. In some embodiments, sealing elements142include ribs, which may be configured to mate with recesses formed in plug connector104. The ribs and the recesses may have any suitable shape and size. Alternatively, or additionally, ribs may be formed on plug connector104and recesses may be formed in seal132. Mating of the ribs with respective recesses may ensure that the position of seal132relative to plug connector104is maintained over time.

In some embodiments, seal132may include one or more sealing elements152for sealing gaps between the plug connector104and the panel102, and/or panel connector130and panel102. As described in connection with sealing elements142, sealing elements152may include ribs, which may be configured to mate with recesses formed in panel102(though the opposite arrangement is also possible). The ribs may extend along the z-axis, thereby forming a skirt. Mating of the ribs with respective recesses may ensure that the position of seal132relative to panel102is maintained over time.

In some embodiments, seal132may include a base and a sidewall extending away from the base (along the z-axis) and configured to wrap around an outer border166of panel connector130.

In some embodiments, the plug connector104may have a surface forming a seal with a first surface of the seal132(thus forming a first sealing interface) and the panel102may have a surface forming a seal with a second surface of the seal132(thus forming a second sealing interface). In some embodiments, the first and second sealing interfaces are orthogonal to one another. In the example illustrated inFIG.4A, the sealing interface between the plug connector104and the seal132is parallel to the z-axis, and the sealing interface between the panel102and the seal132is parallel to the y-axis. It should be appreciated, however, that other arrangements are also possible.

It should be appreciated that seal132may include sealing elements142only, sealing elements152only, or both sealing elements142and152. When seal132is used as described herein, passage of foreign matter inside the cavity formed between plug connector104and panel102may be prevented (or at least limited). In this way, the integrity of the electrical contacts may be preserved and/or the lifetime of the interconnection system may be lengthened.

FIG.4Cis a cross sectional view of another interconnection system, in accordance with some embodiments. In this arrangement, seal133, in addition to sealing elements for engaging with plug connector104and panel102, includes sealing elements for engaging with panel connector130.FIG.4Dillustrates a portion (labeled “B”) ofFIG.4Cin additional detail. As illustrated, seal133includes sealing elements142and152(as in the embodiment ofFIGS.4A-4B). In addition, seal133includes sealing element165arranged to engage with panel connector130. In this example, panel connector includes a recess167and sealing element165is a rib adapted to fit into recess167, though the opposite arrangement is also possible. In this manner, an additional barrier obstructing passage of foreign matter is formed. The embodiment ofFIGS.4C-4Dis arranged such that the sealing interface formed between seal133and panel connector130is parallel to the sealing interface between seal133and panel102. As further illustrated, sealing elements165and152extend from the base of seal133in opposite direction (sealing elements165extending away from panel102and sealing elements152extending toward panel102). However, not all embodiments are limited to having these sealing interface parallel to one another.

In some embodiments, as further illustrated inFIGS.4E-4F, seal133may include ribs extending towards the opening formed in the seal for passage of the panel connector130. These ribs, labeled135, are illustrated inFIG.4F, which illustrates portion C ofFIG.4Ein additional detail. Ribs135may be sized and positioned to engage with recesses formed in panel connector130. Ribs135may extend along the y-axis direction. Engagement of ribs135with the panel connector's recesses may further prevent passage of foreign matter.

An example of a seal in accordance with some embodiments is depicted inFIG.5A. The seal (referred to also as “resilient member”) may be made of a resilient material (e.g., a polymer). In this configuration, the seal includes an opening144for allowing passage of the panel connector130, and openings147for allowing passage of attaching mechanisms141. In some embodiments, the seal includes a base153and a sidewall151. The sidewall may extend away from the base153(parallel to the z-axis) along the perimeter of base153(or at least a portion of the perimeter). In the mated configuration, the inner surface of the sidewall may be arranged to face panel connector130and the outer surface of the sidewall may be arranged to face the plug connector104. In some embodiments, sidewall151may be arranged to wrap around the outer border166(shown inFIGS.4A-4B) of panel connector130.

In some embodiments, sealing elements142are formed around the sidewall151. For example, in at least some of the embodiments in which the sealing elements142include ribs, the ribs may extend away from sidewall151(parallel to the y-axis or the x-axis). In some embodiments, sealing elements152are formed on the base153. For example, in at least some of the embodiments in which the sealing elements152include ribs, the ribs may extend away from base153(parallel the z-axis), thereby forming a skirt. In some embodiments, such ribs may extend opposite the direction along which sidewall151extends. In some embodiments, sealing elements152are formed along the perimeter of respective openings147. In some embodiments, a sealing element152is formed along the perimeter, or at least a portion thereof, of opening144. In some embodiments, though not visible inFIG.5A, seal132may include one or more sealing elements165for sealing the surface between the seal and panel connector130. Sealing elements165may be ribs, in some embodiments, extending in the opposite direction relative to sealing elements152. Connector may have slots positioned to receive the ribs extending from seal132. Each slot may be sized and positioned to snugly receive a corresponding rib. The ribs may be sized such that the distance the rib extends into the corresponding slot is a multiple of its width. The aspect ratio of length to width may be for example greater than 1:1 or, in some embodiments, greater than 2:1 or greater than 3:1.

FIG.5Billustrates another seal that may be used in connection with the arrangements ofFIG.4C-4F, or with any other suitable arrangement, in accordance with some embodiments. In this case, the seal includes multiple sets of sealing elements (e.g., ribs) for sealing the surface between the seal and panel102. For example, as illustrated inFIG.5B, sealing element152may be an inner sealing element enclosed within an outer sealing element159. As further illustrated inFIG.5C, which illustrate the portion labeled D ofFIG.5Bin additional detail, sealing elements152and159may be arranged such that one or more pockets171are formed between them. The pocket(s) may be arranged to surround the perimeter of openings144and147in the xy-plane.

In some embodiments, pocket(s)171may serve as watertight compartments. For example, if dust, moisture, or other foreign matter, inadvertently infiltrates between the panel and the seal (which in some circumstances may occur if the seal in not properly aligned to the panel), at least part of the moisture may be trapped in the pocket(s), thereby reducing the likelihood that the moisture penetrates through openings147and/or144and reaches the mating contacts. In this manner, sealing elements152and159may provide a double barrier against passage of moisture or other foreign matter. Of course, more than two sealing elements may be provided in some embodiments, thus forming additional pockets. As illustrated inFIG.5C, the pockets may be separated by bridges173, where sealing element152meets sealing element159, though in another embodiments, a single continuous pocket may be formed. Further illustrated inFIG.5Bare ribs135(described in connection withFIG.4F), which extends into opening144and may be configured to engage with recesses formed in the panel connector.

FIG.6is an exploded view illustrating a cable assembly101for use in connection with interconnection system100, in accordance with some embodiments. Cable assembly101comprises plug connector104, which may include contact holder140, contact covers143, and mating contacts105. An end of cable106may be inserted in plug connector104, and the cable's conductive wires may be terminated and placed in electrical contact with mating contacts105. Contact holder140and contact covers143are collectively referred to as the “contact carrier.”

Mating contacts105may each include a mating contact portion120configured to contact mating contacts136, contact tails146configured to contact conductive wires108, and intermediate portions121, disposed between contact tails146and120. In some embodiments, contact tail146each include a V-shaped receptacle for receiving an end of a wire108. The V-shaped receptacle may be shaped and sized to secure the end of the wire while providing an electrical contact. Mating contacts105may be supported, at least partially inside opening145, by contact holder140. Contact covers143may include support features for setting the contact force associated with mating contact portions120.

According to one aspect of the present application, the contact force associated with the mating contact portions of the mating contacts105may be adjusted by adjusting the compliance of the mating contact portions. Specifically, the stiffer the mating contact portions, the larger the force with which projection134is retained once it has been inserted in the opening. The inventors have appreciated that in some circumstances the contact force may be set (for example by the manufacturer or the user) based on the anticipated environment in which interconnection system100is to be utilized. For example, if it is anticipated that interconnection system will likely experience mechanical vibrations, it may be desirable to increase the contact force to reduce to likelihood that the mating contacts are disconnected from each other. In some embodiments, the contact force provided by a connector may be determined by the extent to which the mating contact portions in the receptacle can flex when a mating element is inserted.

FIG.7Aillustrates a cross sections of plug connector104, in accordance with some embodiments.FIG.7Aillustrates how a mating contact portion's ability to flex may be adjusted to set a desired contact force. As illustrated, a pair of opposite mating contact portions120may form a receptacle for receiving a mating element in between. When a mating element is inserted, the mating contact portions120may flex away as illustrated by arrows A1and A2. The lower the mating contact portions ability to flex, the larger the resistance to insertion of the mating element and as a result, the larger the retaining contact force. Accordingly, the contact force may be adjusted by adjusting the mating contact's ability to flex. This may be accomplished, at least in some embodiments, by adjusting the hinge axis of the mating contact.

The hinge axis of mating contact105is indicated with numeral199inFIG.7A. When a mating element is inserted in the opening145, the mating element cause mating contact portions120to flex away. Flexing is enabled by pivoting relative to hinge axis199. In some embodiments, the location of the hinge axis along the length of the mating contact can be determined by using contact cover143. In the embodiment illustrated, a portion of mating contact105is disposed between a portion of contact holder140and contact cover143. In some embodiments, contact cover143includes a projection157(also referred to as “finger” or “finger portion”) that extends along the mating direction towards mating contact portion120. Contact cover143is arranged such that its sidewall154is in contact with mating contact105.

In some embodiments, intermediate portions121comprise a first side and a second side. Mating contacts105may be mounted with the first sides of the intermediate portion121against the contact holder140over a first distance D1from an end158of the mating contact adjacent the contact tails146. Contact cover143may be mounted with the second side of the intermediate portions121against the contact cover143over a second distance D2from the end158of the mating contact adjacent the contact tails. In some embodiments, the second distance D2is shorter than the first distance D1, as illustrated inFIG.7A. It should be appreciated, however, that in other embodiments second distance D2may be greater than the first distance D1.

The location of the hinge axis199along the length of the mating contact is determined by the location of the end155of projection157. The closer the end155to the mating contact portion120, the less the mating contact portion's flexibility, and as a result the larger the retaining contact force. Accordingly, the location of the projection157's end may be adjusted to produce a desired contact force.

In some embodiments, the mating contact associated with the mating contact portions120may be adjusted based on the length of projection153. For example, projections that are arranged to extend farther along the mating direction may lead to a larger contact force. The length of the projection153may be set at the factory based for example on the application in which the plug connector is intended to be used.

In some embodiments, the contact force may be adjusted by the user. For example, the contact cover143may be allowed to slide in the mating direction (along the z-axis), such that the location of the projection's end relative to the mating contact may be adjusted. In this way, the user may set the contact force as desired by sliding the contact cover, which may shift the location of the hinge axis199.

To facilitate insertion of a mating element, in some embodiments, the mating contact portions120may include respective convex portions125. In some embodiments, two opposite mating contact portions120are arranged such that their respective convex portions125face one another.

FIG.7Billustrates contact holder140, contact cover143and mating contacts105when placed in opening145of plug connector104. As illustrated, contact cover143may be placed in a cavity formed between a portion of plug connector104and contact holder140. When a mating element (e.g., projection134) is inserted into opening145, the mating contact portions120may flex away thus allowing further insertion of the mating element. As illustrated inFIG.7B, opening145may be disposed between a first opening and a second opening. The first opening may be configured to receive a portion of a complementary connector (such as panel connector130). The second opening may be configured to receive cable106. The shell of plug connector104may be formed to include the first opening, the second opening and opening145.

In the configuration illustrated inFIGS.7B-7C, a gap may be formed between projection157and an inner wall of the plug connector's housing107.FIG.7C, which illustrates the portion labeled F inFIG.7Bin additional detail, shows how a gap161is formed between projection157and wall169. In some circumstances, when the mating contact portions120are flexed (as illustrated by arrows A1and A2ofFIG.7A) following mating of the plug connector with a complementary connector, the distal portion of the projection157may be pushed away by the mating contact thus closing the gap161. This motion of the projection157may lead to a shift in the position of the hinge axis relative to axis199(FIG.7A). As a result, the contact force with which the complementary connector is retained by the mating contacts120diminishes throughout the insertion of the complementary connector. The reduction in the contact force may result in poor electrical connection in the presence of vibrations. The inventors have appreciated, however, that motion of the projection157following mating of the plug connector may be blocked (or at least limited) by reducing or eliminating the gap between projection157and wall169.

Accordingly, in some embodiments, a projection157may include a rib extending toward wall169, as illustrated inFIG.7D. In this example, projection157includes a rib159protruding laterally along the x-axis direction. As further illustrated inFIG.7E, rib159may be sized to abut wall169when the plug connector is assembled, though not all embodiments are limited in this respect. In this way, projection157may have little room (or no room at all) to move following flexure of the mating contacts, thus maintaining desired contact force.

In some embodiments, it may be desirable to overmold the plug connector104to ensure that the cable is reliably secured to the plug connector, and/or to insulate conductors that may be exposed at the cable's termination. The overmolding may be performed, at least in some embodiments, by injecting a fluid in the opening of the plug connector through which the cable is passed. Subsequently, the fluid may be allowed to solidify, thus holding the cable and the plug connector together. One illustrative configuration in which overmold is performed is shown inFIG.8A, which depicts a cross section (in the xz-plane) of the plug connector ofFIG.1, in accordance with some embodiments. In some embodiments, a fluid180may be injected through the opening of the plug connector104that receives cable106. The fluid180may form an insulative material when solidified. The overmold may prevent stress on the electrical connection between the conductors of the cable and the mating contacts in case the cable is accidentally pulled away.

FIG.8Bis an exploded view of plug connector104illustrating how fluid180may appear after solidification, according to another embodiment. Overmold181, obtained by solidifying fluid180, extends in the plug's connector housing and outside cable106, in this non-limiting example. In some embodiments, overmold181may be formed via a low-pressure overmold process. In some embodiments, as further illustrated inFIGS.8B-8C, a potting element182may be positioned inside the plug connector's housing for shock absorption. Potting element182may be made of a resilient (e.g., silicone rubber) or a gelatinous material (e.g., epoxy).

In some embodiments, ribs may be formed in the region of the plug connector where the cable's wires are inserted, as shown inFIG.8C. As shown, ribs183may be formed in the sidewalls of the plug connector in the region that is overmolded. Ribs183may aid in maintaining the overmold in place by increasing the friction between the overmold and the plug connector.

The inventors have appreciated that injecting fluid in the plug connector as described above may cause part of the fluid to reach mating contact portions of the mating contacts105, which may create an undesired insulating barrier around the mating contact portions. The formation of such a barrier may impair the connector's ability to electrically contact a complementary connector. In some embodiments, passage of the fluid may be prevented by blocking the injected portion of the plug connector from the portion in which the mating contacts are placed. In some embodiments, blocking may be accomplished by at least partially filling, with ribs, passageways that may otherwise be formed in the plug connector.

FIG.9Ais an isometric view illustrating a portion of the plug connector ofFIG.1, in accordance with some embodiments. In particular,FIG.9Aillustrates contact holder140, contact cover143, mating contact portions120and the terminated ends of the cable's conductive wires108. In some embodiments, one or more ribs160may be formed on the outer surface of the contact holder140and one or more ribs162may be formed on the outer surface of the contact covers143. As illustrated inFIG.9A, ribs160and162may be longitudinally aligned with one another such that a continuous rib is formed around the outer perimeter of the assembly (the assembly comprising the contact holder140and contact covers143). Ribs160may protrude from the contact holder along a direction perpendicular to the mating direction (e.g., along the x-axis or the y-axis depending on location). Additionally or alternatively, ribs162may protrude from the contact cover in a direction perpendicular to the mating direction (for example along the x-axis).

FIG.9Bis a cross sectional view taken in the xz-plane of the plug connector ofFIG.1, in accordance with some embodiments. As illustrated, when the contact holder140and the contact covers143are placed in the plug connector's housing, passage of the fluid may be prevented by the presence of the ribs160and162. For example, ribs162may be arranged to abut wall169. In this way, the channel that would otherwise exist between wall169and contact cover143is obstructed. Similarly, ribs160may abut against a wall (not shown inFIG.9B) of the plug connector's housing. This wall may be perpendicular to wall169. It should be appreciated that in some embodiments, ribs may be formed in the walls (e.g., wall169) of the plug connector's housing. These ribs may be abut outer surfaces of the contact holder and/or the contact covers.

The inventors have further appreciated that, in some circumstances, non-zero manufacturing tolerances may give rise to a discontinuity in the region where ribs160and162come together. An illustrative discontinuity is shown inFIG.10A, which depicts respective portions of contact holder140and a contact cover143, in accordance with some embodiments. In this case, a discontinuity170is formed between rib160and rib162, which may give rise to a passageway for the fluid.

To prevent the formation of these passageways, in some embodiments, ribs may be formed in the walls against which the ribs160and162are abutted. One example of such a rib is shown inFIG.10B, which depicts an inner portion of the plug connector ofFIG.1, when the contact holder and the contact covers are removed, in accordance with some embodiments.FIG.10Bprovides another perspective of opening145(also shown inFIG.7B). Further,FIG.10Billustrates slots177, through which the ends of mating contact portions120pass when contact holder140is inserted inside opening145. In this case, rib172is formed on the wall169of housing107and is positioned to align with the discontinuity170so as to occupy the void created between ribs160and162. In some embodiments, multiple ribs172may be used, and each one these ribs may be aligned with a respective discontinuity.

FIG.11Ais a cross sectional view of the plug connector of the example ofFIG.1taken in the xy-plane, in accordance with some embodiments. This figure illustrates contact holder140and contact covers143when assembled in the plug connector104.FIG.11Billustrates a portion (labeled “B”) ofFIG.11in additional detail. As illustrated, rib170is aligned with the discontinuity existing between ribs160and162, such that the void between such ribs is filled.

As described above, a plug connector, such as is illustrated inFIG.11Amay mate with a panel connector, such as panel connector130shown inFIG.3A. The panel connector may be installed in a panel of an electronic enclosure, such as is illustrated inFIG.3B. The panel connector may mate with another connector inside the enclosure, such as a board connector110, shown inFIG.3B. Engagement of a panel connector with a board connector may be facilitated by using, at least in some embodiments, guiding structures. These structures may be adapted to allow the panel connector to be guided in position by sliding a projection into a corresponding channel.FIG.12is an isometric view of a board connector having one or more channels for receiving one or more guiding structures from a panel connector, in accordance with some embodiments. As illustrated, in this configuration panel connector130includes a plurality of projections204formed at the mounting interface (the interface through which the panel connector130may be mounted to the board connector110). Board connector110may include channels202formed on the board connector's exterior housing. In one example, channels202include concave surfaces formed on the board connector's housing. However, it should be appreciated that any suitable complementary guiding structures on the panel connector and the board connector may be used, including for example full round or triangular projections and complementary channels.

Channels202and projections204may be arranged to facilitate mounting of the panel connector to the board connector. For example, channels202and projections204may be sized and shaped such that projections204slide in respective channels, thus guiding insertion of the board connector through the opening formed inside the panel connector's exterior housing. It should be appreciated that projections may extend from either the panel connector or the board connector. However, having the projections extend from the panel connector may be beneficial, at least in some embodiments, because it reduces the guiding distance. While two channels and two projection are formed in the embodiment illustrated inFIG.12, any suitable number of channels and projections may be used in other embodiments. Moreover, the guiding projections and channels are shown integrally formed with housings of the connectors, which in the illustrated embodiment results from forming the guiding features as part of molding the housing, integrally formed guidance components are not required. The guidance features, for example, may be a formed in separate modules coupled to either or both of the connector housings.

In some embodiments, to ensure that the board connector and the panel connector are mated in a proper orientation, asymmetric receptacles may be used. In this way, if the board connector is inserted in the panel connector in the wrong orientation, mating is precluded.FIGS.13A-13Billustrate bottom and top views, respectively, of board connector110in the orientation shown inFIG.3B, in accordance with some embodiments. In particular,FIG.13Ais a bottom end view from the perspective of line13-13inFIG.12.FIG.13Bis a cross section along the line15-15inFIG.12.FIGS.13A and13Billustrate two parallel planes taken at different locations of the board connector, where the plane ofFIG.13Bis the closer to panel102.

As illustrated, board connector110includes receptacles, of which receptacles224and226are numbered. The receptacles are configured to receive the ends of mating contacts136(shown for example inFIG.15E). Receptacles224and226may be arranged to be symmetric with respect to line HH, which passes through the center of the panel connector to board connector mating interfaces. As a result, mating contacts136would align with respective receptacles even if the panel connector130were rotated 180 degrees relative to the board connector. However, projections204and channels202may be arranged to be asymmetric with respect to line HH. In the embodiment ofFIG.13B, channels202are not centered on line HH. Rather, the centers of channels202and projections204are offset from the line HH. As a result, if an attempt to mate the panel connector with the board connector in the wrong orientation is made, insertion of the mating contacts in the receptacles is precluded. Vice versa, if the board connector is inserted in the panel connector properly, mating is permitted.

The inventors have appreciated that the seals described above may be damaged or otherwise wear off due to prolonged contact with foreign matter penetrating inside the interconnection system. Accordingly, the inventors have developed a design for protecting the seal from accidental damage. In some embodiments, the seal may be protected by raising the portion of the panel in contact with the panel connector relative to the plane of the panel, thus forming a wall at the base of the panel. In this way, foreign matter that may otherwise penetrate and contact the seal may be blocked by the walls of the raised portion.

One example of such an arrangement is illustrated inFIGS.14A-14B.FIG.14Ais an isometric view, partially cut away, of an interconnection system having a plug connector engaged to a panel connector, which is mounted to a panel.FIG.14Bis an enlarged view of portion E ofFIG.14A, in accordance with some embodiments. As illustrated, in this embodiment panel102includes a planar base103and a raised portion220, whose top surface is offset (along the z-axis) relative to the top surface of the planar base. As further illustrated, the raised portion220may surround the opening through which panel connector130is inserted. Even if foreign matter accidentally passes through a gap formed between the panel and the plug connector, the likelihood that the foreign matter will contact the seal by climbing the raised portion220is substantially reduced relative to panels having completely flat surfaces.

Plug connector104may comprise slanted ends212formed on the sidewalls210of the plug connector's housing. The slanted ends may be shaped to extend, at an angle, outwardly relative to the plug connector's housing. The slanted ends may be arranged to protect the raised portion220and thus the seal against passage of foreign matter. In some embodiments, when the plug connector is attached to the panel, the slanted ends212are separated from the top surface of the panel's planar base103by a gap214(though in other embodiments, the slanted ends214may contact the top surface of the panel's planar base103).

FIGS.15A-15Eillustrate an example of a sequence for fabricating a panel connector, in accordance with some embodiments. This fabrication sequence may lead to a lower cost and more robust connector. In the step ofFIG.15A, a plurality of mating contacts136are provided. The mating contacts may be formed by stamping, plating and any other suitable operations. In the embodiment illustrated, the contacts each have the same shape with planar surfaces, for mating with beams of a cable connector, and elongated ends for entering receptacles of a board connector. In the embodiment illustrated, the contacts have shoulders1536at an interface between the planar surfaces and a shaft joining the planar surfaces and the elongated ends.

In the step ofFIG.15B, the mating contacts136may be inserted into first housing portion230. In some embodiments, the first housing portion230is formed by overmolding the mating contacts. In other embodiments, the first housing portion230is formed separately, and the mating contacts are inserted through channels formed in the first housing portion230. In such an approach, shoulders1536may engage corresponding ledges within housing portion230so as to position contacts136. In either event, the mating contacts136may be positioned to match the arrangement of corresponding mating contact in a plug connector.

First housing portion230may include a protrusion231, which may be shaped and sized to fix an exterior housing234to the first housing portion.

In the step ofFIG.15C, a second housing portion232may be installed over the shaft portions of the mating contacts136. First and second housing portions, or any suitable number of housing portions, may be used, as molding multiple shorter housing portions may be simpler and more accurate than molding one housing portion. Similar to first housing portion230, second housing portion232may be formed by overmolding the mating contacts or may be molded separately. It should be appreciated that, at least in some embodiments, the first and second housing portions are separate pieces, though they may be placed in contact with each other when assembled with the mating contacts136. It should be further appreciated that the order in which the housing portions are positioned is not limited to the sequence illustrated, as the second housing portion may be positioned prior to positioning of the first housing portion in some embodiments. In some embodiments, the second housing portion may include one or more protrusions shaped and sized to fix the second housing portion to the exterior housing. The first and second housing portions may be offset relative to one another along the length of the mating contact136.

The steps ofFIGS.15B-15Cmay ensure that the shoulders of the mating contacts are engaged with the ledges of the housing portion230. WhileFIGS.15B-15Cillustrate two separate housing portions, in other embodiments, a single housing portion may be used.

As shown inFIG.15D(showing a perspective view of the resulting panel connector) exterior housing234of the panel connector may be formed. In some embodiments, the exterior housing may be formed by high-pressure overmolding the structure ofFIG.15C.

As further shown inFIG.5D, to allow electrical connection of the mating contacts136to corresponding mating contacts (such as mating contacts105ofFIG.2), the ends of mating contacts136(which are not necessarily limited to having flat shapes, as shown inFIGS.15A-15D) may be exposed in an exterior surface of the exterior housing234.

As further shown inFIG.15D, the exterior housing may be molded around protrusion231, thus fixing the two pieces together.

During this overmolding, the mating contacts may be held in place by squeezing them between the metal of a mold and the plastic housing230. In some embodiments, such as is shown inFIG.3A, the planar surfaces forming the mating contacts may be flush with an outer surface of the overmolded panel connector. Accordingly, the surface of the mold used during the overmolding to squeeze the contacts and hold them in place may be largely flat. Such a mold may be relatively inexpensive—less expensive than a mold contoured to hold the two columns of contacts in place without a pre-formed housing230.

As a further benefit of preforming first and second housing portions, the volume of material used in the overmolding may be reduced relative to the volume of overmolded material needed to form the exterior housing entirely via overmolding. This reduction in the amount of material may reduce the formation of shrink holes that may otherwise arise, absent the first and second housing portions, due to the thickness of the exterior housing's walls.

The exterior housing234may be molded in any desired shape, including with guidance projections, features to receive a seal and a widened portion236configured to be mounted to a panel102. The widened portion236may have a plurality of threaded holes adapted for passage of screws, which may be used for mounting the panel connector to the panel.

In the step ofFIG.15E, a potting element238may be placed inside exterior housing234. Potting element238may be made of a resilient (e.g., silicone rubber) or a gelatinous material (e.g., epoxy). Potting element238may enclose, at least partially, mating contacts136. In accordance with some embodiments, potting element238may form an environmental seal around the contacts136and/or may act as a shock absorbing material, and may reduce vibration of the mating contact surfaces between the panel connector and cable connector if, for example, there is a fan or other vibrating part within an electronic enclosure. Absorbing shocks may increase the life of the mating contacts.

A connector as described herein supports a simple assembly operation of an electronic enclosure. Assembly of a rugged, environmentally sealed interconnection system is illustrated inFIGS.16A-16C, in accordance with some embodiments.FIG.16Aillustrates a panel102, a board connector110and a circuit board111.FIG.16Ashows only a portion of a panel that may form an enclosure or other structure supporting electric components. A printed circuit board, including a board connector110may be installed in the electronic enclosure. The printed circuit board may be positioned to align board connector110with an opening in a panel. Such alignment may be achieved by attaching the printed circuit board to rails or other suitable mounting hardware.

In the step ofFIG.16B, a panel connector130may be inserted through the opening in panel102, for example by passing the panel connector through an opening of the panel. Alignment projections of the panel connector may align the panel connector with the board connector, The panel connector may then be screwed or otherwise attached to the panel. In the step ofFIG.16C, a plug connector104may be assembled to the panel102. The plug connector may be assembled such that its mating contacts are placed in contact with the panel connector's mating contacts.

In some embodiments, the components may be configured to be assembled simply, such that the assembly process may be performed automatically. For example having alignment features that ensure that the panel connector aligns with board connector and that are asymmetrical such that the connectors may be assembled in only one orientation may enable the use of automated assembly tooling. Likewise, the shape of the cable connector relative to the interface of the electronic enclosure may simplify alignment of the cable connector and panel connector such that those components similarly can be automatically assembled.

Some embodiments described herein relate to plug connectors arranged to mate with panel connectors attached to a panel. For example,FIG.1illustrates a plug connector104mated to a panel connector attached to panel102. Panel102may form a portion of an electronic enclosure (which is not shown fully for simplicity) such that the panel connector130forms electrical connections between the plug connector104and an interior of the electronic enclosure. A mechanism may be included to complete electrical connections from the panel connector130to components inside the electronic enclosure. In embodiments described above, that mechanism was a further mating interface on the panel connector130, which mated to a board connector110that could be attached to a printed circuit board111inside the enclosure.

It should be appreciated, however, that the present application is not limited to these types of electrical interconnection systems, as alternative mechanisms to make electrical connections between a panel connector and components inside an electronic enclosure are also possible. With such alternative arrangements, the external mating interface of the panel connector may be configured and manufactured using techniques described above, including the molding process ofFIGS.15A-15Dand the sealing arrangement discussed above in connection withFIGS.3A-5C and14A-14B.

One possible configuration involves a panel connector being configured to mate with a second cable connector. The second cable connector may support conductive terminals having ends arranged to form electric contacts with the panel connector's mating contacts. Those mating contacts, configured to mate with the second cable connector inside the enclosure, may be configured as in the external mating interface shown inFIGS.3A and3B. However, the specific configuration of the internal mating contacts need not match the configuration of the mating contacts at the external interface.

One example of such an arrangement is depicted inFIG.17A, which illustrates an interconnection system with a plug connector104and a second cable connector304, in accordance with some embodiments. In this example, plug connector104is electrically connected to cable306via cable connector304and panel connector302. Panel connector302has two interfaces, a first, external interface, to which plug connector104is attached, and a second, internal interface, to which cable connector304is attached. The conductors of cable306are then routed to components inside the enclosure. Though panel, such as panel102, is not illustrated inFIG.17Afor simplicity, it can be seen that panel connector302has, similar to the panel connector inFIGS.3A and3B, raised elements that will fit through a panel opening and attachment features that enable the connector to be attached to that panel, such as with screws or other fasteners.

As further shown inFIG.17B, which illustrates the cable connector ofFIG.17Awhen not mated to the plug connector104, panel connector302may have an external mating interface as shown above. It may present ends308of the conductive terminals that are connected to cable306via the internal interface of panel connector302.

In some embodiments, the same plug connector can be engaged to a cable connector, as shown inFIG.1, and to a panel connector (though of course at different times), as shown inFIG.17A.

Further, it should be appreciated that a panel connector with an external interface as described herein is not limited to use in systems in which cable assemblies, including a plug connector attached to a cable, are mated to that interface. Any other component that has a mating interface complementary to that the of the panel connector may be used. For example, in place of a plug connector, a jumper may be attached to the mating interface.

FIG.18is an isometric view illustrating a plug connector104juxtaposed with a jumper310, in accordance with some embodiments. Jumper310may have a mating interface sized and shaped like the mating face of plug connector104so as to mate with the external interface of a panel connector, such as is shown inFIG.3B or17B. However, jumper310is not attached to a cable, as in cable connector104. In the embodiment illustrated, the mating contacts within jumper310that mate with the panel connector are attached to each other. A jumper may be used to set a configuration of the components inside an electronic enclosure by selectively form connections between points inside the enclosure.

As a specific example, two terminals of a control input and ground may be coupled to contacts of a panel connector. A cable connector104may be attached to the panel connector, routing the control inputs to an external controller that will generate a control signal indicating an on or off state. Alternatively, a jumper310may be attached to the panel connector. That jumper may have internally a connection between the control inputs that connects the control input terminals together, creating an always on state. Alternatively, the jumper may have internally connections between the control inputs and ground that creates an always off state.

Though jumper310may contain, internally, connections between the terminals of the panel connector, it may be configured in other ways. It may, for example have no connections to some or all of the terminals of the panel connector, creating a covering for un-used terminals in some systems. Alternatively or additionally, jumper310may contain within its housing electronic components, such as resistors, capacitors, or semiconductor chips, which can generate or modify signals coupled to terminals of the panel connector.

Interconnection systems of the types described herein may be modified in any suitable way. For example, in some embodiments, mating contacts may be placed in the panel connector rather than the plug connector. The contact force of these mating contacts may be adjusted using the techniques described herein. In some such embodiments, the plug connector may include pads for contacting the panel connector's mating contacts.

Techniques described herein may be used in connectors having configurations other than those described above. For example, techniques described herein may be used in mezzanine connectors or in backplane connectors. Such alternative connector configurations may be used with all of the features described herein or a subset of any suitable number of features. Moreover, it should be appreciated that all of the structures, materials and construction techniques described herein may be used together, but, in some embodiments, some or all of the structures, materials or techniques may be omitted.

Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Further, though advantages of the present invention are indicated, it should be appreciated that not every embodiment of the invention will include every described advantage. Some embodiments may not implement any features described as advantageous herein and in some instances. Accordingly, the foregoing description and drawings are by way of example only.

Examples of arrangements that may be implemented according to some embodiments include the following:

A1. A plug connector, comprising:a cable comprising a plurality of conductive wires;a housing comprising:a first opening configured to receive a portion of a mating connector;a second opening; andat least one third opening between the first opening and the second opening; anda plurality of terminals extending through the at least one third opening, the plurality of terminals comprising mating contact portions extending into the first opening and contact tails extending into the second opening, wherein the plurality of conductive wires of the cable are electrically connected to the contact tails of the plurality of terminals within the second opening; andan insulative material within the second opening encapsulating the contact tails of the plurality of terminals within the second opening and closing off passage between the at least one third opening and the second opening.

A2. The plug connector of example A1, wherein the housing comprises:a shell comprising the first opening, the second opening and the at least one third opening; anda contact carrier inserted into the at least one third opening.

A3. The plug connector of example A2, wherein:the plurality of terminals comprise intermediate portions interconnecting respective mating contact portions with respective contact tails; andthe intermediate portions of the plurality of terminals are attached to the contact carrier.

A4. The plug connector of examples A2 or A3, wherein:the contact carrier comprises a contact holder and a contact cover comprising at least one finger portion;the plurality of terminals comprise intermediate portions interconnecting respective mating contact portions with respective contact tails, the intermediate portions comprising first and second sides, and wherein the terminals are mounted with the first sides against the contact holder over a first distance from an end of the terminals adjacent the contact tails; andthe contact cover is mounted with the second sides of the intermediate portions against the contact cover over a second distance from the end of the terminals, the second distance being shorter than the first distance.

A5. The plug connector of any of examples A2-A4, wherein:the at least one third opening is elongated in a first direction; andthe contact carrier comprises an outer surface and the at least one third opening is bounded by an inner surface, facing the outer surface; andat least one of the outer surface and inner surface comprises a plurality of parallel ribs extending transverse to the first direction, wherein the plurality of ribs are configured to close off passage between the at least one third opening and the second opening.

A6. The plug connector of any of examples A4-A5, wherein:the contact carrier comprises a contact holder and a contact cover, configured such that a channel between the contact holder and the contact cover extends in the first direction; and the shell comprises a second rib, extending in the first direction and extending into a groove.

A7. The plug connector of any of examples A1-A6, wherein the housing comprises one or more ribs extending into the second opening and placed in contact with an overmold material occupying at least a portion of the second opening.

B1. An apparatus comprising:an electrical connector having an opening;a plurality of mating contacts inserted through the opening of the electrical connector, each of the plurality of mating contacts having a mating contact portion, a contact tail, and an intermediate portion between the mating contact portion and the contact tail;a contact holder disposed at least partially within the opening of the electrical connector and configured to support the plurality of mating contacts; anda contact cover disposed at least partially within the opening of the electrical connector such that at least one of the plurality of mating contacts is disposed between the contact holder and the contact cover;wherein the intermediate portions comprise first and second sides, and wherein the mating contacts are mounted with the first sides against the contact holder over a first distance from an end of the mating contacts adjacent the contact tails; andthe contact cover is mounted with the second sides of the intermediate portions against the contact cover over a second distance from the end of the mating contacts, the second distance being shorter than the first distance.

B2. The apparatus of example B1, wherein the contact cover comprises one or more projections, and wherein the second sides of the intermediate portions abut the one or more projections over the second distance from the end of the mating contacts.

B3. The apparatus of example B2, wherein at least one of the one or more projections comprises a first surface and a second surface opposite the first surface, the first surface being in contact with the second side of the intermediate portion and the second surface being in contact with an inner wall of the opening of the electrical connector.

B4. The apparatus of any of examples B1-B3, wherein the contact holder and the contact cover are separate pieces.

B5. The apparatus of example B1, wherein at least a portion of the intermediate portion is not in contact with the contact cover.

B6. The apparatus of any of examples B1-B5, wherein the mating contact comprises a convex surface adapted to electrically contact a pad formed in a mating connector.

B7. The apparatus of example B6, wherein the plurality of mating contacts includes at least a first mating contact and a second mating contact, and wherein the convex surface of the first mating contact faces a convex surface of the second mating contact.

B8. The apparatus of any of examples B1-B7, wherein the contact tail comprises a V-shaped mechanism for receiving a wire therein.

B9. The apparatus of any of examples B1-B8, wherein the electrical connector is configured to receive a cable therein.

B10. The apparatus of any of examples B1-B9, further comprising:a cable comprising a plurality of conductive wires; andan insulative material;wherein the opening is a first opening, and the electrical connector further comprises a second opening configured to receive a portion of a mating connector and a third opening configured to receive the cable, the first opening being disposed between the second opening and the third opening;wherein the plurality of mating contacts extend through the first opening, the mating contact portions extend into the second opening and the contact tails extend into the third opening, wherein the plurality of conductive wires of the cable are electrically connected to the contact tails within the third opening; andwherein the insulative material is disposed within the third opening encapsulating the contact tails within the third opening and closing off passage between the first opening and the third opening.

B11. The apparatus of any of examples B1-B10, wherein the electrical connector is configured to be mated with an adapter connector such that, when mated, the electrical connector and the adapter connector are attached to a panel, wherein the apparatus further comprises:a resilient member having first and second sealing elements, the resilient member being configured to form a first sealing interface with the panel and a second sealing interface with the electrical connector, the first and second sealing interfaces being orthogonal to each other,
wherein the first sealing element is configured to engage with the panel and the second sealing element is configured to engage with the electrical connector.

C1. An adapter connector configured to be mated with a plug connector such that, when mated, the adapter connector and the plug connector are attached to a panel, the adapter connector comprising:an insulative housing;a first plurality of mating contacts supported by the insulative housing, the first plurality of mating contacts being configured to electrically contact a second plurality of mating contacts supported by the plug connector; anda resilient member having first and second sealing elements, the resilient member being configured to form a first sealing interface with the panel and a second sealing interface with the plug connector, the first and second sealing interfaces being orthogonal to each other,wherein the first sealing element is configured to engage with the panel and the second sealing element is configured to engage with the plug connector.

C2. The adapter connector of example C1, wherein the resilient member comprises a base and a sidewall configured to wrap around an outer border of the adapter connector.

C3. The adapter connector of example C2, wherein the first sealing element is disposed at the base and the second sealing element is disposed at the sidewall.

C4. The adapter connector of any of examples C1-C3, wherein the first sealing element extends in a direction that is parallel to a direction of mating of the adapter connector with the plug connector.

C5. The adapter connector of any of examples C1-C4, wherein the first sealing element comprises a rib configured to engage with a respective recess formed in the panel.

C6. The adapter connector of any of examples C1-C5, wherein the second sealing element comprises a rib configured to engage with a respective recess formed in the plug connector.

C7. The adapter connector of any of examples C1-C6, wherein the adapter connector is attached to the panel through a plurality of screws.

C8. The adapter connector of example C7, wherein the plurality of screws pass through respective openings formed in the resilient member.

C9. The adapter connector of any of examples C1-C8, wherein:the insulative housing comprises a body having a top surface and an angled surface disposed at an edge of the top surface; andthe first plurality of mating contacts extend through the top surface.

C10. The adapter connector of example C9, wherein:the first sealing elements is positioned to form the first sealing interface with the panel; the second sealing element is positioned to form the second sealing interface with the plug connector;the second sealing element has an upper edge; andthe upper edge of the second sealing element is below the angled surface.

C11. The adapter connector of any of examples C1-C10, wherein:the insulative housing comprises a slot; andthe resilient member comprises a rib extending into the slot, and the slot and the rib each have an aspect ratio of at least 2:1.

D1. A resilient member configured to seal first and second electrical connectors attached to a panel, the resilient member comprising:a base having an opening formed therethrough, the base being configured to form a first sealing interface with the panel;a sidewall connected to the base, the sidewall being configured to form a second sealing interface with the second electrical connector;a first sealing element extending from the base; anda second sealing element extending from the sidewall,wherein the first sealing interface and the second sealing interface are perpendicular to each other.

D2. The resilient member of example D1, wherein the base, the sidewall, and the first and second sealing elements are made of an elastic material.

D3. The resilient member of any of examples D1-D2, wherein the first sealing element and the sidewall extend in opposite directions.

D4. The resilient member of any of examples D1-D3, wherein the opening is a first opening, and wherein the resilient member further comprises a second opening, wherein the first sealing element is disposed along at least a portion of a perimeter of the second opening.

D5. The resilient member of any of examples D1-D3, wherein the first sealing element comprises a rib configured to engage with a respective recess formed in the panel.

D6. The resilient member of any of examples D1-D5, wherein the second sealing element comprises a rib configured to engage with a respective recess formed in the second electrical connector.

D7. The resilient member of any of examples D1-D6, further comprising a third sealing element extending from the base, wherein the first sealing element and the third sealing element form one or more pockets enclosed therebetween.

D8. The resilient member of example D7, wherein the one or more pockets surround the opening in a plane defined by the base.

D9. The resilient member of any of examples D1-D8, wherein the base is further configured to form a third sealing interface with the first connector, and wherein the resilient member further comprises a third sealing element extending from the base, the first and third sealing elements extending in opposite directions.

D10. The resilient member of any of examples D1-D9, further comprising a third sealing element extending from the base toward the opening.

E1. An electrical connector comprising:a housing having an opening formed therethrough and a first rib extending into the opening;a plurality of mating contacts inserted through the opening of the housing;a contact holder disposed at least partially within the opening of the housing and configured to support the plurality of mating contacts, the contact holder comprising a second rib abutting a first wall of the opening; anda contact cover disposed at least partially within the opening of the housing such that at least one of the plurality of mating contacts is disposed between the contact holder and the contact cover, the contact cover comprising a third rib abutting the first wall of the opening;wherein the second and third rib are longitudinally aligned with each other and form a discontinuity between each other, and wherein the first rib is disposed in the discontinuity.

E2. The electrical connector of example E1, wherein the housing is configured to receive a cable therein, the cable comprising at least one conductive wire configured to connect to the at least one of the plurality of mating contacts.

E3. The electrical connector of examples E1 or E2, wherein the contact holder and the contact cover are separate pieces.

E4. The electrical connector of any of examples E1-E3, wherein the plurality of mating contacts extend along a first direction, and the third rib extends along a second direction perpendicular to the first direction.

E5. The electrical connector of example E4, wherein the first rib extends in the first direction.

E6. The electrical connector of any of examples E1-E5, wherein:the plurality of mating contacts comprise mating contact portions, contact tails and intermediate portions interconnecting the mating contact portions with the contact tails, the intermediate portions comprising first and second sides, and wherein the terminals are mounted with the first sides against the contact holder over a first distance from an end of the mating contacts adjacent the contact tails; andthe contact cover is mounted with the second sides of the intermediate portions against the contact cover over a second distance from the end of the mating contacts, the second distance being shorter than the first distance.

E7. The electrical connector of any of examples E1-E6, wherein the electrical connector is configured to be mated with an adapter connector such that, when mated, the electrical connector and the adapter connector are attached to a panel, wherein the electrical connector further comprises:a resilient member having first and second sealing elements, the resilient member being configured to form a first sealing interface with the panel and a second sealing interface with the housing, the first and second sealing interfaces being orthogonal to each other, wherein the first sealing element is configured to engage with the panel and the second sealing element is configured to engage with the housing.

F1. An panel connector configured to be attached to a board connector and to be mated with a plug connector such that, when mated, the panel connector and the plug connector are attached to a panel, the panel connector comprising:an insulative housing comprising:a mating interface configured for mating with the plug connector;a mounting interface for mounting to the board connector, the mounting interface comprising a cavity configured to receive a portion of the board connector;one or more projections formed at the mounting interface and configured to slide into respective one or more channels in the board connector; anda first plurality of mating contacts supported by the insulative housing, the first plurality of mating contacts being configured to electrically contact at the mating interface a second plurality of mating contacts supported by the plug connector.

F2. The panel connector of example F1, wherein the first plurality of mating contacts are arranged symmetrically with respect to a first axis that passes through a center of an interface between the panel connector and the board connector, and wherein the one or more projections are arranged asymmetrically with respect to the first axis.

F3. The panel connector of any of examples F1-F2, wherein the insulative housing comprises first and second housing portions supporting the first plurality of mating contacts, and an exterior housing encasing the first and second housing portions.

F4. The panel connector of any of examples F1-F3, further comprising:a resilient member having first and second sealing elements, the resilient member being configured to form a first sealing interface with the panel and a second sealing interface with the plug connector, the first and second sealing interfaces being orthogonal to each other,
wherein the first sealing element is configured to engage with the panel and the second sealing element is configured to engage with the plug connector.

F5. The panel connector of example F4, wherein the resilient member comprises a base and a sidewall configured to wrap around an outer border of the panel connector.

F6. The panel connector of any of examples F1-F5, wherein the insulative housing comprises a body having a top surface and an angled surface disposed at an edge of the top surface.

G1. A panel configured to be attached to a panel connector and to receive thereon a plug connector such that the plug connector electrically contacts the panel connector, the panel comprising:a planar base;an opening formed through the planar base and configured to receive the panel connector therethrough; anda raised portion formed on the planar base and surrounding the opening, the raised portion having a top surface that is vertically offset relative to a top surface of the planar base.

G2. The panel of example G1, further comprising the plug connector, wherein the plug connector comprises:an insulative housing having a plurality of sidewalls forming a cavity configured to receive therein the raised portion of the panel, the plurality of sidewalls having respective slanted ends projecting outwardly relative to the insulative housing; anda first plurality of mating contacts supported by the insulative housing, the first plurality of mating contacts being configured to electrically contact a second plurality of mating contacts supported by the panel connector.

G3. The panel of example G2, wherein the insulative housing is sized such that the respective slanted ends are adjacent to the top surface of the planar base when the plug connector is received on the panel.

G4. The panel of any of examples G1-G3, further comprising a plurality of recesses formed on the top surface of the raised portion and configured to receive respective ribs of a seal, wherein the seal is configured to be disposed between the panel and the panel connector.

H1. A panel connector configured to be attached to a board connector and to be mated with a plug connector such that, when mated, the panel connector and the plug connector are attached to a panel, the panel connector comprising:at least one housing portion;an overmolded exterior housing encasing the at least one housing portion; anda first plurality of mating contacts supported by the at least one housing portion, the first plurality of mating contacts being configured to electrically contact a second plurality of mating contacts supported by the plug connector.

H2. The panel connector of example H1, wherein the at least one housing portion is a first housing portion, and further comprising a second housing portion, wherein the overmolded exterior housing encases the second housing portion, and wherein the first and second housing portions are manufactured separately.

H3. The panel connector of example H2, wherein the mating contacts extend along a first direction, and wherein the first and second housing portions are offset relative to each other along the first direction.

H4. The panel connector of any of examples H1-H3, wherein the at least one housing portion comprises a protrusion configured to engage with an opening formed on the overmolded exterior housing.

H5. The panel connector of any of examples H1-H4, wherein the at least one housing portion comprises a plurality of channels, wherein the first plurality of mating contacts pass through the plurality of channels.

H6. The panel connector of any of examples H1-H5, wherein the first plurality of mating contacts have respective ends that are supported by the overmolded exterior housing and are exposed in an exterior surface of the overmolded exterior housing.

I1. A method for manufacturing a panel connector configured to be attached to a board connector and to be mated with a plug connector such that, when mated, the panel connector and the plug connector are attached to a panel, the method comprising:fabricating at least one housing portion using an insulative material;inserting a plurality of mating contacts in the at least one housing portion; andfabricating an exterior housing by overmolding the at least one housing portion with the plurality of mating contacts inserted therein such that respective ends of the plurality of mating contacts are exposed in an exterior surface of the exterior housing.

I2. The method of example I1, wherein fabricating the at least one housing portion comprises forming a plurality of channels through the at least one housing portion, and wherein inserting the plurality of mating contacts in the at least one housing portion comprises:passing the plurality of mating contacts through the plurality of channels.

I3. The method of any of examples I1-I2, wherein the at least one housing portion is a first housing portion, and wherein the method further comprises:fabricating a second housing portion; andinserting the plurality of mating contacts in the second housing portion;wherein fabricating the exterior housing further comprises overmolding the second housing portion.

I4. The method of any of examples I1-I3, wherein the plurality of mating contacts extend in a first direction, and wherein the first and second housing portions are offset relative to each other along the first direction.

I5. The method of any of examples I1-I4, wherein fabricating the exterior housing further comprises forming a cavity such that the plurality of mating contacts are placed at least partially in the cavity.

I6. The method of example I5, further comprising filling at least a portion of the cavity with a potting material.

Various aspects of the present invention may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described in the foregoing and is therefore not limited in its application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments.

Use of ordinal terms such as “first,” “second,” “third,” etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.

All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”

As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law.

Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.