Patent Application
20070281552
The present invention is directed to an electrical connector. In the past, electrical connectors, sometimes referred to as FAKRA connectors, have been used to connect multiple coaxial cables. One such connector is illustrated in FIGS. 1(A)-1(F).
As illustrated in FIGS. 1(A)-1(F), the connectors include a male housing 108 and a female housing 100. Ferrules 102 are positioned adjacent to the male housing 108 and the female housing 100, respectively. Protrusion 106 on the male housing is adapted to engage latch 104 in the female housing 100.
By way of explanation, FIGS. 1(B) and 1(C) illustrate the connector assembly 110 in a state of pre-engagement and engagement, respectively. FIGS. 1(D) and 1(F) provide perspective views of the connector assembly 110 in a state of connection. FIGS. 1(A) and 1(C) illustrate cross-sectional views of the connector assembly 110 as taken along a midsection, where lines A-A throughout FIGS. 1(A)-1(F) correspond to each other.
However, several problems exist with the configurations illustrated in FIGS. 1(A)-1(F). For example, it is difficult to guarantee proper alignment of the male housing 108 and the female housing 100. Typically, these electrical connectors are installed on assembly lines, which tend to have limited lighting. Because the connectors illustrated in FIGS. 1(A)-1(F) do not include adequate alignment features, misalignment may often occur, which can result in electrical and mechanical damage to the connector assembly 110.
For example, elements 112 and 114 (
Additionally, ferrules 102 cause undesirable wear and tear on the coaxial (or other) cables positioned therein. For example, throughout the life of the connector assembly 110, the coaxial cables experience friction against the ends of ferrules 102. Consequently, the insulation on the coaxial cables may deteriorate and may result in a short circuit, fire, or the like.
As can be seen in FIGS. 1(B), 1(C), 1(E), and 1(F) particularly, space exists between the ferrules 102. During normal use, it is quite likely that a user will grasp the end of the ferrules 102. Pressure applied at the ends of the ferrules causes the ends to become compressed together. This pressure also causes a corresponding splay of the opposite ends of the ferrules (e.g., at ports 140). This corresponding splay often results in misalignment between the ports 140 of the female housing 100 and the ports 140 of the male housing 108.
Another problem with the configurations illustrated in FIGS. 1(A)-1(F) is that the latch 104 is provided at the female housing 100. As a result, it is difficult to achieve secure engagement between the female housing 100 and the male housing 108. In the event that the latches 104 do engage protrusions 106, it becomes very difficult to disengage the connection. Effectively, the latch is a “lazy latch,” which means that the latch often fails to return to its original position after disengagement.
Latches 104 are also subject to significant pressure during normal use. Due to the fragility of the configuration of latches 104, they frequently shatter during use. The latches 104 also fail to properly engage protrusions 106, which can result in failed electrical connections.
As illustrated in FIGS. 1(B) and 1(E), male housing 108 includes pin 120, which creates an electrical connection when received in socket 126 of the female housing 100. Conductive body 138 provides a second area of electrical connection when mated with conductive body 142 of the female housing 100 for electrically connecting the outer conductors in the coaxial cables being connected. Insulators 124 and 128 prevent undesired electrical contact between the inner and outer conductor.
Female housing 100 further includes retaining ring 134, which applies a resilient force at the mating end of ferrule 102. In more detail, when the pin 120 is received by receptacle 126, an outward stress is applied to the ferrule 102. Retaining ring 134 provides a spring-like force at the end of the ferrule 102 of the female housing 100 that strengthens the engagement between the female housing 100 and the male housing 108.
In light of the difficulties described above, the Applicants developed the present invention. To this end, a first non-limiting aspect of the invention provides an electrical connector, including: a female housing configured to include a first mating interface adapted to receive a second mating interface; a male housing configured to include the second mating interface; and at least one first anti-splay ferrule positioned at at least one of the female housing and the male housing, wherein an electrical connection is achieved when the first mating interface receives the second mating interface.
Another aspect of the invention provides an electrical connector, including a female housing configured to include a first mating interface adapted to receive a second mating interface; a male housing configured to include the second mating interface; and at least one means for preventing electrical contact positioned at at least one of the female housing and the male housing, wherein an electrical connection is achieved when the first mating interface receives the second mating interface.
FIGS. 1(A)-1(F) illustrate a connector according to the background art;
FIGS. 2(A)-2(F) illustrate non-limiting exemplary configurations of the connector according to the present invention;
FIGS. 7(A) and 7(B) illustrate exemplary ferrule inner configurations when a female housing and a male housing are connected;
FIGS. 8(A)-8(C) provide more detailed illustrations of an exemplary latch configuration;
FIGS. 11(A)-11(D) provide additional exemplary illustrations of a female housing according to the present invention;
FIGS. 12(A)-12(E) provide additional exemplary illustrations of a male housing according to the present invention;
FIGS. 13(A)-13(D) illustrate key codes according to the background art; and
FIGS. 14(A)-14(D) illustrate key codes according to a non-limiting example of the present invention.
In the following description of the exemplary embodiments, like reference numerals refer to like elements throughout.
FIGS. 2(A)-2(F) illustrate several views of the electrical connector according to a first non-limiting embodiment of the present invention. According to the configurations illustrated in FIGS. 2(A)-2(F), it is possible to improve the mating characteristics between coaxial cables. In each of the embodiments described herein, it is possible that the ferrules (e.g., ferrules 202) may have different diameters as desired to accommodate different sized coaxial cables. In FIGS. 2(A)-2(F), lines A-A correspond throughout.
To this end, as illustrated in FIGS. 2(A) through 2(F), the connector assembly 210 includes a male housing 208 and a female housing 200. Ferrules 202, which may be made of any suitable material, are positioned adjacent to the male housing 208 and the female housing 200, respectively, coaxial with the end portion of conductive bodies 138 and 142. Ferrules 202 may be made of a metal, a polymer, or any combination thereof, and preferably include wider anti-splay portions (e.g., flanges) 202A. By including these wider portions 202A, wear and tear (e.g., wear and tear caused by bending stress) on the coaxial cables (not shown) fed therethrough may be significantly reduced.
As illustrated in FIGS. 2(B) and 2(F), anti-splay portions 202A may include beveled inner diameters 202B to further reduce bending stress and wear and tear on the coaxial cables. However, other configurations, such as rounded edges on inner diameters 202B, are within the scope of the present invention. In addition to reducing damage to the coaxial cables, anti-splay portions 202A also reduce the risk that ports 280 may become misaligned due to pressure applied at the ends of ferrules 202. Because anti-splay portions 202A generally abut each other, the relative positioning of the ferrules 202 does not change if a force is applied at or near anti-splay portions 202A (for example, when a user grasps either the female housing 200 or the male housing 208).
The connector assemblies 210 further include protrusion 206, which is adapted to engage latch 204. As shown in FIGS. 2(B) and 2(E), the latch 204 is mounted to an outer surface of the female housing 200. In other words, the latch 204 is mounted upside down as compared to the latch 104 of the background art.
By configuring the female housing to include the latch 204 as illustrated, the lazy latch problem of the background art is eliminated because the latch may more freely return to its original position. Additionally, fracture of the assembly 210 during use is reduced. Fewer fractures occur because inverting the positioning of the latch 204 enables the latch 204 to be lengthened and widened. This, in turn, reduces the stress on the latch itself. By including gripper portion 204A on latch 204, secure engagement with protrusion 206 may be achieved.
Connector assembly 210 includes keying features 212 and 214, shown in FIGS. 2(D) and 2(F). Because the connector assembly 210 is often assembled on a dimly lit assembly line, the keying features 212 and 214 enable improved alignment between the male housing 208 and the female housing 200. In more detail, keying feature 214 of the female housing can be divided into two subparts (214A and 214B). Subpart 214B includes a slot into which keying feature 212 may be guided. Subpart 214A provides a visual indication of alignment, for example with a colored stripe. Thus, as shown in FIGS. 2(D) and 2(F), keying feature 212, when engaged, may be contained at least partially within subpart 214B and may be visually aligned with keying feature 214A.
Additionally, alignment protrusion 258 may be used to determine the relative alignment of female housing 200. It is also possible to include a visual indicator on the keying feature (or elsewhere on the connector assembly 210), such as an alignment stripe. Preferably, the alignment stripe may be colored differently than the connector assembly 210 to enable easier recognition of alignment.
As a further modification, electrical isolation elements may be included in the anti-splay ferrules 202. By including an electrical isolation element (e.g., elements 202A and 202B), it is possible to prevent accidental and/or undesirable electrical contact between elements of the connector assembly 210. Although all of the ports 280 in FIGS. 2(A)-2(F) are illustrated as populated by ferrules 202, it is possible to leave one or more ports 280 unpopulated, as desired.
As shown in FIGS. 2(B) and 2(C), male housing 208 includes pin 220 that provides an electrical connection when received by receptacle 226. Conductive body 222 provides an additional electrical connection when engaged with conductive body 238 for the outer conductors of coaxial cable, and insulators 228, 230, and 242 prevent undesired electrical contact between the inner and outer conductive elements.
Retaining ring 234 may also be provided, as illustrated in
As shown in detail in
As shown in
Additionally, the female housing 500 includes a shrouded mating face 526, which enables early alignment between the female housing 500 and a male housing. Similarly, the enlarged lead chamfer provides a larger target for a corresponding male housing. Finally, tighter interface criteria in the electrical engagement modules 532 (e.g., the mating ends of ferrules 502) enable secure engagement between the female housing 500 and a male housing. Due to the tighter interface criteria, less force is required to achieve a secure electrical engagement.
The male housing shown in
Ferrules 602, as described above with respect to other embodiments, are shown as being of different sizes. However, it is possible to provide ferrules having identical sizes, if desired. Additionally, it is possible to have the ferrules of the female housing be of different sizes with respect to each other while the ferrules of the male housing may be of the same size relative to each other and/or relative to at least one of the ferrules of the female housing. Of course, other configurations of the ferrule sizes are also within the scope of the present invention. Ferrules 602 also include beveled edges 602B on the inner diameters of the flanges 602A.
If separation of the female housing 600 and the male housing 610 is desired after the housings have been connected, it is possible to press latch releases 620 and/or 622. Once the latch releases have been pressed, the latches disengage from protrusions 624 on the male housing 610. While two latch releases and two protrusions are illustrated in
Of course, the location of insulator 230 is not limited to the location shown in FIGS. 7(A) and 7(B). Preferably, the insulator is coaxial to the pin. However, the insulator is not limited in axial position.
FIGS. 8(A)-8(C) provide additional illustrations of the female housing latch geometry. As these figures illustrate, latch 804 is mounted to an exterior surface of the female housing. Like the other embodiments described above, alignment features 858 and 860 enable improved alignment of the female housing with a male housing (not shown) during connection of the assemblies.
Additionally, conductive body 238 provides an electrical connection between the coaxial cables (not shown) when the female housing 200 is mated with a corresponding male housing. Receptacle 236, made of a conductive material, provides a second electrical connection between the coaxial cables.
As shown in
FIGS. 11(A)-11(D) illustrate yet another embodiment of the present invention. The female housing of this non-limiting embodiment may be equally substituted into any of the other embodiments described herein.
As shown in
It is important to note that any of the ports may be populated or not populated, as desired. For example, port 1184 is shown unpopulated, while port 1180 (e.g., where the mating end of ferrule 1102 is positioned) is shown populated.
Like the other exemplary embodiments, ferrules 1102 include flanges 1102A (anti-splay portions 1102A) and optionally beveled inner diameters 1102B. Conductive receptacle 1126, conductive body 1138, and insulator 1128 are also provided.
As shown in
Additionally, the height and/or width of the alignment feature 1192 may be set such that the mating ends of ferrules 1102 do not accidentally contact an improperly aligned ferrule from a corresponding male housing. In this way, it is possible to prevent damage to the connection elements.
FIGS. 12(A)-12(E) provide additional partial views of an exemplary male housing 1208 according to the present invention. The male housing 1208 may be incorporated into any other embodiment discussed herein.
As shown in
Male housing 1208 may also include alignment guide 1212, which provides a visual indication of successful alignment when mated with a corresponding female housing (not shown). Alignment feature 1292 may also be included, as illustrated in
Like the embodiments described above, ferrules 1202 preferably include flanges 1202A and beveled inner diameters 1202B, as shown in
Pin 1220 provides a first electrical connection between male housing 1208 and a female housing. Conductive body 1222 provides a second electrical connection between male housing 1208 and a female housing. Insulators 1230 and 1224 prevent undesired electrical contact between elements of the male housing.
FIGS. 13(A)-13(D) provide illustrations of exemplary key codes according to the background art. In more detail, FIGS. 13(A) and 13(B) depicted female housings 1342 and 1340, respectively. As shown in FIGS. 13(A) and 13(B), the female housings include latches 1326, alignment guides 1312 and 1318, and ports 1324. Ports 1324 may be populated or unpopulated, as desired. Additionally, keys 1320 and 1322 are present to prevent misalignment with male housings 1344 and 1346, respectively. However, keys 1332 and 1330 in male housings 1344 and 1346 (shown in FIGS. 13(C) and 13(D)) may be overcome by brute force and misalignment may occur. In other words, it is possible to improperly mate key 1320 with key 1330 and to improperly mate key 1332 with key 1322. Male housings 1344 and 1346 each include ports 1324 (which may be populated or unpopulated as desired), protrusions 1306 adapted to engage latches 1326, and alignment guides 1304.
FIGS. 14(A)-14(D) illustrate male and female housings according to a non-limiting example of the present invention. As shown in FIGS. 14(A) and 14(B), female housings 1442 and 1440 include keys 1420 and 1422, respectively. Male housings 1444 and 1446 include corresponding keys 1432 and 1430, respectively. Through the improved configurations of FIGS. 14(A)-14(D), misalignment achieved by brute force is prevented.
Male housings 1444 and 1446 further include ports 1424 (populated or unpopulated as desired), protrusions 1406, and alignment guides 1412. Female housings 1442 and 1440 each include ports 1424 (also populated or unpopulated as desired), latches 1426, which are adapted to engage protrusions 1406 of the male housings 1444 and 1446 (respectively), and alignment guides 1418.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspect is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
