EP0512438A2 — Electrical connector assemblies

Claim 1

Independent Claim 148 words

An electrical connector assembly (20), comprising: a housing (28) having an open-ended cavity (42), the housing being unitarily molded of dielectric material; a plurality of terminal-receiving modules (34) each being unitarily molded of dielectric material and sized and shaped to be juxtaposed in a nested array for positioning in the cavity of the housing through the open end thereof; and complementary interengageable latch means between the housing and each terminal-receiving module to hold all the modules in their nested array within the cavity, the latch means being molded integral with the housing and the modules, the latch means including a pair of common latches (54) disposed on opposite sides of the housing and individual latches (52) disposed on end surfaces of the modules, each common latch extending along the array of modules for engagement with the individual latches thereof and comprising a cantilever portion of said opposite sides.

Claim 2

Dependent Claim 148 words

An electrical connector assembly (20), comprising: a housing (28) having an open-ended cavity (42), the housing being unitarily molded of dielectric material; a plurality of terminal-receiving modules (34) each being unitarily molded of dielectric material and sized and shaped to be juxtaposed in a nested array for positioning in the cavity of the housing through the open end thereof; and complementary interengageable latch means between the housing and each terminal-receiving module to hold all the modules in their nested array within the cavity, the latch means being molded integral with the housing and the modules, the latch means including a pair of common latches (54) disposed on opposite sides of the housing and individual latches (52) disposed on end surfaces of the modules, each common latch extending along the array of modules for engagement with the individual latches thereof and comprising a cantilever portion of said opposite sides.

Claim 3

Dependent Claim 54 words

The electrical connector assembly of claim 1 wherein said cavity is generally rectangularly shaped, and said modules are elongated with lengths each generally equal to one cross-dimension of the rectangular cavity and with the total of the widths of all of said modules being generally equal to the opposite cross-dimension of the rectangular cavity.

Claim 4

Dependent Claim 149 words

A shielded electrical connector assembly (20), comprising: an insulating housing (28) having a top, a bottom and opposite sides; top and bottom conductive shield sections (30, 32) stamped and formed from metal material and positionable over the top and bottom (28a, 28b), respectively, of the housing, each shield section including side walls (30b, 32b) overlying at least portions of the sides (28c) of the housing; and complementary interengageable latch means between the sides of the housing and the side walls of each of the shield sections for holding the shield sections on the housing, said latch means including only one channel (62) molded in and extending along each side wall generally parallel to said top and bottom of the housing, and at least one latching tab (64, 66) formed from each side wall of the shield sections, each latching tab snapping into one of the channels on the housing.

Claim 5

Dependent Claim 149 words

A shielded electrical connector assembly (20), comprising: an insulating housing (28) having a top, a bottom and opposite sides; top and bottom conductive shield sections (30, 32) stamped and formed from metal material and positionable over the top and bottom (28a, 28b), respectively, of the housing, each shield section including side walls (30b, 32b) overlying at least portions of the sides (28c) of the housing; and complementary interengageable latch means between the sides of the housing and the side walls of each of the shield sections for holding the shield sections on the housing, said latch means including only one channel (62) molded in and extending along each side wall generally parallel to said top and bottom of the housing, and at least one latching tab (64, 66) formed from each side wall of the shield sections, each latching tab snapping into one of the channels on the housing.

Claim 6

Dependent Claim 126 words

A shielded electrical connector assembly (20) for mating with an appropriate mating connector assembly (22), comprising: an insulating housing (28) having a top (28a), a bottom (28b) and opposite sides (28c); a shield member including separate top (30) and bottom (32) conductive shield components positionable over the top and bottom, respectively, of the housing, each shield component including side walls (30b, 32b) overlying at least portions of the sides of the housing; and latch arms (76) integrally formed from said shield member and folded rearwardly from front edges (78) of the side walls of the shield member for latching the connector assembly to said appropriate mating connector assembly, said latch arms extending rearwardly outside the periphery of said insulative housing and having latching tabs (80) thereon.

Claim 7

Dependent Claim 126 words

A shielded electrical connector assembly (20) for mating with an appropriate mating connector assembly (22), comprising: an insulating housing (28) having a top (28a), a bottom (28b) and opposite sides (28c); a shield member including separate top (30) and bottom (32) conductive shield components positionable over the top and bottom, respectively, of the housing, each shield component including side walls (30b, 32b) overlying at least portions of the sides of the housing; and latch arms (76) integrally formed from said shield member and folded rearwardly from front edges (78) of the side walls of the shield member for latching the connector assembly to said appropriate mating connector assembly, said latch arms extending rearwardly outside the periphery of said insulative housing and having latching tabs (80) thereon.

Claim 8

Dependent Claim 204 words

An electrical connector (20), comprising: an inner connector assembly including a stamped and formed metal shield (30, 32) and a pair of spring latch arms (76) integrally formed with and folded rearwardly from front edges (78) of said shield for latching the connector assembly to an appropriate mating connector (22), the latch arms being movable between an operative latching position when the connectors are mated and an inoperative unlatching position to allow unmating of the connectors, the latch arms further being normally biased outwardly of the inner connector assembly toward said operative latching position; an outer cover (26) about at least a portion of the inner connector assembly and movable relative thereto in a mating/unmating direction, said outer cover including recess means (82) for accommodating the latch arms in their outwardly biased operative latching position; and complementary engageable cam means (76a, 82a, 82b) between the outer cover and the latch means for moving the latch means to the inoperative unlatching position when the cover is moved relative to the inner connector assembly in the unmating direction and for allowing movement of the latch means to the operative latching position when the cover is moved relative to the inner connector assembly in the mating direction.

Claim 9

Dependent Claim 204 words

An electrical connector (20), comprising: an inner connector assembly including a stamped and formed metal shield (30, 32) and a pair of spring latch arms (76) integrally formed with and folded rearwardly from front edges (78) of said shield for latching the connector assembly to an appropriate mating connector (22), the latch arms being movable between an operative latching position when the connectors are mated and an inoperative unlatching position to allow unmating of the connectors, the latch arms further being normally biased outwardly of the inner connector assembly toward said operative latching position; an outer cover (26) about at least a portion of the inner connector assembly and movable relative thereto in a mating/unmating direction, said outer cover including recess means (82) for accommodating the latch arms in their outwardly biased operative latching position; and complementary engageable cam means (76a, 82a, 82b) between the outer cover and the latch means for moving the latch means to the inoperative unlatching position when the cover is moved relative to the inner connector assembly in the unmating direction and for allowing movement of the latch means to the operative latching position when the cover is moved relative to the inner connector assembly in the mating direction.

Claim 10

Dependent Claim 49 words

The electrical connector of claim 5 wherein said complementary engageable cam means include a cam portion on the outer cover for moving the latch arm inwardly against said bias toward the inoperative unlatching position when the cover is moved relative to the inner connector assembly in said unmating direction.

Claim 11

Dependent Claim 36 words

The electrical connector of claim 5, including stop means (26a, 84) between the outer cover and the inner connector assembly to limit movement of the cover relative to the inner connector assembly in said mating direction.

Claim 12

Dependent Claim 122 words

An electrical connector assembly (22), comprising: housing means (90) defining a module-receiving cavity (96), the housing means including open ends (118, 122) in generally perpendicular planes; and a plurality of generally flat terminal modules (94) nested within the cavity in the housing means in a side-by-side relationship, each terminal module including a plurality of generally coplanar flat terminals (102) fabricated of stamped sheet metal material and configured in right angles with opposite ends (98, 100) projecting from said open ends of the housing means, the terminals of each module being surrounded and maintained in a desired array by an overmolded module encasement (110) fabricated of dielectric material such as molded plastic, with said opposite ends of the terminals projecting from the encasement.

Claim 13

Dependent Claim 122 words

An electrical connector assembly (22), comprising: housing means (90) defining a module-receiving cavity (96), the housing means including open ends (118, 122) in generally perpendicular planes; and a plurality of generally flat terminal modules (94) nested within the cavity in the housing means in a side-by-side relationship, each terminal module including a plurality of generally coplanar flat terminals (102) fabricated of stamped sheet metal material and configured in right angles with opposite ends (98, 100) projecting from said open ends of the housing means, the terminals of each module being surrounded and maintained in a desired array by an overmolded module encasement (110) fabricated of dielectric material such as molded plastic, with said opposite ends of the terminals projecting from the encasement.

Claim 14

Dependent Claim 37 words

The electrical connector of claim 8 wherein said terminal modules include complementary interengageable locking means (124, 126) on opposite sides thereof for holding the modules together in said side-by-side relationship within the cavity in the housing means.

Claim 15

Dependent Claim 32 words

The electrical connector of claim 9 wherein said cavity has locking means (126, 144) for locking engagement with at least one end-most module of the plurality of modules in said side-by-side relationship.

Claim 16

Independent Claim 109 words

A method of fabricating an electrical connector assembly (22), comprising the steps of: providing a housing (90) defining a module-receiving cavity (96) and having open ends (118, 122) in generally perpendicular planes; forming a plurality of generally flat terminals (102) in a generally coplanar right-angled array; overmolding a module encasement (110) about the coplanar flat terminals, with opposite ends (98, 100) of said terminals projecting from the encasement, to define a plurality of generally flat terminal modules (94); and nesting said terminal modules within the cavity in the housing in a side-by-side relationship whereby the opposite ends of the terminals project from said open ends of the housing means.

Claim 17

Independent Claim 109 words

A method of fabricating an electrical connector assembly (22), comprising the steps of: providing a housing (90) defining a module-receiving cavity (96) and having open ends (118, 122) in generally perpendicular planes; forming a plurality of generally flat terminals (102) in a generally coplanar right-angled array; overmolding a module encasement (110) about the coplanar flat terminals, with opposite ends (98, 100) of said terminals projecting from the encasement, to define a plurality of generally flat terminal modules (94); and nesting said terminal modules within the cavity in the housing in a side-by-side relationship whereby the opposite ends of the terminals project from said open ends of the housing means.

Claim 18

Dependent Claim 168 words

An electrical connector system, comprising: a first connector assembly (20) including a first housing (28) having therein a plurality of female terminals (36) fabricated of sheet metal material having opposed generally planar smooth surfaces and perpendicular edges, each terminal having a pair of opposed cantilevered beams (150), said pair of beams having opposed contact surfaces thereon formed from said smooth surfaces of said sheet metal material; and a second connector assembly (22) for connection with the first connector assembly and including a second housing (96) having therein a plurality of male terminals (102) for mating with the female terminals, the male terminals being fabricated of sheet metal material having opposed generally planar smooth surfaces and perpendicular edges so that each said male terminal has a pair of opposed surfaces formed from said smooth surfaces, and the male terminals being oriented in the second housing such that the opposed surfaces of said male terminals engage the opposed contact surfaces of the female terminals when the connector assemblies are mated.

Claim 19

Dependent Claim 168 words

An electrical connector system, comprising: a first connector assembly (20) including a first housing (28) having therein a plurality of female terminals (36) fabricated of sheet metal material having opposed generally planar smooth surfaces and perpendicular edges, each terminal having a pair of opposed cantilevered beams (150), said pair of beams having opposed contact surfaces thereon formed from said smooth surfaces of said sheet metal material; and a second connector assembly (22) for connection with the first connector assembly and including a second housing (96) having therein a plurality of male terminals (102) for mating with the female terminals, the male terminals being fabricated of sheet metal material having opposed generally planar smooth surfaces and perpendicular edges so that each said male terminal has a pair of opposed surfaces formed from said smooth surfaces, and the male terminals being oriented in the second housing such that the opposed surfaces of said male terminals engage the opposed contact surfaces of the female terminals when the connector assemblies are mated.

Claim 20

Dependent Claim 30 words

The electrical connector system of claim 12 wherein said contact beams of the female terminals are generally parallel and are generally parallel to the opposed surfaces of the male terminals.

Claim 21

Dependent Claim 50 words

The electrical connector system of claim 12 wherein said second connector assembly includes a plurality of male terminal modules (94) located within said second housing, each said module including an array of right angle male terminals (102) maintained in their desired, predetermined positions by an encasement (110) of dielectric material.

Claim 22

Dependent Claim 44 words

The electrical connector system of claim 14 wherein said first connector assembly includes a plurality of female terminal modules (34) located within said first housing, each said female terminal module being oriented generally perpendicular to the male terminal modules of said second connector assembly.

Electrical connector assemblies

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