Low-profile, pierce-through connector backshell

Claim 2

A backshell housing for use with a multi-position connector and a flat cable, the backshell housing comprising: a. a top shell having a front section and a rear section; b. a bottom shell having a front section and a rear section, said front sections of the top and bottom shells defining a substantially (rectangular opening) for facilitating the entry and placement of the flat cable within the backshell; c. a first ledge located in the rear section of the top shell having a plurality of longitudinal grooves for placement of a plurality of cables of the flat cable; d. a second ledge located in the rear section of the bottom shell having a plurality of longitudinal grooves, said grooves being in the same position as the grooves of the top shell so that when the top shell and bottom shell are assembled, openings for said cables are created between the longitudinal grooves; e. at least one piercing means for piercing a web of the flat cable located between two longitudinal grooves on at least one said ledge, said piercing means piercing the web by application of both pressure and ultrasonic vibration; f. means for locking the top shell to the bottom shell the locking means comprising at least first and second energy directors formed as raised heads and disposed on lateral edge surfaces of one of the top or bottom shells, whereupon application of ultrasonic energy, said locking means welds the top shell to the bottom shell to form a rigid, unitary backshell housing; and (means for rigidly affixing the housing to the multi-position connector), said means comprising at least one energy director 41 found or a raised bead and disposed on an interior surface of each of the top and bottom shells, said means being operable to absorb ultrasonic energy and to melt and rigidly affix to the multi-position connector.

Claim 3

An electrical connector assembly comprising: a. a multi-position connector having a plurality of contact positions; b. a flat cable comprising a plurality of cables surrounded by at least one jacket of insulation, wherein individual cables are further identified as pods, and jacket areas located between adjacent cables are identified as webs, and further, the cables have ends which are capable of being terminated to contact positions of the multi-position connector; and c. a backshell housing comprising: i) a top shell having a front section and a rear section; ii) a bottom shell having a front section and a rear section wherein the two shells are positioned so that the front sections are paired to form a substantially rectangular opening to receive the flat cable; iii) a first ledge located in the rear section of the top shell having a plurality of longitudinal grooves; iv) a second ledge located in the rear section of the bottom shell having a plurality of longitudinal grooves, said grooves being in the same position as the grooves of the top shell so that when the top shell and bottom shell are assembled, openings for said cables are created between the longitudinal grooves; v) at least one piercing means (for) piercing a web of the flat cable located between two longitudinal grooves on at least one of the first and second ledges, said piercing means piercing the web by application of both pressure and ultrasonic vibration; vi) means for locking the top shell to the bottom shell, the locking means comprising at least first and second energy directors formed as raised beads and disposed on lateral edge surfaces of one of the top or bottom shells, whereupon application of ultrasonic energy said locking means welds the top shell to the bottom shell to form a rigid, unitary backshell housing; and vii) means for rigidly affixing the backshell housing to the multi-position connector, said means comprising at least one energy directors disposed on an interior surface of both the top and bottom shells, said means being operable to absorb ultrasonic energy and to melt and rigidly affix to the multi-position connector.

Claim 4

An electrical connector assembly comprising: a. a multi-position connector having a plurality of contact positions; b. a flat cable comprising a plurality of cables surrounded by at least one jacket of insulation, wherein individual cables are further identified as pods, and jacket areas located between adjacent cables are identified as webs, and further, the cables have ends which are capable of being terminated to contact positions of the multi-position connector; and c. a backshell housing comprising: i) a top shell having a front section and a rear section; ii) a bottom shell having a front section and a rear section wherein the two shells are positioned so that the front sections are paired to form a substantially rectangular opening to receive the flat cable; iii) a first ledge located in the rear section of the top shell having a plurality of longitudinal grooves; iv) a second ledge located in the rear section of the bottom shell having a plurality of longitudinal grooves, said grooves being in the same position as the grooves of the top shell so that when the top shell and bottom shell are assembled, openings for said cables are created between the longitudinal grooves; v) at least one piercing means (for) piercing a web of the flat cable located between two longitudinal grooves on at least one of the first and second ledges, said piercing means piercing the web by application of both pressure and ultrasonic vibration; vi) means for locking the top shell to the bottom shell, the locking means comprising at least first and second energy directors formed as raised beads and disposed on lateral edge surfaces of one of the top or bottom shells, whereupon application of ultrasonic energy said locking means welds the top shell to the bottom shell to form a rigid, unitary backshell housing; and vii) means for rigidly affixing the backshell housing to the multi-position connector, said means comprising at least one energy directors disposed on an interior surface of both the top and bottom shells, said means being operable to absorb ultrasonic energy and to melt and rigidly affix to the multi-position connector.