Power cable connector system

• US 7,641,500 B2
• Filed: 03/24/2008
• Issued: 01/05/2010
• Est. Priority Date: 04/04/2007
• Status: Active Grant

• Current Assignee: FCI Americas Technology Incorporated (FCI)
• Original Assignee: FCI Americas Technology Incorporated (FCI)
• Inventors: Stoner, Stuart C., Kolivoski, Christopher J.
• Primary Examiner(s): NASRI, JAVAID H
• Application Number:
  US12/054,023
• Publication Number:
  US 20080248680A1
• Time in Patent Office: 652 Days
• Field of Search: 439350-352, 439/355, 439/357, 439/358, 439/79, 439/449
• US Class Current: 439/357
• CPC Class Codes: H01R 13/633 for disengagement only in combination with safety switch H01R13/7132
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

This invention relates to an improved power connector that has a housing comprising a plurality of slots that are each for receiving a receptacle contact. Preferably, the housing has a plurality of quick-disconnect contacts each disposed in one of the housing slots. Further, a cover, may be coupled to the housing, and the housing may comprise a top portion and a bottom portion. A strain relief member, may be disposed between the cover top and bottom portions. A plurality of cables extend through the channels disposed in the strain relief members and are attached to the housing quick disconnects. A latching spring assembly that may comprise two latching springs is coupled to the housing and attaches the power cable connector to a receptacle connector, such as a right-angle or straight board connector.

Claims

1. A power cable connector, comprising:

a housing comprising a top, a bottom mated to the top, a first plurality of slots disposed in the top and the bottom, and a second plurality of slots disposed in the housing, each of the second plurality of slots including a first slot portion having a first width and a second slot portion having a second width that is less than the first width;

a plurality of latches configured to mate the power cable connector with a mating connector, each latch comprising a lip extending through one of the first plurality of slots;

a plurality of quick disconnect contacts, each quick disconnect contact supported in the housing and disposed in a corresponding one of the second plurality of slots;

a cover, coupled to the housing;

a strain relief member disposed within the cover and comprising a plurality of passages; and

a plurality of cables, each cable being connected to one of the quick disconnect contacts and extending through one of the strain relief member passages.

2. The power cable connector of claim 1, wherein the housing top portion comprises projections that are disposed in holes disposed in the housing bottom portion.

3. The power cable connector of claim 1, wherein the cover comprises a top cover and a bottom cover that are mated together.

4. The power cable connector of claim 3, flirt her comprising a fastener that assembles the top cover to the bottom cover.

5. The power cable connector of claim 1, wherein the latches comprise springs.

6. The power cable connector of claim 1, wherein the plurality of latches comprise beams that are coupled to the latch lips that are for mating with a receptacle connector.

7. The power cable connector of claim 6, wherein the cover comprises flexible tabs and the latch beams are disposed at least partially proximal to the cover tabs so that the cover tabs can be depressed to deflect the latch beams and thereby release the connector from the mating connector.

8. The power cable connector of claim 6, wherein the power cable connectors are disposed off the connector centerline and one of the quick disconnect contacts is mounted along the centerline of the power cable connector.

9. The power cable connector of claim 1, further comprising a mating connector, wherein each quick disconnect contact engages a mating contact of the mating connector, the mating contact comprising parallel contact beams, shaped contact beams, and a contact portion that mates with the quick disconnect contact.

10. The power cable connector of claim 9, wherein the contact portion is flexible.

11. The power cable connector of claim 1, wherein each quick disconnect contact engages a single mating contact of the mating connector.

12. A power connector system, comprising:

a plug connector, comprising;

a plug housing comprising a top, a bottom, a first plurality of slots disposed in the top and the bottom;

a plurality of latches that each comprises a lip extending through one of the first plurality of slots, the latches configured to mate the connector with a mating connector;

a plurality of contacts, each contact being disposed in a corresponding one of a second plurality of slots formed in the housing;

a cover, coupled to the housing;

a strain relief member disposed within the cover and comprising a plurality of passages;

a plurality of cables, each cable being connected to one of the contacts and extending through one of the strain relief member passages, wherein the plug connector defines first and second lateral sides separated by a central axis, an odd number of the cables is disposed on the first lateral side, and an even number of the cables is disposed on the second lateral side; and

wherein the plug connector is configured to mate with a receptacle connector, comprising;

a receptacle housing comprising a plurality of holes through which the latch lips can extend when the plug connector is mated to the receptacle connector;

the receptacle housing is larger than the plug housing and is for extending into the receptacle housing when the plug and receptacle connectors are mated;

a plurality of receptacle contacts, disposed in the receptacle housing, that are for extending into the plug housing and mating with the contacts.

13. The power connector system of claim 12, wherein the plug housing further comprises a tab, connected to the housing and disposed proximal to the latches, that is for depressing to move the latch lip out from the receptacle holes to release the plug connector from the receptacle connector.

14. The power connector system of claim 12, wherein the plug housing top portion comprises projections that are disposed in holes disposed in the housing bottom portion.

15. The power connector system of claim 12, wherein the cover comprises a top cover and a bottom cover that are mated together.

16. The power connector system of claim 15, further comprising a fastener that assembles the top cover to the bottom cover.

17. The power connector system of claim 12, wherein the receptacle contacts comprise at least one pair of parallel beams and at least one pair of beams, each beam having first portions that extend outward from each other, and second portions that extend inward toward each other.

18. The power connector system of claim 12, wherein the latches comprise springs.

19. The power connector system of claim 12, wherein the plurality of latches comprise beams that are coupled to the latch lips.

20. The power connector system of claim 19, wherein the cover comprises flexible tabs and the latch beams are disposed at least partially proximal to the cover tabs so that the cover tabs can be depressed to deflect the latch beams and thereby release the connector from the mating connector.

21. The power connector system of claim 12, wherein each contact engages a single one of the receptacle contacts.

22. The power connector system of claim 21, wherein each of the receptacle contacts comprises parallel contact beams, shaped contact beams, and a contact portion that mates with one of the plurality of contacts.

23. The power cable connector of claim 22, wherein the contact portion is flexible.

24. The power cable connector of claim 12, wherein each contact includes a vertical wall extending between the top and bottom of the housing, and a pair of horizontal walls extending from top and bottom ends of the vertical wall, each horizontal wall terminating at a free distal end.

25. The power connector system of claim 12, wherein each contact comprises a vertical wall extending between the top and bottom of the housing, and the vertical wall is configured to engage the single mating contact.

26. The power connector system of claim 12 wherein the latches define an opening therebetween, and a select cable of the plurality of cables extends through one of the passages of the strain relief member, and through the opening between the latches, and connects to one of the quick disconnect contacts.

27. The power connector system of claim 26, wherein the opening between the latches is laterally offset with respect to said one of the passages of the strain relief member.

28. The power connector system of claim 27, wherein the latches are connected to each other.

29. A method of assembling a power cable connector, the method comprising the steps of:

providing a housing;

providing a cover that has a cover bottom and a cover top;

attaching each of a plurality of power cables to a corresponding quick disconnect contact among a plurality of quick disconnect contacts;

placing each of the quick disconnect contacts into a one of a first plurality of slots disposed in the housing;

attaching a pair of latch springs to the housing by disposing lips of the latch spring in one of a second plurality of slots disposed in the housing such that the latch springs define an opening therebetween;

inserting a select power cable of the plurality of power cables through a passage of a strain relief member, through the opening between the latch springs, and connecting the select power cable to the corresponding quick disconnect contact; and

assembling the cover bottom to the cover top around the strain relief member, such that the cover is disposed over at least part of the latches.

30. The method of assembling of claim 29, wherein the step of attaching comprises crimping the quick disconnects onto the power cables.

31. The method of assembling of claim 29, wherein the first plurality of housing slots is disposed in housing bottom portion and the method further comprises attaching a housing top portion to the housing bottom portion.

32. The method of claim 29, wherein the latch springs are joined together.

33. The method of claim 29, wherein the providing steps further comprise providing the housing and the cover separately such that the housing and the cover are not integrally connected.