US 12,463,371 B2
Robust high speed, high density connector
Scott Carbaugh, Orbisonia, PA (US); Mark R. Gray, York, PA (US); and James J. Muha, Boiling Springs, PA (US)
Assigned to FCI USA LLC, Etters, PA (US)
Filed by FCI USA LLC, Etters, PA (US)
Filed on Jul. 19, 2022, as Appl. No. 17/868,165.
Claims priority of provisional application 63/224,819, filed on Jul. 22, 2021.
Prior Publication US 2023/0026708 A1, Jan. 26, 2023
Int. Cl. H01R 13/514 (2006.01); H01R 12/72 (2011.01); H01R 13/6585 (2011.01); H01R 43/20 (2006.01)
CPC H01R 13/514 (2013.01) [H01R 12/724 (2013.01); H01R 13/6585 (2013.01); H01R 43/20 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A lead assembly comprising:
a plurality of conductive elements, each of the plurality of conductive element comprising a mating end, a mounting end opposite the mating end, and an intermediate portion extending between the mating end and the mounting end, the mating ends of the plurality of conductive elements aligned in a first row, the mounting ends of the plurality of conductive elements aligned in a second row parallel to the first row, wherein the intermediate portions of the plurality of conductive elements are bent so as to provide first segments parallel to the mating ends and second segments parallel to the mounting ends;
an assembly housing holding the intermediate portions of the plurality of conductive elements, the assembly housing comprising a first portion holding the first segments of the plurality of conductive elements and comprising a first plurality of projections, and a second portion holding the second segments of the plurality of conductive elements and comprising a second plurality of projections; and
a shield separated from the plurality of conductive elements by the assembly housing, the shield comprising:
a first plurality of openings having the first plurality of projections extending therethrough;
a second plurality of openings having the second plurality of projections extending therethrough;
a plurality of mating ends aligned in the first row; and
a plurality of mounting ends aligned in a third row that is parallel to and offset from the second row,
wherein:
the second plurality of openings are partially unfilled.
 
9. An electrical connector comprising:
a housing; and
a plurality of lead assemblies held by the housing, each lead assembly comprising:
a plurality of conductive elements, each of the plurality of conductive elements comprising a mating end, a mounting end opposite the mating ends, and an intermediate portion extending between the mating end and the mounting end,
an assembly housing holding the intermediate portions of the plurality of conductive elements and comprising a first plurality of projections and a second plurality of projections, and
a shield coupled to the assembly housing and comprising a body comprising:
a first plurality of openings having the first plurality of projections extending therethrough; and
a second plurality of openings having the second plurality of projections extending therethrough,
wherein:
the first plurality of projections have a same size of the second plurality of projections,
the first plurality of openings are smaller than the second plurality of openings, and
the first plurality of openings of the body of the shield is closer to the mating ends than the second plurality of openings of the body of the shield.
 
17. A method of manufacturing a lead assembly that comprises a plurality of conductive elements each comprising a mating end, a mounting end opposite the mating ends, and an intermediate portion extending between the mating end and the mounting end, and an assembly housing holding the intermediate portions of the plurality of conductive elements, the method comprising:
inserting a first plurality of projections extending from the assembly housing into a first plurality of openings of a shield;
moving the shield such that the first plurality of projections slide in the first plurality of openings of the shield until a second plurality of projections extending from the assembly housing enter a second plurality of openings of the shield; and
deforming the first plurality of projections and the second plurality of projections to mechanically lock the assembly housing and the shield together.