The present invention relates to electrical connectors, systems and assemblies, and their methods of assembly. In particular, the present invention relates to shielded electrical connectors.

From the prior art, it is known to provide an electrical connector having two separate insulating parts which are assembled the one to other, for example by firm snapping.

One of these insulating parts is an inner housing, which defines paths to receive respective electrical terminals provided at the end of electrical wires. The other one of these insulating parts is an outer housing which is usually provided for other functions, such as a mechanical lock on a complementary connector, as a connector position assurance mechanisms, etc...

To ensure the shielding of the electrical connector against electromagnetic interferences, an electrically conductive shield is generally inserted between the inner housing and the outer housing. Such shield should be connected to other electrically conductive parts of the electrical connector, such as another electrical connector, a cable... to provide an uniform potential thereto.

One strives to improve the shielding efficiency without impairing the other features of the electrical connector.

For this purpose, it is provided a shielded electrical connector which comprises an insulating housing. The electrical connector further comprises an electrically conductive shield extending between two open ends. The electrically conductive shield has an inner face and an outer face. The electrically conductive shield has a protuberance which protrudes from the inner face or the outer face.

The housing has a locking part which cooperates with the protuberance to lock the housing and the shield the one to other.

Thanks to these features, it is anymore necessary to assemble the inner housing and the outer housing the one other through the shielding.

Conversely, one of the housings is assembled directly on the electrically conductive shield. In this way, apertures in the electrically conductive shield is prevented and, consequently, shielding efficiency could be improved.

In some embodiments, one might also use one or more of features defined in the dependent claims. Of course, different features, alternatives and/or embodiments of the present invention can be combined with each other in various arrangements to the extent that they are not incompatible or mutually exclusive of others.

The present invention will be better understood and other features and advantages will become apparent upon reading the following detailed description including embodiments for illustrative purposes with reference to the figures, presented as non-limitative examples, which can be used to complete the understanding of the present invention and the description and, where appropriate, contribute to its definition, in which: Figure 1 is an exploded view of a connector assembly according to the present invention with two electrical connectors shown along different perspectives,

Figure 2 is an exploded view of one of the electrical connectors of Figure 1,

Figure 3 is a partial view of the electrical connector of Figure 2,

Figure 4 is a section view along line IV-IV of Figure 3,

Figure 5 is a view similar to Figure 4 of the other side of the electrical connector,

Figure 6 is a section view along line VI-VI of Figure 4,

Figure 7 is a half section view along line VI I -VI I of the connector assembly of Figure 1,

Figure 8 is an detailed perspective view as shown by reference VIII on Figure 4,

Figure 9 is a partial section view of a second embodiment according to the present invention,

Figure 10 is a partial section view of a third embodiment according to the present invention,

Figure 11 is a section view along line XI-XI on Figure

3 , and

Figure 12 is a partial perspective view of an outer housing of one of the electrical connectors of Figure 1.

It should be noted that, on figures, structural and/or functional elements which are common to different embodiments may have the same reference sign. Thus, unless otherwise stated, these elements have structural, dimensional and material properties which are identical.

Figure 1 is an exploded view of a connector assembly with two electrical connectors shown along different perspectives according to the present invention. More particularly, Figure 1 schematically shows an connector assembly comprising a male connector 1, or mating connector 1, assembled to an electrical wire 2. The connector assembly further comprises a female connector 3, which can be mated to another electrical wire, which is not currently shown, which may be similar to the cable 2 of the male connector 1. The following description will be primarily given by reference to the female connector 3. However, most of these descriptions can equally be applied to the male connector 1. The female connector 3 will be described using a frame of reference X-Y-Z which comprises a longitudinal axis X corresponding to a mating direction along which the female connector 3 is mated with the male connector 1. In addition, a transversal axis Y and a vertical axis Z are arranged in a Y-Z plane defined to be perpendicular to the normal longitudinal axis X.

Moreover, the longitudinal axis X, the transversal axis Y and the vertical axis Z are perpendicular one to another.

For the present example, the transversal axis Y is defined as an axis along which two neighbour receptacles of the female connector 3 are offset. The female connector 3 has at least one receptacle to receive electrical wires 2, with any wanted configuration. According to the present example, the female connector 3 has three receptacles arranged along the transversal axis Y. In the present example, the receptacles are straight along the longitudinal axis X. The vertical axis Z is the third axis. The female connector 3 comprises an inner housing 4. The inner housing 4 defines one or more receptacles suitable to receive and hold electrical contacts, such as electrical contacts 5 of the electrical wire 2. For example, electrical contacts 5 are very schematically shown for the electrical wire 2. Preferably, the inner housing 4 is made of an electrically insulating material.

The female connector 3 further comprises a shield 6 which, at least partly, surrounds the inner housing 4. The shield 6 is made of an electrically conductive material. The shield 6 comprises a front portion 6a. The front portion 6a may be in contact with a shield 106 of the mating connector 1 upon mating the two connectors, i.e. of the male connector 1 and the female connector 3.

Opposite the front portion 6a, the shield 6 further comprises a rear portion 6b which may be in contact with a shield of the cable, such as an electrically conductive braid 7 of the cable 2.

The shield 6 further comprises an intermediate portion 6c arranged between the front portion 6a and the rear portion 6b. The front portion 6a and the rear portion 6b have respectively open ends. Consequently, the shield 6 is continuous and surrounds, at least partly and preferably completely, the inner housing 4 between those two open ends . As can be seen on Figure 1, the shield 6 can be pre- assembled with the inner housing 4. In the present example, the inner housing 4 is longer than the shield 6, along the mating direction, such that the inner housing 4 respectively project, preferably on both sides, from the shield 6. As particularly visible on Figure 2 which is an exploded view of one of electrical connectors of Figure 1, a front portion 4a of the inner housing 4 projects radially outwardly with respect to an intermediate portion 4c of the inner housing 4.

The front portion 4a of the inner housing 4 defines a rearward facing wall 8. Advantageously, the rearward facing wall 8 has a plurality of portions spaced from one another along the periphery of the inner housing 4.

A rear portion 4b of the inner housing 4 also defines a frontward facing wall 9. Advantageously, the frontward facing wall 9 extends along the whole periphery of the inner housing 4.

The rearward facing wall 8 and the frontward facing wall 9 comprise, between them, a recess 10 suitable to receive the shield 6.

When the shield 6 is pre-assembled on the inner housing 4, a front edge 11 of the shield 6 abuts on the rearward facing wall 8 of the front portion 6a of the inner housing 4 and a rear edge 12 of the shield 6 abuts on the frontward facing wall 9 of the rear portion 6b of the inner housing 4.

Therefore, the shield 6 is prevented from moving in either direction along the longitudinal axis X with respect to the inner housing 4.

The female connector 3 further comprises an outer housing 13, which can also be seen on Figure 12 which is a partial perspective view of the outer housing 13 of one of the connectors of Figure 1. The outer housing 13 is for example made of an electrically insulating material.

The outer housing 13, at least partially, surrounds the shield 6. The outer housing 13 can be provided with additional functions of the female connector 3. For example, the outer housing 13 can comprise a base portion 14 for mechanical assembly of the female connector 3 onto a support which is not currently shown.

The outer housing 13 can also comprise a mate assisting system 15, a connector position assurance system 16 and/or other functions. The connector position assurance system 16 can define other paths for electrical wires 2 which do not need any shielding.

According to a particular embodiment, as shown on Figure 3 which is a partial view of the electrical connector 3 of Figure 2, the shield 6 can be formed from a plurality of sheet plates 17a and 17b, particularly metallic sheet plates 17a and 17b, which are assembled together in order to surround, at least partly and preferably completely, the inner housing 4. According to the disclosed embodiment, the shield 6 is provided as the assembly of two sheet plates 17a and 17b, respectively assembled on the top and on the bottom of the inner housing 4. The sheet plates 17a can be identical or similar. Therefore, the shield 6 has two junctions which, in the disclosed embodiment, are provided on each lateral side of the inner housing 4.

As shown on Figure 11 which is a section view along line XI-XI on Figure 3, a lateral end portion 44 of one of the sheet metal plates 17a, respectively 17b, extends over and contacts with a lateral end portion 45 of the other of the sheet metal plates 17b, respectively 17a. The number of plates and the locations of their junctions are only given as a particular embodiment.

In the following description, especially in relation with Figure 3, one side of the shield 6 will be described. In the present embodiment, opposite sides are provided in a similar way. The number and locations of the below described features can vary.

In the disclosed embodiment, the shield 6 comprises an outer face 18, which faces the outer housing 13, and an inner face 19, which faces the inner housing 4. The outer face 18 extends sensibly parallel to the inner housing 4.

If the shield 6 is provided from two or more jointed sheet plates, there can be some bulging at the location of the junction of the sheet plates.

The outer face 18 of the shield 9 is here defined from the outer face of the sheet plates which overlies the other one. The shield 6 is provided with a protuberance 20 which protrudes from the outer face 18.

As can be seen on Figure 6 which is a section view along line VI-VI of Figure 4, the outer housing 13 is provided with a locking part 21 which cooperates with the protuberance 20 of the shield 6, to lock the outer housing 13 onto the shield 6.

As an example, the protuberance 20 comprises a rearward facing border 22, which can be seen on Figure 8 which is an detailed perspective view as shown by reference VIII on Figure 4, which cooperates with a locking face 23, preferably with a frontward facing border 23, of the locking part 21. The interaction between the rearward facing border 22 and the frontward facing border 23 would prevent any movement of the outer housing 13 with respect to the shield 6 along the longitudinal axis X.

The protuberance 20 cooperates with a suitable part of the outer housing 13 to prevent any movement of the outer housing 13 with respect to the shield 6 in the opposite direction along the longitudinal axis X. For example, the protuberance 20 may comprise a frontward facing edge 25, which is preferably opposed to the rearward facing border 22 of the protuberance 20. As visible on Figure 12, the outer housing 13 comprises two abutting walls 48 located on either side of the locking part 21. Abutting walls 48 are also located frontward respective thereto. This geometry allows molding of the locking part 21. Abutting walls 48 each comprise a rear face 47.

According to the disclosed embodiment, as shown in particular on Figure 6, the locking part 21 is born on a flexible arm 28 of the outer housing 13. The flexible arm 28 is linked to a body 29 of the outer housing 13 and is flexible with respect thereto.

Further, as shown on Figure 6, when the outer housing 13 is locked on the shield 6, the locking part 21 can be provided with an inward facing side 30, which extends from the frontward facing border 23 to a rearward facing side 27.

The locking part 21 is supported on the outer face 18 of the shield 6 to prevent any radial movement of the shield 6 outward with respect to the inner housing 4. Further, the locking part 21 can press the sheet plate 17b in contact with the sheet plate 17a as shown.

In order to assemble the female connector 3 according to the above embodiment, in a first step, the inner housing 4 is assembled to the shield 6. If the shield 6 is provided from a plurality of portions, they can be arranged radially with respect to the inner housing 4 and placed in the recess 10, as explained above, to result in the assembly as shown on Figure 3.

Then, the outer housing 13 can be slid with respect to the above assembly along the opposite direction to the longitudinal axis X.

The rearward facing side 27 of the locking part 21 can be provided with a slanted surface, so that the protuberance 20 smoothly deflects the flexible arm 28 as the outer housing 13 moves rearward until the flexible arm 28 snaps back with the locking part 21 in a depression, to lock the outer housing 13 onto the shield 6 and the inner housing 4.

At this stage, the frontward facing edge 25 of the protuberance 20 abuts on the rear face 47 of the abutting wall 48 of the outer housing 13 to stop the movement along the assembly direction. In particular, the frontward facing edge 25 has a top portion 25a and a bottom portion 25b disposed on either side of a central portion 25c of the frontward facing edge 25.

According to this disclosed embodiment, the inner housing 4 is assembled directly onto the shield 6, and the shield 6 is assembled directly onto the outer housing 13. Therefore, the shield 6 can be provided without any through hole which would impair the shielding capability of the shield 6 between the front portion 6a, which is for the electrical connection with the shield of the complementary connector, and the rear portion 6b, which is for the electrical connection with the shield 6 of the cable. Advantageously, the shield 6 totally surrounds the inner housing 4 between its two open ends.

Figure 4 is a section view along line IV-IV of Figure 3 and will now be used to describe an particular embodiment of the protuberance 20, in the case where the shield 6 is provided from thin metallic sheet plates.

In particular, when one uses a metallic sheet plate which is stamped to provide part of the shield, it is easy to use stamping and forming tools to provide the above protuberances 20.

In particular, the protuberances 20 are provided from one or more bends of the metallic sheet plate. As can be seen in particular on Figure 4, the protuberance 20 is formed from an extension comprising a first portion 31 which covers the edge of the other sheet plate 17a, as already detained .

Then, the extension comprises a second portion 32 which extends parallel to the first portion 31 and radially outwardly, downwardly to a location to the level of the other sheet plate 17b.

A third portion 33 extends parallel between the first portion 31 and the second portion 32 and radially between them until the edge of the extension. Thus, the thickness of the protuberance 20 is at least twice the thickness of the sheet plate 17b. This is in particular true for the part which interacts with the locking part 21. A top portion 25a and a bottom portion 25b of the protuberance 20, which cooperate with the abutting wall 48, are at least three times as thick as the metal sheet plate.

As can also be seen on Figure 8, the second portion 32 may comprise locking faces 34a and 34b, preferably two lateral wing portions 34a and 34b which are bent with respect to the second portion 32 along the axis Z. The lateral wing portions 34a and 34b thus cover any sharp edge of the metal sheet plate, so as to prevent any cutting of the locking part 21, which can be made of plastic.

Preferably, one of the locking face 34b is a first locking face 34b of the protuberance 20, and the other locking face 34a is a second locking face 34a of the shield 6. Advantageously, the second locking face 34a cooperates with an abutting wall 48 of the housing, to lock the housing and the shield 6 to one another.

Since the lateral edge portion of the bottom sheet plate 17b is provided to cover the top sheet plate, the lateral wing portions 34a and 34b are provided with a recess 35, for example provided as a cut out, to accommodate a bulge 36 provided by the covering of one of the metal sheet plate by the other one. The above description is provided on one lateral side of the shield 6, at the junction between sheet plates.

In the case of two assembled sheet plates, at the other junction of the two sheet plates, a similar geometry can be provided, with the extensions being provided both from the sheet plate, to form a protuberance 120.

Alternatively, in the other side, as shown on Figure 5, which is a view similar to Figure 4 of the other side of the electrical connector, the extensions could be provided from the sheet plate, covering the lateral edge of the other sheet plate. In such way, two identical sheet plates could be used. For this junction, locking parts 21, 121 are provided to cooperate with the protrusions in the suitable housing.

In the description which has been done above, the shield 6 is provided as a "male" shield 6, since it is inserted inside a volume defined by a "female" shield 106 of the mating connector 1.

The "female" shield 106 has a body with a front end 38 facing toward the mating connector 1, and a rear end 39, as shown on Figure 1.

The shield 106 is provided with a plurality of flexible tongues 40, visible on Figure 7 which is a half section view along line VII-VII of the connector assembly of Figure 1, which extend from the front end 38 of the body 37 and are spaced apart from one another along a peripheral dimension of the shield 106.

Upon mating of the male connector 1 with the female connector 3, these tongues 40 have an inward facing face, which is pressed in contact with the outer face 18 of the shield 6.

Hence, a good electrical connection between the "male" shield 6 and the "female" shield 106 is provided. It will be recognized that the flexibility of the tongues 40 allows, upon connection of the male connector 1 with the female connector 3, to pass by the front portion 6a of the inner housing 4 of the mating connector 1. In the above description, in particular of the female connector 3, the shield 6 is first pre-assembled to the inner housing 4, for example, by being retained between bulges of this inner housing 4. The shield 6 has a protrusion protruding from this outer face which cooperates with the locking part of the outer housing 13. However, this mounting could be reversed. As shown on Figure 9, the shield 6 could be assembled to the inner face of the outer housing 13.

In such case, it is the outer housing 13 which comprises a front bulge 41a and a rear bulge 41b, which are directed toward the inner housing 4, and together define the recess 10 for the shield 6. In such case, the shield 6 is provided pre-assembled to the outer housing 13, and with the protuberance 20, which protrudes from the inner face of the shield 6.

The protuberance 20 will cooperate with a not shown locking part of the inner housing 4, in order to lock the inner housing 4 to the assembly of the outer housing 13 and the shield 6, in a mechanism similar to the one described above . In the above description, the locking of the shield 6 to the outer housing 13, with respect to the first embodiment, as shown on Figures 1 to 8, or the inner housing 4, as shown in a second embodiment of Figure 9, which is a partial section view of a second embodiment according to the present invention, involves for example an elastic deformation of an elastic arm of the plastic housing to cooperate with the rather rigid protrusion of the shield.

In another embodiment, as shown on Figure 10, which is a partial section view of a third embodiment according to the present invention, the elasticity could be provided rather on an elastic arm 42 of the shield 6, a part, for example an end 46, of which protrudes with respect to the outer face 18 of the shield 6. This can be provided in the way similar to the protuberance 20, except that lateral wing portion 34a and 34b, will not be folded down as shown on Figure 8, but rather protrude as a spring blade. The corresponding stop in the outer housing 4 or the inner housing 13, can be provided as a rigid stop 43.

This system can be applied for locking the shield 6 with the inner housing 4, as shown on Figure 10, or on the outer housing 13, not currently shown. Obviously, the present invention is not limited to embodiments which are here above described and provided only as examples. It also includes different modifications, and alternatives that may be considered by the person skill in the art as part of the present invention, including all combinations of different embodiments here above described, taken alone or in combination.