Flexible and breakaway mechanisms for connectors

1. A connector comprising:

a connecting portion supporting a plurality of contacts near a front end and having a flange at a back end;

a collar to fit over the flange and mechanically limit the travel of the flange in a forward direction while allowing at least a portion of the flange to travel at least a limited amount in a backward direction;

a barrel secured to a rear of the collar by a first plurality of tabs on the barrel;

a spring in the barrel, the spring compressed to push a rear portion of the flange in the forward direction;

a plunger in the barrel, the plunger having a narrow portion surrounded by the spring and tapering to a wider portion, wherein an end of the narrow portion of the plunger extends through an opening in a rear portion of the barrel; and

a fastener at the end of the narrow portion of the plunger, wherein when one or more of the first plurality of tabs on the barrel break, the fastener secures the barrel to the plunger, thereby preventing the spring from exiting the barrel.

2. The connector of claim 1 wherein

the plunger tapers to a wider portion, the wider portion between the spring and a back of the flange.

3. The connector of claim 2 , wherein the collar includes an inside raised portion to limit the travel of the flange in the forward direction.

4. The connector of claim 3 , wherein the connecting portion comprises a first portion of the plurality contacts in a first opening and a second portion of the plurality of contacts in a second opening, the first opening and the second opening surrounded by a ground ring.

5. The connector of claim 1 , wherein the first plurality of tabs are designed to break before damage occurs to a device that the connector is connected to.

6. The connector of claim 1 , wherein the fastener is a C-clip around the end of the narrow portion of the plunger.

7. The connector of claim 1 , wherein the fastener is a locking-clip.

8. The connector of claim 3 , wherein the flange comprises a second plurality of tabs having intervening spaces, the spaces aligned with ribs on an inside surface of the collar to prevent rotation of the connecting portion relative to the collar.

9. The connector of claim 8 , wherein the second plurality of tabs on the flange and the ribs on the inside surface of the collar provide a positive restore feature such that connecting portion returns to an original position relative to the collar following a deflection.

10. The connector of claim 1 , further comprising:

a plurality of wires attached to a rear portion of the flange; and

a strain relief formed around ends of the wires at the rear portion of the flange.

11. The connector of claim 1 , wherein the fastener allows the plunger to be depressed into the barrel and prevents the plunger from exiting the barrel.

12. A method of manufacturing a connector, the method comprising:

inserting a front end of a connecting portion into a rear opening of a collar, the connecting portion supporting a plurality of contacts near the front end and having a flange at a back end, the collar to mechanically limit the travel of the flange in a forward direction while allowing at least a portion of the flange to travel at least a limited amount in a backward direction;

inserting a spring into a barrel;

placing a plunger in the barrel such that the spring is in the barrel and around a narrow portion of the plunger and an end of the narrow portion of the plunger passes through an opening in a rear of the barrel;

placing a fastener at the end of the narrow portion of plunger extending through the opening in the rear of the barrel; and

securing the barrel to the collar by aligning tabs on a front end of the barrel to features on an inside of the collar, inserting the front end of the barrel into a rear opening of the collar, and twisting the barrel to lock the tabs to features on the inside of the collar,

wherein when one or more of the tabs on the barrel break, the fastener secures the barrel to the plunger, thereby preventing the spring from exiting the barrel.

13. The method of claim 12 , wherein the plunger tapers to a wider portion, the wider portion between the spring and a back of the flange.

14. The method of claim 12 , wherein the fastener is a C-clip around the end of the narrow portion of the plunger.

15. The method of claim 14 , wherein the barrel is further secured to the collar by laser welding the tabs on the front end of the barrel to the features on the inside of the collar.

16. The method of claim 15 , wherein the tabs are designed to break before damage occurs to a device that the connector is connected to.

17. The method of claim 12 , wherein the fastener is a locking-clip.

18. The method of claim 12 , wherein the collar comprises a ring around the inside of the collar near a front opening, wherein the ring limits the travel of the flange in the forward direction.

19. The method of claim 18 , wherein the spring is compressed such that the spring pushes the flange against the ring around the inside of the collar.

20. The method of claim 19 , further comprising:

attaching a plurality of wires to a back of the flange; and

forming a strain relief around ends of the wires at the back of the flange.