阅读说明：本技术 带角度的电连接器组件及其制造方法 (Angled electrical connector assembly and method of making same ) 是由 M·L·佩恩 J·M·莱尼 B·马加洛斯 J·R·莫瑞罗 于 2019-09-12 设计创作，主要内容包括：一种电连接器组件,包括：电端子,该电端子具有附接端和连接端；第一端子外壳,该第一端子外壳具有第一腔体,其中设置有附接端。该第一腔体限定了供连接端延伸穿过的端子延伸开口。该组件还包括第二端子外壳,该第二端子外壳具有第二腔体,其中设置有连接端。该第二腔体限定了供连接端穿过而被接纳的端子接纳开口。第一端子外壳限定了围绕端子延伸开口的第一附接表面,并且第二端子外壳限定了围绕端子接纳开口的第二附接表面。第一附接表面被密封到第二附接表面。第一附接表面相对于纵向轴线形成第一角度,且第二附接表面相对于横向轴线形成第二角度。(An electrical connector assembly comprising: an electrical terminal having an attachment end and a connection end; a first terminal housing having a first cavity with an attachment end disposed therein. The first cavity defines a terminal extension opening through which the connection end extends. The assembly also includes a second terminal housing having a second cavity in which the connection end is disposed. The second cavity defines a terminal-receiving opening through which the connection end is received. The first terminal housing defines a first attachment surface surrounding the terminal extension opening and the second terminal housing defines a second attachment surface surrounding the terminal receiving opening. The first attachment surface is sealed to the second attachment surface. The first attachment surface forms a first angle with respect to the longitudinal axis and the second attachment surface forms a second angle with respect to the lateral axis.)

1. An electrical connector assembly comprising:

an electrical terminal having an attachment end extending along a longitudinal axis and a connection end extending along a transverse axis, the attachment end configured to attach to a wire cable, the connection end configured to attach to a corresponding mating terminal;

a first terminal housing having a first cavity extending along the longitudinal axis with the attachment end disposed therein, the first cavity defining a cable opening through which the wire cable extends and defining a terminal extension opening through which the attachment end extends; and

a second terminal housing having a second cavity extending along the transverse axis, wherein the connecting end is disposed, the second cavity defining a terminal-receiving opening through which the connecting end is received and a mating opening configured to receive the corresponding mating terminal, wherein the first terminal housing defines a first attachment surface surrounding the terminal-extending opening and the second terminal housing defines a second attachment surface surrounding the terminal-receiving opening, wherein the first attachment surface is sealed to the second attachment surface, and wherein the first attachment surface forms a first angle relative to the longitudinal axis and the second attachment surface forms a second angle relative to the transverse axis.

2. The electrical connector assembly of claim 1, wherein the second angle is complementary to the first angle.

3. The electrical connector assembly of claim 1, wherein the first angle has a first angle value of about 45 degrees and the second angle has a second angle value of about 45 degrees.

4. The electrical connector assembly of claim 1, wherein said first attachment surface defines a circumferential ridge around said terminal-extension opening and said second attachment surface defines a circumferential groove around said terminal-receiving opening in which said circumferential ridge is received.

5. The electrical connector assembly of claim 4, wherein the circumferential ridge is welded to the circumferential groove using an infrared laser welding process.

6. The electrical connector assembly of claim 1, wherein said first attachment surface is welded to said second attachment surface, thereby forming a water-tight joint between said first and second terminal housings.

7. The electrical connector assembly of claim 1, wherein the first attachment surface is welded to the second attachment surface using a laser welding process.

8. The electrical connector assembly of claim 1, wherein said first terminal housing is formed of a first material and said second terminal housing is formed of a second material different from said first terminal housing.

9. The electrical connector assembly of claim 8 wherein said first material is infrared transparent and said second material is infrared absorptive.

10. The electrical connector assembly of claim 1, wherein a longitudinal axis of said attachment end is substantially perpendicular to a transverse axis of said connection end.

11. A method of manufacturing an electrical connector assembly comprising the steps of:

providing an electrical terminal having an attachment end extending along a longitudinal axis and a connection end extending along a transverse axis, the attachment end configured to attach to a wire cable, the connection end configured to attach to a corresponding mating terminal;

providing a first terminal housing having a first cavity extending along the longitudinal axis with the attachment end disposed therein, the first cavity defining a cable opening through which the wire cable extends and defining a terminal extension opening through which the attachment end extends;

providing a second terminal housing having a second cavity extending along the transverse axis with the attachment end disposed therein, the second cavity defining a terminal-receiving opening through which the attachment end is received and a mating opening configured to receive the corresponding mating terminal, wherein the first terminal housing defines a first attachment surface surrounding the terminal-extending opening and the second terminal housing defines a second attachment surface surrounding the terminal-receiving opening;

inserting an attachment end of the electrical terminal within a first cavity of the first terminal housing;

inserting the connection end of the electrical terminal into the second cavity of the second terminal housing; and

sealing the first attachment surface to the second attachment surface.

12. The method of claim 11, wherein the first attachment surface defines a circumferential ridge that extends an opening around the terminal and the second attachment surface defines a circumferential groove around the terminal-receiving opening, and wherein the method further comprises the step of disposing the circumferential ridge within the circumferential groove.

13. The method of claim 12, wherein the step of sealing the first attachment surface to the second attachment surface is performed by welding the circumferential ridge to the circumferential groove using an infrared laser welding process.

14. The method of claim 11, wherein the step of sealing the first attachment surface to the second attachment surface is performed by welding the first attachment surface to the second attachment surface.

15. The method of claim 11, wherein the step of sealing the first attachment surface to the second attachment surface is performed using a laser welding process.

16. The method of claim 11, wherein the first terminal housing is formed of a first material and the second terminal housing is formed of a second material different from the first terminal housing.

17. The method of claim 16 wherein said first material is infrared transparent and said second material is infrared absorptive.

18. The method of claim 11, wherein a longitudinal axis of the attachment end is substantially perpendicular to a transverse axis of the attachment end.

Technical Field

The present invention relates generally to electrical connectors, and more particularly to an electrical connector in which an end attached to a wire cable and another end configured to receive a mating connector are angled with respect to each other.

Background

Coaxial cable connector assemblies have been used in many automotive applications, such as Global Positioning Systems (GPS), infotainment systems, and airbag systems. Coaxial cables typically include a conductor comprised of an outer shield, an inner center conductor, a dielectric, and an insulating jacket. The outer and inner conductors of a coaxial cable are typically electrically coupled to a mating coaxial cable via receptacle and plug connectors. Such conventional coaxial cable connectors are known in the art.

In order to standardize various types of connectors and thereby avoid confusion, certain industry standards have been established, one of which is referred to as FAKRA, which is an automobile standards Committee in German institute of standardization ("Deutsches institute f ü r Normung," best known by the acronym DIN), representing an international standardization interest in the automotive field.

Right angle sealed electrical connector assemblies such as those conforming to the FAKRA standard typically require two-piece terminals. These two-piece terminals may have inferior electrical performance compared to one-piece terminals.

There remains a need for a right angle hermetic electrical connector that can accommodate a one-piece terminal.

The subject matter discussed in the background section should not be admitted to be prior art merely by virtue of its mention in the background section. Similarly, problems mentioned in the background section or related to the subject matter of the background section should not be considered as having been previously discovered in the prior art. The subject matter in the background section merely represents different scenarios that may themselves be inventions.

Disclosure of Invention

According to one embodiment of the present invention, an electrical connector assembly is provided. The electrical connector assembly includes an electrical terminal having an attachment end extending along a longitudinal axis configured to attach to a wire cable and a connection end extending along a transverse axis configured to attach to a corresponding mating terminal. The electrical connector assembly also includes a first terminal housing having a first cavity extending along a longitudinal axis with an attachment end disposed therein. The first cavity defines a cable opening through which the wire cable extends and defines a terminal extension opening through which the connection end extends. The electrical connector assembly further includes a second terminal housing having a second cavity extending along a transverse axis with a connection end disposed therein. The second cavity defines a terminal-receiving opening through which the connecting end is received and a mating opening configured to receive a corresponding mating terminal. The first terminal housing defines a first attachment surface surrounding the terminal extension opening and the second terminal housing defines a second attachment surface surrounding the terminal receiving opening. The first attachment surface is sealed to the second attachment surface. The first attachment surface forms a first angle with respect to the longitudinal axis and the second attachment surface forms a second angle with respect to the lateral axis.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the second angle is complementary to the first angle.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the first angle has a first angle value of about 45 degrees and the second angle has a second angle value of about 45 degrees.

In an exemplary embodiment having one or more features of the electrical connector assembly of the preceding paragraph, the first attachment surface defines a circumferential ridge extending around the terminal extension opening and the second attachment surface defines a circumferential groove around the terminal receiving opening in which the circumferential ridge is received.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the circumferential ridge is welded to the circumferential groove using an infrared laser welding process.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the first attachment surface is welded to the second attachment surface, thereby forming a watertight joint between the first and second terminal housings.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the first attachment surface is welded to the second attachment surface using a laser welding process.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the first terminal housing is formed of a first material and the second terminal housing is formed of a second material different from the first terminal housing.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the first material is infrared transparent and the second material is infrared absorptive.

In an exemplary embodiment having one or more features of the electrical connector assembly of the preceding paragraph, the longitudinal axis of the attachment end is substantially perpendicular to the transverse axis of the connection end.

According to one embodiment of the present invention, a method of manufacturing an electrical connector assembly is provided.

The method comprises the following steps:

a) providing an electrical terminal having an attachment end extending along a longitudinal axis and a connection end extending along a transverse axis, the attachment end configured to attach to a wire cable, the connection end configured to attach to a corresponding mating terminal;

b) providing a first terminal housing having a first cavity extending along a longitudinal axis with an attachment end disposed therein, the first cavity defining a cable opening through which a wire cable extends and defining a terminal extension opening through which a connection end extends;

c) providing a second terminal housing having a second cavity extending along a transverse axis with an attachment end disposed therein, the second cavity defining a terminal-receiving opening through which the connection end is received and a mating opening configured to receive a corresponding mating terminal, wherein the first terminal housing defines a first attachment surface around the terminal-extending opening and the second terminal housing defines a second attachment surface around the terminal-receiving opening;

d) inserting an attachment end of an electrical terminal within a first cavity of a first terminal housing;

e) inserting the connection end of the electrical terminal into the second cavity of the second terminal housing; and

f) the first attachment surface is sealed to the second attachment surface.

In an exemplary embodiment having one or more features of the method of the previous paragraph, the first attachment surface defines a circumferential ridge extending around the terminal-extension opening and the second attachment surface defines a circumferential groove around the terminal-receiving opening. The method further comprises the step of disposing a circumferential ridge within the circumferential groove.

In an exemplary embodiment having one or more features of the method of the previous paragraph, step f) is performed by welding a circumferential ridge to a circumferential groove using an infrared laser welding process: the first attachment surface is sealed to the second attachment surface.

In an exemplary embodiment having one or more features of the method of the previous paragraph, step f) is performed by welding the first attachment surface to the second attachment surface: the first attachment surface is sealed to the second attachment surface.

In an exemplary embodiment having one or more features of the method of the previous paragraph, step f) is performed using a laser welding process: the first attachment surface is sealed to the second attachment surface.

In an exemplary embodiment having one or more features of the method of the previous paragraph, the first terminal housing is formed of a first material and the second terminal housing is formed of a second material different from the first terminal housing.

In an exemplary embodiment having one or more features of the method of the previous paragraph, the first material is infrared-transparent and the second material is infrared-absorptive.

In an exemplary embodiment having one or more features of the method of the preceding paragraph, the longitudinal axis of the attachment end is substantially perpendicular to the transverse axis of the attachment end.

Drawings

The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

fig. 1 is a perspective view of an angled electrical connector assembly engaged with a mating connector assembly according to one embodiment of the present invention;

fig. 2 is an exploded view of the angled electrical connector assembly of fig. 1 according to one embodiment of the present invention;

fig. 3 is a cross-sectional side view of the angled electrical connector assembly of fig. 1 in accordance with one embodiment of the present invention;

fig. 4 is a cross-sectional top view of the angled electrical connector assembly of fig. 1 in accordance with one embodiment of the present invention;

figure 5 is a cross-sectional end view of the angled electrical connector assembly of figure 1 according to one embodiment of the present invention.

Fig. 6 is a flow chart of a method of manufacturing the angled electrical connector assembly of fig. 1 according to another embodiment of the present invention.

Detailed Description

Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, one skilled in the art will recognize that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and interrelationships have not been described in detail as not to unnecessarily obscure aspects of the embodiments.

Fig. 1 shows an electrical connector system 100 for interconnecting wire cables 102, such as coaxial cables. The illustrated connector system includes a right angle coaxial connector 104 and a straight mating coaxial connector 106. The connectors shown in fig. 1 each conform to the FAKRA standard.

As best shown in fig. 2 and 3, the right-angled connector 104 includes a right-angled coaxial electrical terminal (hereinafter terminal 108) having an attachment end 110 extending along a longitudinal axis X and a connection end 112 extending along a transverse axis Y, the attachment end 110 configured to attach to the wire cable 102, the connection end 112 configured to attach to a corresponding mating terminal (not shown) contained in the mating connector 106. Since this is a right-angled terminal, the longitudinal axis X of the attachment end 110 is substantially perpendicular to the transverse axis Y of the connection end 112. substantially perpendicular, as used herein, means ± 5 degrees of absolute perpendicular.

The terminal 108 is contained within an electrically insulative two-part housing. The first terminal housing (hereinafter referred to as the first housing 114) has a first cavity 116 extending along the longitudinal axis X, in which the attachment end 110 is disposed. The first cavity 116 defines two openings: a cable opening 118 through which the wire cable 102 extends and a terminal extension opening 120 through which the connection end 112 of the right-angled terminal extends. The second terminal housing (hereinafter referred to as second housing 122) has a second cavity 124 extending along the transverse axis Y, in which the attachment end 110 is disposed. The second cavity 124 also defines two openings: a terminal-receiving opening 126 through which the connection end 112 is received and a mating opening 128 configured to receive a corresponding mating connector 106. The first housing 114 defines a first attachment surface 130 that circumferentially surrounds the terminal extension opening 120. The second housing 122 defines a second attachment surface 132 surrounding the terminal-receiving openings 126. The first attachment surface 130 is sealed to the second attachment surface 132, thereby providing a waterproof, preferably airtight seal between the first housing 114 and the second housing 122. The first attachment surface 130 forms a first acute angle 134 with respect to the longitudinal axis X and the second attachment surface 132 forms a second acute angle 136 with respect to the transverse axis Y. Since this is a right-angled connector 104, the second acute angle 136 is complementary to the first acute angle 134, i.e., the sum of the first angular value of the first acute angle 134 and the second angular value of the second acute angle 136 is about 90 degrees. Preferably, the first acute angle 134 has a first angle value of about 45 degrees and the second acute angle 136 has a second angle value of about 45 degrees. As used herein, "about" a particular angle value means ± 5 degrees of the particular angle value.

The first attachment surface 130 defines a circumferential ridge (hereinafter ridge 138) around the terminal extension opening 120 and the second attachment surface 132 defines a circumferential groove (hereinafter groove 140) around the terminal receiving opening 126 in which the ridge 138 is received. The first attachment surface 130 is welded to the second attachment surface 132 by welding the upper surface 142 of the ridge 138 to the lower surface 144 of the groove 140 using an infrared laser welding process. The first housing 114 is formed of an infrared absorbing material such as a polymer doped with an infrared absorbing pigment, and the second housing 122 is formed of an infrared transmitting material such as polyethylene or polypropylene. When infrared laser energy is applied to the area of the ridge 138, the laser energy passes through the second skin 122 and is absorbed by the ridge 138 of the first skin 114, thereby forming a melted section 146 between the first skin 114 and the second skin 122, as shown in fig. 3, 4, 5. An infrared welding system capable of preforming such infrared laser welding is available from Branson Ultrasonics Corporation of Danbury, Connecticut, while transmitting by infrared (SIMULTANEOUS THROUGH TRANSMISSION)

) A welding system.

As shown in fig. 3, the right angle connector 104 also includes a compliant cable seal 148 and a compliant housing seal 150 to prevent environmental contaminants, such as water, dust, or electrolyte, that may corrode the terminals 108 from entering the cavity.

In the connector design of the prior design, the right angle FAKRA compliant connector uses a one-piece housing that contains a two-piece terminal shield to meet environmental sealing requirements. Such a construction was found to be expensive and may exhibit unstable connection characteristics due to the two-piece terminal.

The angled parting line of the two- piece housings 114, 122 of the right angle connector 104 shown in fig. 1-5 provides the benefit of allowing for the direct insertion of a one-piece terminal shield that provides more reliable connection performance than a two-piece terminal. The infrared laser welding features of the ridges 138 and grooves 140 allow the seam between the first housing 114 and the second housing 122 to provide a water-tight or air-tight seal.

Fig. 6 shows an example of a method 200 of manufacturing the terminal 108 according to one embodiment of the invention. The method 200 comprises the following steps:

a step 202 of providing an electrical terminal includes providing a terminal 108, the terminal 108 having an attachment end 110 extending along a longitudinal axis X and a connection end 112 extending along a transverse axis Y, the attachment end 110 configured to attach to a wire cable 102, the connection end 112 configured to attach to a corresponding mating terminal. The longitudinal axis X of the attachment end 110 is substantially perpendicular to the transverse axis Y of the link end 112;

a step 204 of providing a first terminal housing includes providing a first housing 114, the first housing 114 having a first cavity 116 extending along a longitudinal axis X, with an attachment end 110 disposed therein, the first cavity 116 defining a cable opening 118 through which the wire cable 102 extends and defining a terminal extension opening 120 through which the connection end 112 extends.

Providing 206 a second terminal housing includes providing a second housing 122 having a second cavity 124 extending along a transverse axis Y, wherein the attachment end 110 is disposed, the second cavity 124 defining a terminal receiving opening 126 through which the connection end 112 is received and a mating opening 128 configured to receive a corresponding mating connector 106, wherein the first housing 114 defines a first attachment surface 130 surrounding the terminal extension opening 120, and the second housing 122 defines a second attachment surface 132 surrounding the terminal receiving opening 126.

Inserting 208 the electrical terminals within the first and second terminal housings, including inserting the attachment ends 110 of the terminals 108 within the first cavities 116 of the first housing 114 and inserting the connection ends 112 of the terminals 108 within the second cavities 124 of the second housing 122;

the first attachment surface 130 may define a ridge 138 surrounding the terminal extension opening 120 and the second attachment surface 132 defines a groove 140 surrounding the terminal receiving opening 126. A step 210 of providing ridges within the grooves, which is an optional sub-step of step 202, which includes providing ridges 138 within grooves 140; and

the step 212 of sealing the first terminal housing to the second terminal housing includes sealing the first attachment surface 130 to the second attachment surface 132. Step 212 may be performed by welding the first attachment surface 130 to the second attachment surface 132, for example, by a laser welding process. Step 212 may be performed by welding ridge 138 to groove 140 using an infrared laser welding process. In this case, the first housing 114 is formed of a first material, and the second housing 122 is formed of a second material different from the first housing. The first material is substantially infrared transparent and the second material is infrared absorbing.

While the exemplary electrical connectors presented herein are of a right angle configuration, other embodiments of the present invention are contemplated having an angle between the attachment end 110 and the connector end of the terminal 108 in the range of 1 degree to 179 degrees.

While the invention has been described in terms of its preferred embodiments, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. The dimensions, types, orientations of the various components, and numbers and locations of the various components described herein are intended to define the parameters of the particular embodiment, are not meant to be limiting, but rather are merely prototype embodiments.

Various other embodiments and modifications within the spirit and scope of the claims will become apparent to those of ordinary skill in the art from reading the foregoing description. The scope of the invention is, therefore, indicated by the appended claims, along with the full scope of equivalents to which such claims are entitled.

As used herein, "one or more" includes a function performed by one element, a function performed by more than one element, in a distributed fashion, a function performed by one element, a function performed by several elements, or a combination of these.

For this reason, although the terms first, second, etc. may be used to describe various elements in some embodiments, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, the first contact can be referred to as a second contact, and similarly, the second contact can be referred to as a first contact without departing from the scope of the various embodiments described. The first contact and the second contact are both contacts, but they are not the same contact.

The terminology used in the description of the various embodiments is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the various embodiments described, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. "it should also be understood that the terms and/or are used herein to refer to and include any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the term "if" is optionally to be interpreted to mean when or on "or" in response to a decision "or" in response to a detection, depending on the context. Similarly, the phrase "if it is decided" or "if a [ condition or event already described ] is detected" is optionally to be construed as meaning "upon deciding.. or" in response to deciding "or" upon detecting [ the condition or event ] or "in response to detecting [ the condition or event ] depending on the context. "

Additionally, although terms of ordinance or orientation may be used herein, these elements should not be limited by these terms. All terms or orientations are used for the purpose of distinguishing one element from another, unless otherwise stated, and do not imply any particular order, sequence of operations, direction, or orientation, unless otherwise stated.