Patent Application
20240106154
This application is based on and claims priority under 35 U.S.C. Section 119 to Japanese Patent Application No. 2022-153923 filed on Sep. 27, 2022, the entire content of which are incorporated herein by reference.
This disclosure relates to a connector module.
JP2021-166161A discloses a connector module configured to connect a coaxial cable with a camera module. The connector module includes a connector case, a housing, and a terminal module. The connector case is made of an electrically insulative material such as resin, and has an insertion hole. The housing is made of an electrically insulative material such as resin, has a cylindrical space, and is fitted through the insertion hole. The terminal module is in the cylindrical space of the housing.
The terminal module includes an electrically conductive center conductor, an electrically conductive cylindrical shell outward of the center conductor, and a holder made of an electrically insulative material and disposed between the two conductors. The coaxial cable is provided with a coaxial connector having a jack, and includes an inner conductor and an outer conductor. The terminal module is configured to be connected with the coaxial cable in response to, for example, insertion of the jack, causing the center conductor and the cylindrical shell to be electrically conductive to the inner and outer conductors, respectively.
The connector module includes a shield case at an inner peripheral portion of the connector case. The shield case is electrically conductive to the cylindrical shell.
JP2018-107097A discloses a connector case (“case section” in the document) die-casted from an aluminum alloy and integrally including a cylindrical fitting section protruding outward. The fitting section has an internal space and includes a partition wall inside. To place a terminal module (“external connector” in the document) in the internal space, the fitting section has a space through which the terminal module is inserted through the partition wall.
The partition wall has a depression at its inner circumference. The terminal module has a portion on the base-end side which portion includes a fitting protrusion at its outer circumference which fitting protrusion is configured to be fitted in the depression. Fitting the fitting protrusion into the depression allows the external connector to be held by the case section.
Similarly to JP2018-107097A, JP2018-98069A discloses a connector case (“case section” in the document) die-casted from an aluminum alloy and integrally including a cylindrical fitting section. The fitting section includes a partition wall inside, through which a terminal module (“external connector” in the document) is inserted. JP2018-98069A discloses, in particular, screwing the terminal module into a screw hole in the partition wall to be fastened.
JP2019-53943A discloses a terminal module (“connector body” in the document) connectable with a coaxial cable. The terminal module includes a contact at the center, a cylindrical shell, and an insulator between the contact and the shell. The document also discloses a connector case (“rear case” in the document) including a connector insertion section having a connection rib at its inner circumference.
The shell and the rear case are each made of an electrically conductive metal. The shell includes a connection flange. Pressing the connection flange to fit it with the connection rib causes the flange and the rib to press each other in an electrically conductive manner due to plastic deformation.
A connector module needs to function not only to connect a communication cable such as a coaxial cable with a connection target such as a camera module, but also to block external electromagnetic waves. A connector module may, for this reason, include a shield element inside the connector case as disclosed in JP2021-166161A.
However, a connector module including a shield case inside the connector case as in JP2021-166161A not only includes a large number of parts, but also may have a complicated structure as a result of the need to cause the shield case to be electrically conductive to the cylindrical shell.
JP2021-166161A discloses the connector case and also discloses a housing with a first cylindrical portion. The connector case holds the terminal module. This configuration may disadvantageously involve a large number of assembly steps and require use of strong parts to firmly attach the terminal module to the connector case.
JP2018-107097A and JP2018-98069A each disclose, to overcome the above disadvantage, a case section made of aluminum and fitting or screwing a terminal module in the case section to be fixed. This configuration involves a smaller number of production steps and parts, as compared to JP2021-166161A. The configuration of JP2018-107097A will, however, require higher processing accuracy for higher fitting accuracy. The configuration of JP2018-98069A, which requires rotation during assembly, will require a longer cycle time or use of a dedicated jig.
The configuration of JP2019-53943A, to overcome the above disadvantage, requires pressing the connection flange against the connection rib, meaning that this configuration will require use of a dedicated tool to hold the connection flange and the connection rib in contact with each other and press the connection flange and the connection rib together to deform at least one of the connection flange and the connection rib for tight contact.
The techniques disclosed in the above four documents may allow production of a connector module with necessary capabilities, but require time and effort in the processing and production.
The above circumstances have led to a demand for a connector module capable of being assembled easily and blocking electromagnetic waves.
A connector module as an embodiment of this disclosure includes: a connector unit connectable with an end of a communication cable; and a case holding the connector unit, the connector unit including: a shaft-shaped terminal made of an electrically conductive material; a cylindrical shell made of an electrically conductive material and coaxial with the shaft-shaped terminal; and a holder made of an electrically insulative resin material and disposed around the shaft-shaped terminal, the case being made of an electrically conductive material, including a wall with an insertion hole, and holding the connector unit through the insertion hole, the shell including a plurality of radially outward protrusions at an outer surface of a portion disposed through the insertion hole, the protrusions being press-fitted through the insertion hole and in contact with the inner surface of the wall for electric connection between the shell to the case.
The above embodiment is configured as follows: Press-fitting the connector unit through the insertion hole in the case causes the protrusions at the outer surface of the shell to be pressed against that inner surface of the case which defines the insertion hole. This not only electrically connects the shell to the case for a shielding effect, but also keeps the connector unit firmly coupled with the case. Further, the connector unit is press-fittable in a relatively large space. This eliminates the need for a dedicated tool or a long cycle time during production. The connector module is thereby capable of being assembled easily and blocking electromagnetic waves. This configuration also allows effective heat conduction between the case and the shell and effective heat dissipation over an increased heat dissipation area.
The connector module may further be configured such that the shell further includes: a cylindrical shell body; and a flange disposed on a side of the protrusions which side is opposite to the shell body and protruding radially outward, and the shell is die-casted so that the shell body, the protrusions, and the flange are integral with one another.
The above configuration prevents material waste even if the flange has a large diameter, and allows the shell body, the protrusions, and the flange to be integral with one another as compared to a case of, for example, producing a shell by processing a metal material on a lathe.
The connector module may further include: a housing including a cylindrical case surrounding a leading end of the connector unit which leading end protrudes from the wall, wherein the wall has a plurality of through holes around the insertion hole, the housing further includes a plurality of bridges coupling the cylindrical case and disposed inside the respective through holes, and the housing is molded from resin to be integral with the cylindrical case and the plurality of bridges.
The above configuration includes (i) a cylindrical case made of resin and disposed on an outer surface of the wall of the case and (ii) bridges inside the respective through holes in the case for coupling the cylindrical case with restrictors. This allows the case to hold the housing in such a manner as to prevent detachment of the housing from the case, and also prevents rotation of the housing as a whole.
The connector module may further be configured such that the holder is insert-molded with the shaft-shaped terminal as an insert.
The above configuration allows resin to be between the outer surface of the shaft and the inner surface of the shell. This allows the shaft and the shell to be electrically insulated from each other, and also allows the shaft and the shell to be integral with each other. Further, positioning the shaft in a mold during resin injection improves the accuracy of position of the shaft.
The description below deals with an embodiment of this disclosure with reference to drawings.
The connector module CM is electrically connectable to a coaxial cable L (which is an example of the “communication cable”) through which to transmit information on images captured by a camera unit D mounted in an automobile or the like (vehicle-mounted camera). The present embodiment is configured such that the information on captured images transmitted through the coaxial cable L is displayed on a monitor (not illustrated in the drawings) or stored in a storage (not illustrated in the drawings). The information on captured images is not only simply displayed on the monitor, but also fed back for image analysis for driving assistance, processed as necessary by the electronic control unit (ECU) before being displayed on the monitor, or used to assist parking.
As illustrated in
The camera casing 1 is in the form of a box dividable into a front case 1a configured to house the camera module 2 and a rear case 1b provided with the connector unit A. The front case 1a has an opening 1as, whereas the rear case 1b has an opening 1bs. Coupling the front case 1a with the rear case 1b in such a manner as to join the opening las with the opening 1bs connects the connector unit A with the receptacle E on the substrate 2c of the camera module 2 as illustrated in
The front case 1a and the rear case 1b are each produced through die casting or cold forging of aluminum. Joining the opening 1as with the opening 1bs provides a hermetically sealed camera casing 1.
As illustrated in
The terminal connector La is a jack connector. The connector module CM may include a lock mechanism configured to prevent detachment of the terminal connector La from the cylindrical case 21.
As illustrated in
The holder 13 is integrated with the shaft-shaped terminal 11 by insert molding and press-fitted into the shell 12, which is then rotated for a bottom portion thereof to be caulked (high-spin caulking) to prevent detachment of the holder 13. This produces a connector unit A, with the shaft-shaped terminal 11, the shell 12, and the holder 13 integral with one another. The shaft-shaped terminal 11 includes a large-diameter portion 11a for impedance matching of the connector unit A.
As illustrated in
As illustrated in
The wall 1w of the rear case 1b has two or more (four for the present embodiment) through holes 1d around the insertion hole 1c and apart from the central axis X by an equal distance in a direction radially outward of the insertion hole 1c. The rear case 1b also has through holes 1e configured to receive coupling screws 3 (see
The connector unit A extends from inside the rear case 1b to outside the rear case 1b. The description below may use the term “leading-end side” to refer to the side on which the connector unit A is exposed from the wall 1w and the term “base-end side” to refer to the side opposite to the leading-end side.
The shell 12 is die-casted from an electrically conductive metal material such as zinc. The shell 12 includes, as integral with one another, (i) a cylindrical shell body 12a, (ii) a first large-diameter portion 12b around a portion of the shell body 12a which portion is on the base-end side of the shell body 12a, (iii) a second large-diameter portion 12c adjacent to the first large-diameter portion 12b, and (iv) a flange 12d on the base-end side of the second large-diameter portion 12c. The flange 12d is in the form of a plate extending radially from the central axis X. The flange 12d has two or more notches 12S at its edge as illustrated in
The second large-diameter portion 12c has an outer surface provided with two or more protrusions 12T configured to be pressed against that inner surface of the insertion hole 1c which is defined by the rear case 1b. The protrusions 12T protrude radially outward of the shell 12. The protrusions 12T are each in the shape of a bullet (see
The bullet-shaped protrusions 12T facilitate press-fitting the connector unit A (specifically, the shell 12) through the insertion hole 1c. As illustrated in
The strong press causes electric conduction between the rear case 1b and the shell 12 for a shielding effect to reduce the influence of noise, and also allows effective heat conduction between the rear case 1b and the connector unit A and effective heat dissipation over an increased heat dissipation area.
With the connector unit A held by the rear case 1b as illustrated in
The housing B is molded from resin to be integral with the rear case 1b, and then receives the connector unit A as press-fitted inside.
The housing B molded as above includes a cylindrical case 21. The cylindrical case 21 is, as illustrated in
As illustrated in
As illustrated in
The cylindrical contact 31 is soldered and electrically conductive to ground lines of a printed circuit on the substrate 2c. The contact case 32 has a guide surface 32a disposed along the circumference and facing away from the substrate 2c (that is, facing the side of the connector unit A). The guide surface 32a is inclined relative to the central axis X.
The press-fit contact 33 includes a pair of press-fit pieces 33a so close to each other as to sandwich a portion of the shaft-shaped terminal 11 which portion is on the base-end side. The press-fit pieces 33a are soldered and electrically conductive to signal lines of the printed circuit on the substrate 2c. The press-fit pieces 33a are elastic. Bringing the rear case 1b close to the receptacle E brings the press-fit pieces 33a into contact with a base-end portion of the shaft-shaped terminal 11 in such a manner as to sandwich the base-end portion. This causes the press-fit pieces 33a to be electrically conductive to the shaft-shaped terminal 11.
As illustrated in
The ring 35a and the first and second contact pieces 35b and 35c are made of an electrically conductive metal material (for example, a copper alloy), and are integral with one another in such a manner as to be electrically conductive to one another. The first contact pieces 35b are so elastic as to remain in contact with that face of the flange 12d which is opposite to the wall 1w. The first contact pieces 35b extend radially with the central axis X at the center as viewed along the central axis X (see
The second contact pieces 35c have respective first ends held by the ring 35a. The second contact pieces 35c are so elastic as to press the outer surface of the cylindrical contact 31 from outside. Bringing the rear case 1b close to the receptacle E causes the second contact pieces 35c to sequentially (i) come into contact with the guide surface 32a, (ii) flexibly deform in such a direction that the respective second ends of the second contact pieces 35c move away from the central axis X, and (iii) come into contact with the cylindrical contact 31 due to the elasticity.
The connector module CM is, as described above, configured such that as illustrated in
The above operation also brings the second contact pieces 35c into contact with the outer surface of the cylindrical contact 31. This causes electric conduction between the ground of the substrate 2c and the shell 12.
The connector module CM is configured such that inserting the terminal connector La of the coaxial cable L into the cylindrical case 21 causes electric conduction between the center conductor 5 and the shaft-shaped terminal 11 and also causes electric conduction between the outer conductor 6 and the shell 12 (see
The signal lines on the substrate 2c are thereby conductive to the center conductor 5 and the ground of the substrate 2c to the outer conductor 6. This allows information on captured images to be transmitted from the camera unit D through the coaxial cable L.
The connector module CM is configured as follows: The holder 13 is made of resin and integral with the shaft-shaped terminal 11. The holder 13 is press-fitted into the shell 12, which is then rotated for a bottom portion thereof to be caulked (high-spin caulking) to prevent detachment of the holder 13. This allows the shaft-shaped terminal 11, the shell 12, and the holder 13 to integrally provide a connector unit A. Press-fitting the connector unit A through the insertion hole 1c in the wall 1w of the rear case 1b to be fixed allows the shell 12 and the rear case 1b to be fixed in position relative to each other.
The shell 12 has an outer surface provided with two or more protrusions 12T. The protrusions 12T protrude radially outward of the shell 12. The protrusions 12T are each in the shape of a bullet that extends along the central axis X, that is tapered at the leading end in the direction in which the shell 12 is inserted, and that has a trailing end with a surface orthogonal to the central axis X. This facilitates press-fitting the connector unit A through the insertion hole 1c, and reliably fixes the connector unit A to the rear case 1b. In particular, the protrusions 12T are pressed strongly against that inner surface of the insertion hole 1c which is defined by the rear case 1b. This not only allows the connector unit A and the rear case 1b to be fixed in position relative to each other, but also causes electric conduction between the rear case 1b and the shell 12 for a shielding effect to reduce the influence of noise. This configuration also allows effective heat conduction between the shell 12 and the rear case 1b and effective heat dissipation.
The shell 12 is die-casted to integrally include a shell body 12a, a first large-diameter portion 12b, a second large-diameter portion 12c, two or more protrusions 12T on the outer surface of the second large-diameter portion 12c, and a flange 12d. This reduces material waste as compared to a case of, for example, producing a shell by processing a metal material on a lathe.
The housing B is made of an electrically insulative resin, and includes a cylindrical case 21 and bridges 23. The cylindrical case 21 is on the outer face of the wall 1w. The bridges 23 are disposed inside the respective through holes 1d. This allows the cylindrical case 21 to be reliably fixed to the rear case 1b.
The substrate 2c is provided with a receptacle E including members such as a cylindrical contact 31 and a press-fit contact 33 each having a center on the central axis X. With this configuration, coupling the front case 1a of the camera unit D with the rear case 1b in such a manner that the respective openings 1as and 1bs are in close contact with each other allows the connector unit A to be electrically conductive to a predetermined circuit on the substrate 2c, and thereby allows information on captured images from the camera unit D to be transmitted through the coaxial cable L.
This disclosure may be configured as below in addition to the embodiments described above. Any element described below that functions as described for the embodiments above is assigned with the same reference numeral as that for embodiments above.
The arrangements disclosed for the above embodiments (including the alternative embodiments) may each be combined with an arrangement disclosed for another embodiment, as long as such a combination does not cause a contradiction. Further, the embodiments disclosed in the present specification are mere examples. The present disclosure is not limited to those embodiments, and may be altered as appropriate, as long as such an alteration does not result in a failure to attain an object of the present disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2022-153923 | Sep 2022 | JP | national |
