This application claims benefit of priority to European Patent Application No. 21168031.9 filed on Apr. 13, 2021, the entire disclosure of which is hereby incorporated by reference.
The present application relates to relates to an electrical connector for automotive applications and a method of assembling such an electrical connector for automotive applications, preferably for super high frequency (3-30 GHz) applications. In particular, the disclosure relates to a high speed modular twisted-pair-data connector, in particular a super high frequency differential pair connector, and to a method of assembling a high speed modular twisted-pair-data connector.
An example of a currently produced high speed modular twisted-pair-data connector is the H-MTD® connection system is produced by Rosenberger Hochfrequenztechnik GmbH & Co. KG. Connectors of this system are meant to allow data transmission up to 15 GHz or 20 Gbps while having a small package size. The H-MTD® system is used in 4K camera systems, autonomous driving, radar, lidar, high-resolution displays and rear seat entertainment systems.
There is a need for a male and female high speed modular twisted-pair-data connectors with smaller manufacturing tolerances regarding the position of a male contact pin or a female signal contact portion and a method of assembling such a connector in a manner suitable for mass production.
The present disclosure provides male and female high speed modular twisted-pair-data connectors for automotive applications with at least one signal contact having an elongated male pin or an elongated female signal contact portion. A section of the signal contact is covered by a molded part that is manufactured by overmolding the section of the signal contact.
Overmolding a section of the at least one signal contact has shown to hold the elongated male pin of the male connector or the elongated female signal contact portion in position precisely so that manufacturing tolerances can be met. Furthermore, it has been shown that the male and female connector can be mass produced and can therefore be used for automotive mass-market production.
In order to hold the signal contact in position precisely in every direction, the section of the signal contact should be completely covered, i.e., covered along its complete circumference, by the molded part. The at least one elongated male pin is usually configured to be plugged into an opening of a corresponding female connector. Similarly, the at least one elongated female signal contact portion is usually configured to be connected to a corresponding male connector by receiving an elongated male pin of the connector.
Preferably, the molded part is formed by a non-conducting material, in particular by plastic.
According to an embodiment, the at least one signal contact of the male or female connector for automotive applications comprises a twisted section. The twisted section can be twisted around the longitudinal axis by at least 35°, in particular by approximately 90°. The twisted section has the effect that the signal contact including the male pin or female signal contact portion can be mass produced by coining and a good connectivity between the connector and a respective matching connector, e.g., a male and/or female high speed modular twisted-pair-data connectors, can be achieved.
According to an embodiment, the signal contact has at least one non-circular cross-section adjacent to the twisted section. In particular, the non-circular cross-section can be a rectangular cross-section. Such a non-circular, in particular rectangular, cross-section can be used for applying a tool to form the twisted section by twisting, i.e., applying a torsional force to, a section of a non-twisted signal contact.
According to a further embodiment, the signal contact has two non-circular cross-sections, wherein the two non-circular cross-sections are arranged on opposite sides of and adjacent to the twisted section. Preferably, the two non-circular cross-sections are arranged on opposite sides of and directly adjacent to the twisted section. That simplifies manufacturing the twisted section in that tools can be more securely applied on each end of the section that is going to be twisted.
According to an embodiment, the connector comprises at least two signal contacts arranged in parallel to one another. Preferably, the molded part covers a section of both signal contacts. This allows the molded part to hold the two signal contacts in position to each other which reduces skew and/or time delay. In particular, the molded part can fully cover, i.e., enclose, a section of both signal contacts along their circumferential surfaces. Furthermore, the molded part can be manufactured by simultaneously overmolding the two signal contacts in the section. In other words, the molded part can be manufactured by overmolding the two signal contacts in the section in one step.
According to an embodiment, the at least two signal contacts each comprise a twisted section. The twisted sections can be in corresponding locations, i.e., next to each other, along the respective signal contacts. Furthermore, the two signal contacts can be formed correspondingly to each other. In particular, both signal contacts can have corresponding non-circular cross-sections that can be used to apply a tool to form the twisted sections.
According to a further embodiment, the at least one twisted section is covered by the molded part. In particular, the at least one twisted section can be fully covered by the molded part. If there are two signal contacts having a twisted section, both twisted sections can be covered, in particular fully covered, by the molded part. This feature allows a compact design of the connector.
According to an embodiment, the at least one signal contact forms a rear end region being arranged perpendicular to the at least one elongated male pin or female signal contact portion. In particular, the at least one signal contact can be bent by about 90° so that a rear-end portion of the at least one signal contact extends in a direction perpendicular to the at least one elongated male pin or elongated female signal contact portion forming a front-end portion of the signal contact.
According to an embodiment, the at least one male pin is a coined pin, i.e., is formed by coining. Alternatively, the at least one pin is a stamped and rolled pin, i.e., is formed by stamping and afterwards rolling a stamped part to form the pin. In order to minimize mold flowing into the hollow male stamped and rolled pin, a barrier can be created, in particular by deforming at least a proximal section of the rolled pin. According to a further option, the pin is a solid pin electrically and mechanically connected to the signal contact. The solid pin can be connected to the signal contact via welding, in particular laser-welding or resistance-welding, or soldering. This allows a good surface of the pin improving connectivity between the male and female connector.
According to an embodiment, the at least one female signal contact portion forms an elongated inner space for receiving a male pin of a male connector. The at least one female signal contact portion can be a stamped female signal contact portion, i.e., can be formed by stamping. In particular, the at least one female signal contact portion can be a stamped and rolled female signal contact portion, i.e., can be formed by stamping and rolling. As discussed in regard to the male stamped and rolled pin, a barrier can be formed at a proximal end of the at least one female signal contact portion to block flow of liquid mold into the at least one female signal contact portion during the overmolding of the section of the signal contact. Alternatively, the at least one female signal contact portion can be a stamped and twisted female signal contact portion, i.e., can be formed by stamping and twisting. The at least one female signal contact portion could further be a coined female signal contact portion, i.e., could be formed by coining.
According to an embodiment, the at least one female signal contact portion has a tune fork-like shape. In other words, the at least one female signal contact portion forms two approximately longitudinally extending segments, a connecting segment connecting the two longitudinally extending segments at their respective proximal ends and a further longitudinally extending segment extending from the connecting segment in a proximal direction. The two approximately longitudinally extending segments are preferably elastically deformable. Furthermore, a distance between the two approximately longitudinally extending segments is preferably smaller than a respective thickness of a corresponding male pin so that the pin can be clamped between the two longitudinally extending segments. Generally, it is preferable if the male pin of the male connector and the female signal contact portion of the female connector form a press-fit connection when they are attached to each other.
According to an embodiment, the at least one female signal contact has a proximal end having a crimping portion for crimping the female signal contact to a wire. Preferably, the section forming the crimping portion is not over-molded, i.e., covered by the molded part.
According to an embodiment, the connector is a super high frequency differential pair connector. In particular, the connector can be a male or female high speed modular twisted-pair-data connector.
According to another aspect of the disclosure, a method for producing a male or female connector for automotive applications is provided, the method including the steps of providing at least one signal contact having an elongated male pin or an elongated female signal contact portion; and overmolding a section of the at least one signal contact.
According to an embodiment, the method comprises twisting the signal contact in a section. Preferably, the signal contact is twisted around its longitudinal axis by at least 35°, in particular by about 90°. Preferably, twisting the signal contact can be done by a tool that engages with at least one non-circular section of the signal contact and that is then rotated along a main axis, i.e., the longitudinal axis, of the signal contact.
According to a further embodiment, the twisted section is overmolded to create a molded part covering the twisted section.
Furthermore, according to another embodiment, the at least one male pin is formed by coining. In particular, the whole signal contact can be formed by coining. Alternatively, the at least one pin is formed by stamping and rolling. According to a third option, the at least one pin is a solid pin which is mechanically and electrically connected to the remaining contact signal, preferably by laser-welding.
If the connector is a female connector, the at least one elongated female signal contact portion can be formed by stamping. In particular, the at least one elongated female signal contact portion can be formed by stamping and rolling. Alternatively, the at least one elongated female signal contact portion can be formed by stamping and twisting. Preferably, the at least one elongated female signal contact portion can be stamped so that it is formed like a tuning fork.
According to an embodiment, two signal contacts each having an elongated male pin or an elongated female signal contact portion are provided. In a second step, a section of each of the two signal contacts can be overmolded. While the two signal contacts are being overmolded, they can be mechanically linked or attached to each other. In particular, the two signal contacts can be formed from the same part and still be linked together after the forming of the two signal contacts and during overmolding. Afterwards, the two signal contacts can be electrically separated, i.e., insulated, from each other while the molded part holds the signal contacts in position to each other. This can be done by removing mechanically linking parts between the two signal contacts. This method allows to manufacture a male or female connector having two elongated pins or two elongated female signal contact portions being positioned precisely relative to each other and that will remain in that position under abuse forces.
The present invention is now described, by way of example with reference to the accompanying drawings, in which:
Furthermore, the male connector 10 comprises a connecting part 24 that is mechanically connected to the front part 22a and that forms a mechanical fastening structure 24a to mechanically connect the male connector 10 to a female super high frequency differential pair connector via a snap-lock connection. In order to make sure that the male and female connectors 10, 18 are connected correctly, the connecting part 24 has a passage 26 with a non-circular opening 26a that allows connecting the male connector 10 to a female connector 18 only in one particular angular alignment.
The front part 22a of the housing 22 has a tubular section 28 that—as can be best seen in
As can be seen in
In a first step, a first tool 30, e.g., a twist tube, is brought into a form-fitting engagement with a first rectangular portion 32 of the signal contact 12 and a second tool 34, i.e., a tool to hold a second rectangular portion 36 of the signal contact 12, is brought into a form-fitting engagement with the second rectangular portion 36. In a second step, the first tool 30, the twist tube, is rotated around its main axis by at least and/or approximately 90° rotating the first rectangular portion 32 of the signal contact 12 by at least and/or approximately 90° while the second tool 34 holds the second rectangular portion 36 in its original position. In step three, the twisting of the twisted section 12a is completed. In step four, the tools 30, 34 are being disengaged from the rectangular portions 32, 36 respectively. As described earlier, by twisting the signal contact 12, the former top and bottom surfaces of the pins 14 become the side surfaces 14a′ that contact the respective surfaces of the female high speed modular twisted-pair-data connector better than the side surfaces 14a of the elongated pins of non-twisted signal contacts 12.
In
After the twisted section 12a is formed, sections of the signal contacts 12 are being overmolded (see
According to a second embodiment shown in
According to a third embodiment shown in
As can be seen from
While this invention has been described in terms of the preferred embodiments thereof, 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 configure a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments and are by no means limiting and are merely prototypical embodiments.
Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.
As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.
It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. 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 described embodiments herein is for the purpose of describing embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “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, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any order of arrangement, order of operations, direction or orientation unless stated otherwise.
Number | Date | Country | Kind |
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21168031.9 | Apr 2021 | EP | regional |