Patent Application
20170271807
The subject matter herein relates generally to connector assemblies.
Radio frequency (RF) connector assemblies have been used for numerous applications including military applications and automotive applications, such as global positioning systems (GPS), antennas, radios, mobile phones, multimedia devices, and the like. The connector assemblies are typically coaxial cable connectors that are provided at the end of coaxial cables.
In order to standardize various types of connector assemblies, particularly the interfaces for such connector assemblies, certain industry standards have been established. One of these standards is referred to as FAKRA, which is an abbreviation for the German term Fachnormenausschuss Kraftfahrzeugindustrie. FAKRA is the Automotive Standards Committee in the German Institute for Standardization, representing international standardization interests in the automotive field. The FAKRA standard provides a system, based on keying and color coding, for proper connector attachment. Specific jack keys can only be connected to like plug keyways in FAKRA connectors. Secure positioning and locking of connector housings is facilitated by way of a FAKRA-defined catch on the housing of a jack or first assembly and a cooperating latch on the housing of a plug or second assembly.
The connector assemblies typically include a housing with a mating interface for coupling to a mating connector. The housing holds a contact assembly that electrically connects to corresponding mating contacts of the mating connector. A cavity insert of the contact assembly is typically used to secure the contact assembly within the housing so the contact assembly does not become dislodged as the mating connector is mated or unmated from the housing. The cavity insert is an adapter that engages both an outer contact of the contact assembly and an interior portion of the housing. The cavity insert may allow the contact assembly to be compatible with various different housings.
Typically, the cavity insert is cylindrical and is loaded over the outer contact by sliding the cavity insert over an end of the outer contact. For example, the cavity insert may be loaded over a rear end of the outer contact which has a smaller diameter than a front end of the outer contact. However, sliding the cavity insert over an end of the outer contact may not be feasible or at least desirable in some connectors. For example, some known outer contacts are configured to electrically connect to relatively large cables at the rear end of the outer contact, so the rear end of the outer contact may be too large to be received within the cavity insert. Due to spacing restrictions within the housing, it may not be possible to enlarge the cavity insert in order to accommodate the large rear end of the outer contact. Furthermore, some known outer contacts are formed on carrier strips, and the contact assembly may be assembled while the outer contact remains on the carrier strip. Even if the rear end of the outer contact is small enough to be received within the cavity insert, the rear end may be secured to the carrier strip which blocks the ability of the cavity insert to be loaded over the rear end. A need remains for an electrical connector that is able to accommodate various outer contacts therein while adhering to the space restrictions within the housing and any applicable industry standard specifications.
In one embodiment, an electrical connector is provided that includes an outer contact and a cavity insert. The outer contact has a mating segment, a terminating segment, and a middle segment therebetween. The mating segment is configured to engage a mating contact of a mating connector. The terminating segment is configured to be electrically connected to a cable. The cavity insert defines a channel that receives the outer contact therein. The cavity insert surrounds the middle segment of the outer contact. The cavity insert is defined by an upper shell and a lower shell that couple together at an interface. The upper shell extends along a portion of a perimeter of the outer contact, and the lower shell extends along a remaining portion of the perimeter of the outer contact. The upper shell includes a first strap that extends across the interface. The first strap includes a latching surface that engages a corresponding first catch of the lower shell to couple the upper shell to the lower shell.
In another embodiment, an electrical connector is provided that includes an outer contact and a cavity insert. The outer contact has a mating segment, a terminating segment, and a middle segment therebetween. The mating segment is configured to engage a mating contact of a mating connector. The terminating segment is configured to be electrically connected to a cable. The cavity insert defines a channel that receives the outer contact therein. The cavity insert surrounds the middle segment of the outer contact. The cavity insert is defined by an upper shell and a lower shell that couple together at an interface. The upper shell extends along a portion of a perimeter of the outer contact, and the lower shell extends along a remaining portion of the perimeter of the outer contact. The upper shell has a curved body extending between a first edge and a second edge. The upper shell includes a first strap extending from the first edge towards the lower shell. The first strap includes a latching surface. The upper shell further includes a first catch extending from an outer surface of the upper shell proximate to the second edge. The lower shell has an identical shape as the upper shell and is oriented 180 degrees relative to the upper shell about a mating axis that is parallel to the channel. The first edge of the upper shell aligns with a second edge of the lower shell such that the latching surface of the first strap of the upper shell engages a first catch of the lower shell. The second edge of the upper shell aligns with a first edge of the lower shell such that the first catch of the upper shell engages a latching surface of a first strap of the lower shell.
In another embodiment, an electrical connector is provided that includes an outer housing and a contact assembly. The outer housing has a front end and defines a cavity that extends into the outer housing from the front end. The cavity is configured to receive a mating connector therein along a mating axis. The contact assembly is disposed within the cavity of the outer housing. The contact assembly includes a center contact, a dielectric body, an outer contact, and a cavity insert. The center contact is configured to engage a first mating contact of the mating connector. The dielectric body surrounds the center contact. The outer contact surrounds the dielectric body. The outer contact extends between a mating segment and a terminating segment. The mating segment is configured to engage a second mating contact of the mating connector. The terminating segment is configured to be electrically connected to a cable. The cavity insert surrounds the outer contact. The cavity insert is defined by an upper shell and a lower shell that couple together at an interface. The upper shell extends along a portion of a perimeter of the outer contact, and the lower shell extends along a remaining portion of the perimeter of the outer contact. The upper shell includes a first strap that extends across the interface. The first strap includes a latching surface that engages a corresponding first catch of the lower shell to couple the upper shell to the lower shell.
One or more embodiments described herein disclose a connector system that includes a first connector and a second connector. At least one of the first connector or the second connector includes an outer contact and a cavity insert that surrounds the outer contact. The cavity insert extends between the outer contact and an outer housing of the connector to hold the outer contact (and any components within and/or coupled to the outer contact) in a secured position relative to the outer housing. The cavity insert has a two-piece construction that is formed of two shells that couple together to define the cavity insert. The two shells are moved towards each other to be coupled together with the outer contact between the two shells. Thus, the cavity insert is not loaded axially over an end of the outer contact in order to surround the outer contact.
The two shells are coupled to one another by a latching mechanism. The latching mechanism includes at least one strap that extends from one of the shells towards the other shell and a catch on the other shell that engages a latching surface on the strap. The latching mechanism may include multiple straps and corresponding catches. Optionally, each shell may be hermaphroditic, including both at least one catch and at least one latching strap. In an embodiment, the latching components (e.g., the latching straps and catches) of each shell are integrally formed on the respective shell, such as during a molding process. Furthermore, the two shells may have an identical shape as one another, such that the same mold or process may be used to make both shells that couple to form the cavity insert.
As used herein, the term “surrounding” means extending around a periphery of another object in at least one dimension, such as encircling the object along a segment of the length of the object. The term “surrounding” as used herein does not necessarily require that the surrounded object be completely enclosed or encased by the surrounding object in all dimensions.
The connector system 100 may be used in numerous applications across various industries, such as the automotive industry, the home appliance industry, the aviation industry, and the like, to electrically couple two or more devices and/or electrical components. For example, in the automotive industry, the electrical connectors 102, 104 may be used for radio frequency communications, such as to electrically connect an antenna to a controller and/or processing device.
The male connector 102 and the female connector 104 each electrically connect to different electrical components and provide a conductive pathway between the corresponding electrical components. In the illustrated embodiment, the male connector 102 and the female connector 104 are electrically connected to corresponding conductive cables or wires 114, 116, such as coaxial cables. In an alternative embodiment, the male connector 102 and/or the female connector 104 may be mounted (e.g., edge-mounted) to a corresponding circuit board. The cable 114 is electrically terminated (e.g., crimped, soldered, etc.) to electrical contacts of the male connector 102. The cable 116 is electrically terminated to electrical contacts of the female connector 104. The electrical contacts of the male connector 102 engage the electrical contacts of the female connector 104 when the connectors 102, 104 are mated. Various electrical signals conveying power, control messages, data, or the like, may be transmitted through the connectors 102, 104 between the cable 114 and the cable 116.
The male connector 102 and the female connector 104 both have in-line shapes in the illustrated embodiment. For example, the mating axis 112 along which the male connector 102 is loaded into the cavity 106 is generally parallel to the orientations of the cable 114 exiting the male connector 102 and the cable 116 exiting the female connector 104. In an alternative embodiment, the male connector 102 and/or the female connector 104 may have a right angle shape.
In the illustrated embodiment, the male connector 102 and the female connector 104 constitute FAKRA connectors which are RF connectors that have an interface that complies with the standard for a uniform connector system established by the FAKRA automobile expert group. The FAKRA connectors have a standardized keying system and locking system that fulfill the high functional and safety requirements of automotive applications. The FAKRA connectors are based on a subminiature version B connector (SMB connector) that feature snap-on coupling and are designed to operate at specific impedances, such as 50, 75, 93, and/or 125 Ohms. The connector system 100 may utilize other types of connectors other than the FAKRA connectors described herein.
During mating, a front end 126 of the male connector 102 is moved along the mating axis 112 and is plugged into the cavity 106 of the female connector 104 through a front end 128 thereof. As used herein, relative or spatial terms such as “front,” “rear,” “top,” or “bottom” are only used to distinguish the referenced elements and do not necessarily require particular positions or orientations relative to the surrounding environment of the connector system 100. The male connector 102 has one or more keying features 118, and the female connector 104 has one or more keying features 120 that complement the keying features 118 of the male connector 102. In the illustrated embodiment, the keying features 118 are ribs and the keying features 120 are channels that receive the ribs 118. Any number of keying features 118, 120 may be provided. The keying features 118, 120 may be part of the standardized design of the FAKRA connector. For example, the keying ribs 118 and the keying channels 120 may be configured to restrict the mate-ability of each of the connectors 102, 104 to one or more specific mating connectors.
The male connector 102 has a latching feature 122 that is configured to engage a complementary latching feature 124 of the female connector 104 to retain a mating connection between the two connectors 102, 104 (by restricting undesired un-mating of the connectors 102, 104). In the illustrated embodiment, the latching feature 122 is a catch, and the latching feature 124 is a deflectable latch that engages the catch 122 when the connectors 102, 104 are mated together. The latch 124 is configured to be lifted or pivoted over the catch 122 in order to disconnect the male and female connectors 102, 104.
The cable 116 may be a coaxial cable that has a center conductor 170 (for example, one or more wires) surrounded by a dielectric layer 172. A cable braid 174 surrounds the dielectric layer 172. The cable braid 174 provides shielding for the center conductor 170 along the length of the cable 116. A cable jacket 176 surrounds the cable braid 174 and provides protection for the cable braid 174, the dielectric layer 172, and the center conductor 170 from external forces and contaminants. The cable 116 is configured to be electrically connected to the contact assembly 130 via crimping, soldering, or the like.
In the illustrated embodiment, the center contact 132 of the contact assembly 130 constitutes a socket contact that is configured to receive and electrically engage a pin contact of the male connector 102 (shown in
The dielectric body 134 surrounds the center contact 132. For example, the dielectric body 134 defines a passage 142 that receives the center contact 132 therein. The dielectric body 134 is composed of a dielectric material, such as one or more plastics. The dielectric body 134 is configured to extend between the center contact 132 and the outer contact 136 to electrically insulate the two contacts 132, 136 from each other.
The outer contact 136 surrounds the dielectric body 134 and the center contact 132 that is within the dielectric body 134. The outer contact 136 is composed of a conductive material such as one or more metals. The outer contact 136 provides shielding for the center contact 132, such as from electromagnetic or radio frequency interference. The outer contact 136 is configured to be electrically connected to the cable braid 174 of the cable 116.
The outer contact 136 extends between a front end 144 and a rear end 146, and defines a chamber 148 that extends through the outer contact 136 between the front and rear ends 144, 146. The dielectric body 134 is received in the chamber 148, and the cable 116 that is terminated to the center contact 132 protrudes from the rear end 146 of the outer contact 136. The outer contact 136 has a generally cylindrical or barrel shape. In an embodiment, the outer contact 136 is stamped and formed into the cylindrical shape by stamping and then rolling a panel of sheet metal.
The outer contact 136 includes a mating segment 150 that extends rearward from the front end 144 and a terminating segment 152 that extends frontward from the rear end 146. The mating segment 150 is configured to engage an outer mating contact (not shown) of a mating connector, such as the male connector 102 (shown in
The cavity insert 138 surrounds at least a portion of the outer contact 136. The cavity insert 138 extends between a front end 162 and a rear end 164 and defines a channel 166 that extends through the cavity insert 138 between the front and rear ends 162, 164. The outer contact 136 is held within the channel 166. In an embodiment, the outer contact 136 surrounds the middle segment 156 of the outer contact 136, such that an inner surface 168 of the cavity insert 138 engages the middle segment 156. The cavity insert 138 optionally may surround at least a portion of the mating segment 150 and/or the terminating segment 152. The inner surface 168 of the cavity insert 138 may engage the first step 158 and/or the second step 160. The cavity insert 138 is configured to secure the outer contact 136 axially within the channel 166, such that the outer contact 136 does not move axially relative to the cavity insert 138. Optionally, the cavity insert 138 does not allow the outer contact 136 to rotate relative to cavity insert 138. The cavity insert 138 is an adapter that is configured to engage the outer housing 110 to hold the contact assembly 130 in a fixed axial position within the cavity 106 of the housing 110. For example, the cavity insert 138 may include at least one flange 186 that extends circumferentially along a perimeter of the cavity insert 138. The flange 186 is configured to engage the outer housing 110 within the cavity 106 in order to secure the axial position of the contact assembly 130.
The ferrule 140 is configured to be crimped over the cable 116 to the terminating segment 152 of the outer contact 136. The ferrule 140 provides electrical termination of the braid 174 to the outer contact 136 and strain relief for the cable 116. In an exemplary embodiment, the ferrule 140 is configured to be crimped to both the cable braid 174 and the cable jacket 176 of the cable 116.
The female outer housing 110 extends between the front end 128 and a rear end 129. The outer housing 110 has a generally box shaped outer profile. The cavity 106 of the outer housing 110 may be a generally cylindrical bore extending through the outer housing 110. The cavity 106 may have steps, shoulders and/or channels formed therein for engaging and securing the cavity insert 138 therein.
In an embodiment, the outer housing 110 is configured to receive a retainer clip 182 that extends through an opening in a side wall 184 of the housing 110. The retainer clip 182 is configured to be loaded into the housing 110 subsequent to the contact assembly 130 in order to secure the contact assembly 130 to the housing 110. For example, the retainer clip 182 may engage one or more flanges 186 of the cavity insert 138 to secure the axial position of the contact assembly 130 within the cavity 106.
Although the female connector 104 is shown and described in
In an embodiment, the cavity insert 138 is formed of a two-piece construction, including a first shell 188 and a second shell 190. The first and second shells 188, 190 are separate, discrete parts that couple together to define the cavity insert 138. For example, the first shell 188 extends along a portion of the perimeter of the outer contact 136, and the second shell 190 extends along a remaining portion of the perimeter of the outer contact 136. The first and second shells 188, 190 engage one another at an interface 194 to form the assembled and intact cavity insert 138 that is shown in
Optionally, the outer contact 136 is connected to a metal carrier strip 196 when the cavity insert 138 is assembled around the outer contact 136. The terminating segment 152 of the outer contact 136 is mechanically connected to the carrier strip 196. Since the carrier strip 196 is connected to the terminating segment 152, a pre-assembled cavity insert 138 is not able to be received over the terminating segment 152 to surround the outer contact 136. The channel 166 (shown in
Optionally, the upper and lower shells 188, 190 may each be connected to respective plastic carrier strips 198. The carrier strips 198 include links 200 that extend outward from the respective shells 188, 190 along the lateral axis 193. The links 200 may be severed from the shells 188, 190 prior to or after the shells 188, 190 are coupled to each other to surround the outer contact 136. In an embodiment, the shells 188, 190 are each composed of a dielectric material, such as one or more plastics. The shells 188, 190 may be formed by a molding process. The carrier strips 198 may be formed with the respective shells 188, 190 during the same molding process. In an embodiment, the upper shell 188 has a unitary, one-piece body 202, and the lower shell 190 has a unitary one-piece body 204. Thus, the latching features on the upper and lower shells 188, 190 that are used to couple the shells 188, 190 to each other may be formed integral to the respective bodies 202, 204 of the shells 188, 190. Alternatively, one or more latching features or other components may be attached to a corresponding shell 188, 190 after forming the shell 188, 190, such as via bonding, an adhesive, a fastener, or the like.
The body 202 of the upper shell 188 is curved between a first edge 206 and a second edge 208. The first edge 206 is laterally spaced apart from the second edge 208. The upper shell 188 extends longitudinally along the mating axis 112 between a front end 210 and a rear end 212. The first and second edges 206, 208 extend the length of the upper shell 188 between the front and rear ends 210, 212. The curved body 202 includes an inner surface 214 and an outer surface 216. The inner surface 214 defines a portion of the channel 166 (shown in
The upper shell 188 includes latching components used to couple the upper shell 188 to the lower shell 190. For example, the upper shell 188 in the illustrated embodiment includes a strap 218 that extends beyond the first edge 206 of the upper shell 188 towards the lower shell 190. The strap 218 extends generally vertically downward from the first edge 206. The strap 218 includes a latching surface 220 that is configured to engage a corresponding catch 284 of the lower shell 190 to couple the upper shell 188 to the lower shell 190. The upper shell 188 also includes multiple catches 222 that are spaced apart along the length of the upper shell 188. The catches 222 are each configured to engage a latching surface 250 of corresponding straps 248 of the lower shell 190. In the illustrated embodiment, the upper shell 188 includes three catches 222, including a first catch 222A proximate to the front end 210, a second catch 222B proximate to the rear end 212, and a third catch 222C disposed axially between the first and second catches 222A, 222B. The three catches 222A-C are all disposed along the outer surface 216 proximate to the second edge 208 of the upper shell 188. The upper shell 188 may include other than three catches 222 proximate to the second edge 208 in an alternative embodiment.
In the illustrated embodiment, the catches 222 of the upper shell 188 are defined by hook surfaces of respective tabs 224 that protrude radially outward from the outer surface 216. The tabs 224 may align with corresponding flange segments 226 that define portions of the flanges 186 (shown in
The body 204 of the lower shell 190 is curved between a first edge 236 and a second edge 238 that are spaced apart laterally relative to one another. The lower shell 190 extends longitudinally along the mating axis 112 between a front end 240 and a rear end 242. The first and second edges 236, 238 extend the length of the lower shell 190 between the front and rear ends 240, 242. The curved body 204 includes an inner surface 244 and an outer surface 246. The inner surface 244 defines a portion of the channel 166 (shown in
The lower shell 190 includes latching components used to couple the lower shell 190 to the upper shell 188. For example, the lower shell 190 in the illustrated embodiment includes multiple straps 248 that extends beyond the first edge 236 of the lower shell 190 towards the upper shell 188. The straps 248 extend generally vertically upward from the first edge 236. The straps 248 each include a latching surface 250 that is configured to engage a corresponding catch 222 of the upper shell 188 to couple the upper and lower shells 188, 190. In the illustrated embodiment, the lower shell 190 includes three straps 248, including a first strap 248A proximate to the front end 240, a second strap 248B proximate to the rear end 242, and a third strap 248C disposed axially between the first and second straps 248A, 248B. The latching surfaces 250 of the first, second, and third straps 248A-C align with and engage the first, second, and third catches 222A-C of the upper shell 188, respectively, when the shells 188, 190 are coupled. The three straps 248A-C of the lower shell 190 are all disposed along (and extend from) the first edge 236 of the lower shell 190. The lower shell 190 may include other than three total straps 248 and/or other than three straps 248 along the first edge 236 in an alternative embodiment.
The straps 248A-C may have the same or similar sizes and shapes as one another. Each strap 248 is a cantilevered beam or limb that protrudes beyond or from the first edge 236 to a respective free end 252. The straps 248 are at least semi-rigid, such that the straps 248 are able to deflect and resiliently return towards an initial, resting position when a deflecting force on the strap 248 is removed. Each strap 248 includes an inner side 254 that faces the channel 166 (shown in
Although not shown in
As shown in
In an embodiment, the upper shell 188 and the lower shell 190 have identical shapes. For example, the size, contour, and features of the upper shell 188 are identical to the size, contour, and features of the lower shell 190. The upper and lower shells 188, 190 may be formed via the same process, such as by being formed in the same or an identical mold. Thus, both the upper and lower shells 188, 190 are able to be produced using only a single mold, which may reduce manufacturing costs. In the illustrated embodiment, the lower shell 190 is oriented 180 degrees relative to the upper shell 188 about the mating axis 112. For example, since the upper shell 188 is identical to the lower shell 190, the strap 218 of the upper shell 188 that is visible in
As shown in
The strap 218 extends from a fixed end 276 at the body 202 to a free end 302. The fixed end 276 may be at the first edge 206 or may be spaced apart from the first edge 206 along a perimeter of the outer surface 216 of the upper shell 188. The strap 218 defines an aperture 278 that extends through the strap 218. The aperture 278 is similar to the aperture 258 that extends through the strap 248 of the lower shell 190. The aperture 278 may be defined between a tip segment 280 of the strap 218 and the first edge 206. The tip segment 280 includes the free end 302. The tip segment 280 also includes the latching surface 220. For example, the latching surface 220 may be a distal wall of the aperture 278.
The catch 222 of the upper shell 188 is a hook surface of the tab 224 that protrudes outward from the outer surface 216. In an embodiment, the hook surface 222 may have an acute angle relative to the planar region 228 above the tab 224. For example, the hook surface 222 is angled to extend at least slightly away from the edge 208 along the vertical axis 191. In an alternative embodiment, the hook surface 222 may extend perpendicular to the planar region 228. In the illustrated embodiment, the tab 224 includes a ramp surface 282 that slopes outward away from the planar region 228 of the outer surface 216 as the distance from the second edge 208 increases. The ramp surface 282 extends from the second edge 208 in the illustrated embodiment, but the tab 224 may be spaced apart from the edge 208 in other embodiments. The hook surface 222 is disposed on an opposite side of the tab 224 relative to the ramp surface 282.
The curved body 204 of the lower shell 190 includes a first shoulder 292 at the first edge 236 and a second shoulder 294 at the second edge 238. The shoulders 292, 294 are generally planar surfaces that extend inward from the respective edges 236, 238. The strap 248 of the lower shell 190 is disposed proximate to the first shoulder 292 and extends beyond the first shoulder 292. The catch 284 of the lower shell 190 is disposed along a planar region 286 of the outer surface 246 proximate to the second shoulder 294.
In the illustrated embodiment, the lower shell 190 is identical to the upper shell 188. For example, the lower shell 190 shown in
To couple the upper and lower shells 188, 190, the shells 188, 190 are moved towards one another along a coupling axis 298. The distal end 302 of the strap 218 of the upper shell 188 moves along and/or parallel to the planar region 286 of the lower shell 190 and engages a ramp surface 300 of the tab 296. The strap 218 slides along the tab 296 and deflects radially outward from the natural resting position of the strap 218 shown in
As shown in
It is to be understood that the above description is intended to be illustrative, and not restrictive. 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 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 exemplary 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 appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
