This application claims the benefit of the filing date under 35 U.S.C. § 119(a)-(d) of German Patent Application No. 102017122048.8, filed on Sep. 22, 2017.
The present invention relates to an electrical contact device and, more particularly, to an electrical contact device assembled with a twin-axial cable.
A large number of electrical connectors and counter-connectors are known that transmit electrical currents, voltages, signals and/or data with a large range of currents, voltages, frequencies and/or data rates. In the low, medium, or high voltage and/or current ranges, and especially in the motor vehicle industry, connectors must ensure permanently, repeatedly and/or, after a comparatively long service life, transmission of electrical power, signals and/or data without delay in warm, possibly hot, polluted, humid and/or chemically aggressive environments. Due to a wide range of applications, a large number of specially configured connectors are known.
Connectors or their housings can be installed at an electrical cable, a wire, a cable harness, or an electrical unit or device such as at/in a housing, at/on a leadframe, at/on a printed circuit board etc., of an electrical, electro-optical, or electronic component. A connector located at a cable, a wire, or a cable harness is known as a connector or a plug. A connector located at an electrical component is known as a counter-connector unit, often referred to as a receptacle or header.
Connectors must ensure perfect transmission of electrical signals and/or electrical power, wherein connectors corresponding with one another usually have fastening or locking arrangements for long-term but usually releasable fastening or locking of the connector at/in the counter-connector. Further, an electrical connecting unit having a contact device, such as a contact element, a ferrule, a terminal, or a shield contact sleeve, or a contact unit, must be received securely therein. In an assembled cable, such a connecting unit can be provided as a connector without a housing. Since the housings of the connectors are usually subject to a certain standardization, such as the FAKRA standard, the most important dimensions of the housings have the same dimensions across different manufacturers. Continuous efforts are being made to improve electrical contact devices, contact units, connecting units, connectors and assembled cables to make them smaller and more cost-effective.
Electromagnetically shielded twin-axial cables for high-speed differential signal transmission deviate from a circular cross-sectional geometry that is typical for cables and have an at least partially oval, for example elliptical, cross-sectional geometry. In this case, two electrical inner conductors of the twin-axial cable are surrounded by an electrical outer conductor such as a shielded film. Either the shield or an entire cross-sectional geometry of the twin-axial cable has an oval shape.
In order to obtain a small plug connection, an electromechanical interface of an electrical connecting unit for the twin-axial cable also has an oval cross-sectional geometry. A cross-sectional geometry of a crimping section of a cable has a circular cross-section in the prior art. Typical contact devices for crimping for twin-axial cables also have a circular cross-sectional geometry in a crimping section. A shield contact sleeve for a twin-axial cable which results therefrom, for example, requires a transition from oval, in an electrical contact section, to circular and optionally back to oval at an outer conductor crimping section. Such a transition is located at a critical point in a plug connector, where a comparatively narrow distance of the inner conductor of the twin-axial cable transitions into a wider division of the contact devices or contact units of the connector. Such a transition leads to a barely compensatable discontinuity in the impedance in the prior art, as shown in
An electrical contact device for a twin-axial electrical cable comprises a crimping section. In a crimped state on the twin-axial electrical cable, the crimping section is closed and has an oval cross-sectional shape in at least a portion of the crimping section.
The invention will now be described by way of example with reference to the accompanying Figures, of which:
Embodiments of the present invention will be described hereinafter in detail with reference to the attached drawings, wherein like reference numerals refer to the like elements. The present invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that the disclosure will be thorough and complete and will fully convey the concept of the invention to those skilled in the art.
An electrical twin-axial connecting unit 10 having a plurality of electrical contact devices 100, 200, 300 is shown in
The concepts disclosed herein can, however, be applied to other connectors, connecting units, contact devices or cables (cable harness) in the automotive industry or outside of the automotive industry, such as in an electronics, electrical engineering or power engineering industry; the invention can be applied, for example, to connecting units, contact devices or cables in the computer and (consumer) electronics industry. Furthermore, the terminology connector and counter-connector, connecting unit and counter-connecting unit, pin-/peg-/tab contact device and socket contact device are intended to be interpreted as synonymous, i.e. optionally interchangeable with one another.
An electrical connector 0, shown in
The explanation of the embodiments with reference to the drawings is subsequently related to an axial or longitudinal direction Ax (longitudinal axis Ax, axial plane Ax, also plug-in direction S), a radial direction Ra (radial plane Ra) and a circumferential direction Um (tangent plane Um) of the electrical (plug) connection 0 of the electrical connector 1, of the connector housing 20, of the connecting unit 10, and of the twin-axial cable 50 as shown in
The contact devices 100, 300, as shown in
In an embodiment, the contact device 100 is a ferrule 100 having a ferrule crimping section. In various embodiments, a third contact device 300 can have a single crimping section 301, 303 or can have an insulating crimping section 301 and an outer conductor crimping section 303. The crimping sections 103, 301, 303 can be formed in an open, non-crimped state in sections as a thin oval ring section or even in sections as a thin circular ring section. A cross-section of the entire open crimping section 103, 301, 303 can be u-shaped or v-shaped; the two outer lateral limbs are formed either long or short in comparison with a connecting section of the lateral limbs. An oval cross-section is intended to mean that the cross-section possesses a level, rounded and primarily or substantially completely convex shape, a circular shape and a loop being ruled out. This means that the cross-section is approximately, primarily or substantially formed as two-dimensionally “egg-shaped” or elliptical.
The electrical twin-axial cable 50 is shown in
The two inner insulations 511, 512 are closely surrounded, i.e. with a low tolerance, by an electrically conductive or electrically insulating film 520 and/or an electrical outer conductor 522 as an electro-magnetic shield 522 (e.g. shield conductor 522, braid wire 522, braid line 522), as shown in
As shown in
The contact device 100 embodied as the ferrule 100, as shown in
The contact device 200 embodied as the terminal 200, as shown in
The contact device 300 embodied as the shield contact sleeve 300, as shown in
A construction and a substantially three-stage method for assembling the twin-axial cable 50 with the connecting unit 100 will now be described in greater detail with reference to
The first step I of the method will now be described with reference to
In the first substep I.1 shown in
As shown in
Prior to its mounting in a circumferential direction Um of the connecting unit 100 or the ferrule 100, the plastically deformable and in particular integral ferrule 100 is formed completely open in the axial direction Ax and has two mounting mechanisms 130, 140 which are formed as crimp flanks 130, 140, as shown in
In an embodiment, when plastically deforming the substantially entire ferrule 100, at least one latching unit, in particular a latching projection, can be formed at/in the ferrule 100. Furthermore, alternatively or additionally, when plastically deforming the ferrule 100, at least one other unit, such as a ribbing or another structure, can be installed at/in the ferrule 100. This can result in an improved electrical contact between the ferrule 100 and an end section 524 provided externally on the outer conductor 522 and/or of the shield contact sleeve 300, wherein optionally also an electrically non-conductive ferrule 100 can be used.
The ferrule 100 or the crimp flanks 130, 140 are constituted as a crimping section 103, which is installed at/on the twin-axial cable 50 in the crimped state as a closed and, in substantially all cross-sections, oval crimping section 103 as shown in
In an optional third substep I.3 shown in
In a fourth substep I.4, two free longitudinal end sections, which protrude at a free end of the moved end section 524, of the twin-axial cable 50 are stripped at their longitudinal end regions, as shown in
In the second step II, the terminals 200, 200, in this case formed as socket contact units 200, 200 as shown in
The elongated and in particular integrally configured terminals 200, 200 each have a mounting section, for example a crimping section, at a rear end section. At a front end section, each terminal 200, 200 has an electrical contact section which in this case is designed as a socket contact section. A pin-, peg-, tab contact section, etc. can of course be used. In addition, the respective terminal 200, 200 can have a transition section between the crimping section and the contact section. Moreover, the respective terminal 200, 200 can have a latching unit in the transition section for locking the respective terminal 200, 200 in place.
In the second step II, a respective terminal 200, 200 is first separated from a carrier strip for terminals. Subsequently, the respective crimping section is moved to the related free longitudinal end region of a related inner conductor 501, 502 with the related longitudinal end region of the related inner conductor 501, 502 resting in a foundation of the respective crimping section. The respective crimping section is then crimped to the related inner conductor 501, 502. In an embodiment, this can occur in reverse; crimping the respective crimping section to the related inner conductor 501, 502 with the respective terminal 200, 200 still located at the carrier strip; a pre-assembled twin-axial cable 5 which results therefrom is only then separated from the carrier strip. Instead of a crimping method, a different method can, of course, also be applied, the respective terminal 200, 200 then being configured in a correspondingly different manner such as an adhesive-, soldering-, or welding section instead of a crimping section.
The third step III of the method is shown in
The third step III of the assembly method relates to mounting the shield contact sleeve 300. The elongated and in particular integrally configured shield contact sleeve 300 in this case is formed as a crimp sleeve 300. At a rear end section, the shield contact sleeve 300 has a mounting section 301, in particular an insulating crimping section 301, with two mounting mechanisms 310, 320 which are opposite one another and which are formed as insulating crimp flanks 310, 320. The insulating crimp flanks 310, 320 can be formed open, gaping, curved and/or pre-rolled. Furthermore, the insulating crimp flanks 310, 320 can be curved or pre-rolled within the scope of the third step III.
At a front end section, the shield contact sleeve 300 has a shield contact section 305 shown in
In an embodiment, only the insulating crimping section 301 and the outer conductor crimping section 303 of the shield contact sleeve 300 are at least partially plastically deformable. In such an embodiment, only four crimp flanks 310, 320, 330, 340 are provided. Each crimp flank 310, 320, 330, 340 has a circumferential edge section 312, 322, 332, 342, wherein circumferential edge sections 312, 322; 332, 342 which are related to one another are formed in a substantially complementary or substantially form-fitting manner with one another such that a crimp slit 309 can be formed in a substantially light-tight manner between the crimp flanks 310, 320, 330, 340 of the mounted shield contact sleeve 300 in the axial direction Ax of the shield contact sleeve 300, as shown in
In an embodiment, in a crimped state of the connecting unit 10, the crimp slits 109, 309 of two contact devices 100, 300 of the connecting unit 10 can be arranged offset from one another in the circumferential direction of the connecting unit 10. In various embodiments, the angle of offset may be approximately 90°, approximately 270°, approximately 180°, or other angles of course may alternatively be applied. The crimp slits 109, 309 of two contact devices 100, 300 of the connecting unit 10 can be arranged substantially without overlap in the radial direction of the connecting unit 10.
In an embodiment, the shield contact sleeve 300 has a transition section between the shield contact section 305 and the outer conductor crimping section 303, which is configured sleeve-shaped. Moreover, the shield contact sleeve 300 can have a latching unit, in particular in its outer conductor crimping section 303, for locking the ferrule 100 in place. In another embodiment, a dielectric 400 can be provided or installed inside the shield contact sleeve 300. The dielectric 400 serves for electrical insulation of the shield contact sleeve 300 relative to the terminals 200, 200 and for bearing and/or centering the terminals 200, 200 in the shield contact sleeve 300 and thus in the connecting unit 10.
In a first substep III.1, a shield contact sleeve 300 with originally formed, pre-curved and/or pre-rolled crimp flanks 310, 320, 330, 340 and a pre-assembled twin-axial cable 5 obtained from the second step II or the subassembly are paired, wherein the shield contact sleeve 300 can remain at a carrier strip for second contact devices 300. If crimp flanks are pre-curved or pre-rolled, only the insulating crimp flanks 310, 320 are pre-curved or pre-rolled; a related free pre-assembled longitudinal end section of the twin-axial cable 50 is moved from behind into the related shield contact sleeve 300.
In a subsequent second substep III.2, the crimp flanks 310, 320, 330, 340 are completely closed and crimped in a crimping machine with the ferrule 100 being able to latch with the shield contact sleeve 300. In this case, the crimping section 301, 303 locks the shield contact sleeve 300 in place, both on the twin-axial cable 50 or the outer insulation 530 thereof and on/over the ferrule 100 or on the moved end section 524 of the outer conductor 522. The shield contact sleeve 300 can now be removed from the carrier strip. It is, of course, possible to first remove the shield contact sleeve 300 from the carrier strip, then pair it with the pre-assembled twin-axial cable 5 or the subassembly and then perform the crimping.
The shield contact sleeve 300 is partially constituted as a crimping section 301, 303 or has two crimping sections 301, 303, which are installed at/on the twin-axial cable 50 in the crimped state shown in
The connecting unit 10 enables a transition from oval to circular and optionally back to oval to be completely avoided and therefore improves a frequency performance of the connector 1 by a significant amount, as shown in
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10 2017 122 048 | Sep 2017 | DE | national |
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Entry |
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German Office Action, dated Mar. 6, 2018, 10 pages. |
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Number | Date | Country | |
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20190097330 A1 | Mar 2019 | US |