Patent Application
20060085977
This invention relates to electrical connectors and more particularly to such connectors for receiving a coaxial cable contact. Still more particularly, it relates to a method of making such connectors.
One form of such a connector comprises an electrically conductive member having a longitudinal portion and a transverse portion, at least a part of the longitudinal portion providing a cylindrical hollow end and the transverse portion having protruding legs for engagement with circuit traces on a printed circuit board, and an electrically conductive pin positioned with respect to the electrically conductive member. At least a first part of the electrically conductive pin is substantially centrally located within the hollow end, and a single-piece electrically insulating body surrounds the electrically conductive member and the electrically conductive pin. The single-piece, electrically insulating body was achieved by over-molding the electrically conductive member and the electrically conductive contact pin as they are held in place in a suitable mold cavity.
The small size of the parts and the complexity of the mold parts and the procedures for loading the parts have proved difficult and expensive. Thus, it would be an advance in the art to simplify the method of making such contacts.
It is, therefore, an object of the invention to obviate the disadvantages of the prior art.
It is another object of the invention to enhance the method of making electrical contacts.
These objects are accomplished, in one aspect of the invention, by a method of making an electrical connector comprising the steps of: forming an electrically conductive member having a body including an interface, the body having a longitudinal chamber therein; forming an electrically conductive pin; overmolding the interface with a first electrically insulating material; overmolding at least a part of the electrically conductive pin with a second electrically insulating material to form an overmolded electrically conductive pin; and inserting the overmolded electrically conductive pin into the longitudinal chamber.
The method steps of the invention greatly simplify the mold requirements and provide a physically strong electrical connector.
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof reference is made to the following disclosure and appended claims taken in conjunction with the above-described drawings.
Referring now to the drawings with greater particularity, there is shown in
The body has a longitudinal chamber 18 axially arrayed therethrough and a second chamber 26 that is formed at a right angle to the longitudinal chamber 18. In a preferred embodiment of the invention the body 12 has four legs 19, which, in the final construction, will provide the ground connections for the connector
An electrically conductive pin 20 is L-shaped with two legs 34, 36 and has two termini 28, 30 connected by an intermediate portion 32 and is preferably of brass. The pin 20 has its intermediate portion 32 overmolded with a second electrically insulating material 24 that is preferably unfilled nylon to form an overmolded electrically conductive pin 20a. The insulating material 24 is shown in phantom in
The overmolded pin 20a is inserted freely into the longitudinal chamber 18 until it reaches the position shown in
There is thus provided a method of making electrical connectors that involves relatively simple overmolding procedures. It eliminates several assembly steps and makes the connector less tolerance sensitive than current products.
While there have been shown and described what are present considered to be the preferred embodiments of the invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope of the invention as defined by the appended claims.
