Patent Application
20220239044
This application claims benefit to German Patent Application No. DE 20 2021 100 405.3, filed on Jan. 28, 2021, which is hereby incorporated by reference herein.
The present invention relates to a plug connector for transmitting high-frequency or radio-frequency signals, in particular in a vehicle, and to a plug connector assembly.
In a vehicle, various technical components communicate with each other by exchanging data. The data exchange preferably takes place in the form of high-frequency signals passed through suitable cables, such as coaxial cables or micro-coaxial cables. Often, plug connectors are used at interfaces between cables and/or technical components. To facilitate handling in automotive applications, plug connectors are generally standardized; i.e., certain dimensions and sizes of a plug connector are predetermined and must be observed. The requirements are essentially directed to the durability and releasability of the plug connector and to reliable data transmission. However, the standardized dimensions can lead to difficulties during the assembly of connector components, for example when parts are not always fully visible or when excessive play occurs between parts during assembly.
German Publication DE 10 2016 002 408 A1 relates to a coaxial plug-and-socket connection and a connection system including this plug-and-socket connection. In addition to a first contact junction between a first coaxial connector and a matching second coaxial connector, a second contact junction is implemented in the plug-and-socket connection in the outer conductor portion thereof. To this end, an elastic contact component is provided between the first coaxial connector and the second coaxial connector at a distance from the first contact junction, in particular at a distance from the first latching means. The elastic contact component preferably takes the form of a toroidally wound ring. The toroidally wound wire of the ring is elastic both radially and axially and bridges different distances between a coaxial socket and a coaxial plug, which can occur depending on a respective radial offset between the coaxial plug and the coaxial socket. In the case of a radial offset, the axis of the connecting element and the axis of a coaxial socket form a certain angle other than zero.
However, due to the elasticity of the contact component, the occurrence of a radial offset (i.e., tilting) cannot be ruled out, neither during insertion nor during arrangement of the two connectors within each other. This may lead to further inaccuracies during assembly. Furthermore, the contact component must be disposed as a separate part on a connector, which increases complexity. Finally, the contact component must be configured and mounted such that it is able to withstand the high mechanical dynamics occurring in a vehicle at least over a predetermined lifetime, which is associated with additional effort.
In an embodiment, the present invention provides a plug connector for transmitting high-frequency signals that includes a cable, a contact and a connecting element. The cable has at least one free end. The contact is mounted on the at least one free end of the cable, and has a free contact end on a side facing away from the cable. The connecting element is disposed between the contact and the cable, and, in an assembled state, is fixedly connected to the contact and to the cable. The connecting element has at least a first portion with a first outer diameter on a side facing the contact and a second portion with a second outer diameter on a side facing the cable, the second outer diameter being larger than the first outer diameter. The first portion includes at least a third portion that has, at least in some regions of the third portion, an outer diameter corresponding to the second outer diameter.
Subject matter of the present disclosure will be described in even greater detail below based on the exemplary figures. All features described and/or illustrated herein can be used alone or combined in different combinations. The features and advantages of various embodiments will become apparent by reading the following detailed description with reference to the attached drawings, which illustrate the following:
Embodiments of the present invention provide a plug connector for transmitting high-frequency signals as well as a plug connector assembly which are simple and rugged in construction, meet the required standards, and enable quick and reliable assembly.
In particular, a plug connector that is simple and rugged in construction, meets the required standards, and enables quick and reliable assembly is achieved by a plug connector for transmitting high-frequency signals according to an embodiment of the present invention. The plug connector has a cable having at least one free end, as well as a contact mounted on the free cable end and having a free contact end on a side facing away from the cable, and further has a connecting element which is disposed between the contact and the cable and which, in the assembled state, is fixedly connected to the contact and to the cable. The connecting element has at least a first portion with a first outer diameter on a side facing the contact and at least a second portion with a second outer diameter on a side facing the cable, the second outer diameter being larger than the first outer diameter. Finally, the first portion includes at least a third portion, the connecting element at least in some regions of the third portion having an outer diameter corresponding to the second outer diameter.
The plug connector allows the cable to be connected to a terminal that is complementary to the contact. The cable is preferably a coaxial cable or a micro-coaxial cable, and the terminal is preferably a corresponding coaxial connector. Via the plug connector, high-frequency signals can be transmitted in a vehicle. The plug connector may also be used for other types of cables. The line groups mounted in the plug connector are preferably of the common low loss (LL) and radio guide (RG) types, which differ in their diameter or dimensioning. Due to these differences, a variation in diameter may occur along the connecting element during the assembly of a plug connector, especially during the crimping of the connecting element.
The dimensioning of a housing for receiving at least one plug connector; i.e., also the dimensioning of at least one plug connector receptacle, is essentially strictly defined. In accordance with the defined dimensioning, the at least one plug connector receptacle has a uniform cylindrical shape. In the uniform cylindrical shape, the above-described variation in diameter of the connecting element leads to a variation in the joining situation in the plug connector receptacle, and thus to play between the peripheral wall of the plug connector receptacle and at least a first portion of the connecting element, which first portion has a smaller diameter. Such play may result in tilting of the plug connector and difficulties during assembly. In particular, when the plug connector is inserted at an angle, it is likely to collide with a push-through guard in the housing.
An embodiment of the present invention is intended to compensate for variations in diameter so as to ensure a uniform joining situation without impairing the mechanical and electrical properties of the plug connector. In a certain area, the diameter is, at least in some regions, increased by an embossed formation, preferably a bump or projection. This makes it possible to reduce or prevent the occurrence of (wobbling) play during fitting of the plug connector into the housing. For this purpose, the first portion of the connecting element, which has a smaller outer diameter than a second portion, includes a third portion which has an outer diameter corresponding to the second outer diameter at least in some regions in the circumferential direction of the connecting element.
During insertion of the plug connector into the housing, the plug connector is inserted with the free end of the contact forward into the housing. Since the first portion, and thus also the third portion, is disposed on a side facing the free contact end, the third portion enters the housing before the second portion. Furthermore, the plug connector can be inserted unhindered into the housing up to the third portion, preferably up to the beginning of the third portion, as viewed from the free contact end. The mentioned push-through guard is further away. With the insertion of the third portion, the plug connector can be accurately aligned with the housing or the plug connector receptacle in the housing. In this process, the third portion is visible from the outside and disappears from the field of view as it is inserted into the housing. The visibility simplifies the alignment and thus the assembly process.
Preferably, an outer diameter of the contact is smaller than an outer diameter of the cable. The dimensioning of the contact and of the cable is predetermined. To allow for a space-saving arrangement and connection, the contact typically has a smaller diameter than the cable.
In the assembled state, the connecting element preferably directly embraces the contact and the cable in its first and second portions, respectively. The direct and snug joining ensures a space-saving and reliable connection. The direct joining preferably includes crimping of the connecting element so that the contact and the cable are frictionally connected together. Because the contact and the cable have different outer diameters, different outer diameters are formed along the connecting element as it is directly embraced.
Preferably, the connecting element includes a compression sleeve such as a crimp sleeve or a compression tube. A compression or crimp sleeve is a standard component and is simple and cost-effective to use. The compression or crimp sleeve is preferably formed from a metal. The compression or crimp sleeve can be readily connected to the contact and the cable, in particular using a compression tool. In particular, the third portion may be formed during the compression operation. Preferably, the compressing is performed using a star-type compression tool since this tool allows for an even distribution of compression force or pressure.
Preferably, the third portion has a plurality of embossed formations formed in spaced-apart relationship on the periphery of the connecting element. The embossed formations preferably include projections. The number of embossed formations around the circumference may be defined by the required pull-off strength. The embossed formations can readily be produced or formed into the connecting element during a compression operation. In particular, no additional steps or fastening means are required for the embossed formations. The plurality of embossed formations are arranged such that there is at least one section of the third portion that has an outer diameter corresponding to the second outer diameter. Preferably, the embossed formations are arranged in diametrically opposite pairs on the periphery of the connecting element.
Preferably, the embossed formations are integral with the connecting element. The connecting element preferably includes a dimensionally stable material, in particular metal. Because the embossed formations are formed integrally from the connecting element, the embossed formations are also composed of the dimensionally stable material of the connecting element. Thus, the embossed formations cannot be compressed or bent during assembly without a separate compression tool. Because of this, the plug connector can at all times be reliably inserted into the housing without unwanted play.
Preferably, guide elements are disposed at the embossed formations in the transitions between the first portion and the third portion. Due to their shape, the guide elements facilitate the insertion of the plug connector into the receiving opening of the housing. This simplifies assembly.
Preferably, a distance between the free contact end and the third portion is smaller than a distance between the free contact end and the second portion. This means that the third portion is located closer to the free contact end. The plug connector is inserted with its free contact end first into the housing. Consequently, the third portion reaches or enters the housing before the second portion. The plug connector is aligned with the housing as early as when the third portion is inserted.
A plug connector assembly that is simple and rugged in construction, meets the required standards, and enables quick and reliable assembly is also achieved in particular by a plug connector assembly for at least one plug connector for transmitting high-frequency signals according to an embodiment of the present invention. The plug connector assembly has at least one plug connector and a housing with at least one plug connector receptacle for disposing the at least one plug connector in the housing. The at least one plug connector receptacle has an inner diameter corresponding to the second outer diameter of the connecting element and a length corresponding to at least a distance between the free contact end and the third portion.
The plug connector assembly preferably has a plurality of plug connector receptacles. This allows a plurality of plug connectors to be connected simultaneously to complementary terminals. The housing protects the connectors from the outside environment. In addition, the housing provides latching features for a reliable connection between a plug connector and a complementary terminal. Preferably, in the assembled state, the respective plug connector and the housing are also in engagement with one another, in particular via latching means. The housing and a plug connector receptacle respectively have a predefined fixed length in the longitudinal direction of the cable. In particular, the length is selected such that a plug connector is securely disposed in the housing. The length of the plug connector receptacle may in particular be a multiple of a diameter of a receiving opening, so that an end of the plug connector receptacle opposite the receiving opening is only visible when viewed in a direction along the plug connector receptacle.
Preferably, the plug connector assembly further has a push-through opening with a push-through guard, the push-through opening having a diameter corresponding to the outer diameter of the contact. The push-through opening is surrounded by the push-through guard. The push-through guard forms in particular a wall. In order for a plug connector to reach its final position within the housing, the contact of the plug connector must be pushed through the push-through opening. Since the diameter of the push-through opening corresponds exactly to the outer diameter of the contact, the plug connector must be accurately aligned within the housing and, in particular, along receptacle axis A in order to move the plug connector through the push-through opening. Accurate alignment is important inter alia for reliable connection to a terminal connectable to the contact.
In addition, further advantages and features of embodiments of the present invention will be apparent from the following description of preferred embodiments. The features described therein and hereinabove may be implemented alone or in combination, unless they contradict each other. The following description of the preferred embodiments is made with reference to the accompanying drawings.
Contact 10, also referred to as a cable output, is connectable to a terminal complementary to contact 10, so that signals can be exchanged between cable 20 and the complementary terminal via plug connector 1. The dimensions of contact 10 for connection to the complementary terminal are predetermined. In particular, contact 10 has a predetermined length. Contact 10 further has an outer diameter D11. In the embodiment shown in
Cable 20 is preferably a coaxial cable or micro-coaxial cable for transmission of high-frequency signals. In other embodiments, other types of cables may also be used. Cable 20 has an outer diameter D22. Outer diameter D22 is preferably larger than outer diameter D11 of contact 10.
Connecting element 30 is preferably a crimp sleeve or a compression tube. Connecting element 30 is preferably compressible so that it permanently surrounds an inserted contact and/or a cable as it is compressed or crimped. In the embodiment shown in
First portion I is located on a side facing contact 10. First portion I surrounds an end of contact 10 directly, snugly, and firmly. Second portion II is located on a side facing cable 20. Second portion II surrounds an end of cable 20 directly, snugly, and firmly. Since outer diameter D11 of contact 10 is preferably smaller than outer diameter D22 of cable 20, the first outer diameter D1 of connecting element 30 in first portion I is smaller than the second outer diameter D2 of connecting element 30 in second portion II. In particular, second outer diameter D2 of connecting element 30 corresponds to a maximum outer diameter in the assembled state; i.e., after compression. The maximum outer diameter is preferably in the range of 2-5 mm, more preferably in the range of 2.5-4 mm, even more preferably in the range of 3-3.5 mm. These and all other dimensions can be scaled as desired to other plug connectors.
Second portion II is spaced from free end 12 of contact 10 by a minimum distance L3. Between first portion I and second portion II, there may be provided a transition section 36 in which the outer diameter of connecting element 30 increases from first outer diameter D1 to second outer diameter D2, proceeding from the side facing contact 10.
First portion I has a third portion III, the third portion III being preferably shorter than first portion I and preferably spaced apart from second portion II and from transition section 36. Third portion III preferably has a length in the range of 0.3-1 mm, more preferably in the range of 0.4-0.8 mm, even more preferably in the range of 0.5-0.6 mm. Third portion III is spaced from free end 12 of contact 10 by a minimum distance L1. Distance L1 is preferably smaller than distance L3. Distance L1 is preferably in the range of 12-18 mm, more preferably in the range of 13-16 mm, even more preferably in the range of 14-15 mm.
Third portion III is preferably an annular or cylindrical portion along connecting element 30. Third portion III has in particular at least one embossed formation 32 disposed therein. In the case of a single embossed formation 32, embossed formation 32 preferably extends over more than half the circumference. In an alternate embodiment, embossed formation 32 may also extend over the entire circumference. Preferably, third portion III has a plurality of embossed formations 32. A plurality means two or more embossed formations. The plurality of embossed formations 32 are preferably spaced apart along the circumference of connecting element 30, so that in at least a sub-region of third portion III, the outer diameter of connecting element 30 corresponds to second outer diameter D2 of connecting element 30. For this purpose, in particular, at least two embossed formations 32 are arranged on diametrically opposite sides of the periphery of connecting element 30.
Preferably, guide elements 34 are disposed at the transitions of the at least one embossed formation 32 between the first and the third portions I, III. In the embodiment shown, guide elements 34 have an inclined plane and are disposed on both sides of each embossed formation 32. In other embodiments, guide elements 34 may have other shapes such as curved planes, stepped shapes, rounded edges, etc. Furthermore, in other embodiments, guide elements 34 may be disposed only on the side facing contact 10. Guide elements 34 serve to facilitate the insertion of plug connector 1 with connecting element 30 into a plug connector receptacle 52 of a housing 50 (see
In order for a plug connector 1 to be received in one of plug connector receptacles 52, central axis M of plug connector 1 is aligned with the corresponding receptacle axis A. Then, plug connector 1 is inserted with the free end 12 of its contact 10 forward through receiving opening 54 into plug connector receptacle 52. Diameter D4 of plug connector receptacle 52 and receiving opening 54 preferably corresponds to the maximum outer diameter of plug connector 1; i.e., to second outer diameter D2 in second portion II of connecting element 30. Thus, plug connector 1 can be completely inserted into housing 50 and plug connector receptacle 52 and is finally seated.
A push-through opening 58 is disposed opposite each receiving opening 54. Receptacle axis A extends centrally through plug connector receptacle 52 and push-through opening 58. Each push-through opening 58 is surrounded by a push-through guard 56, which determines inner diameter D3 of push-through opening 58. Push-through guard 56 is in particular a wall. Inner diameter D3 of push-through opening 58 corresponds to outer diameter D11 of contact 10. Plug connector 1 can be pushed through push-through opening 58 up to a sleeve edge 17 of sleeve 16. When sleeve edge 17 abuts against push-through guard 56, plug connector 1 has reached its optimal end position within housing 50. Connector 1 is fixed in its end position by locking means.
Furthermore,
Push-through guard 56 is generally disposed in housing 50 in such a way that it is only visible when viewing in a direction along receptacle axis A. However, when inserting plug connector 1 into housing 50, assembly personnel cannot move plug connector 1 along receptacle axis A and at the same time look along this axis A. When plug connector 1 and central axis M are tilted by an angle α with respect to receptacle axis A, free end 12 of contact 10 abuts against push-through guard 56 in a sub-region of edge 14 of free end 12. This means that when plug connector 1 is in a tilted condition, it cannot be inserted further into plug connector receptacle 52 and housing 50. Plug connector 1 does not reach its optimal end position and is not locked in place. The assembly personnel can only tilt plug connector 1 back and forth to change the angle of inclination a in an attempt to push free end 12 of contact 10 through push-through opening 58. This manner of assembly is time-consuming and frustrating. In addition, components may be damaged if haptic feedback upon abutment is the only way of determining whether plug connector 1 is correctly aligned in plug connector receptacle 52.
The dimensions of the components, in particular of housing 50 and contact 10, are predetermined. In particular, the dimensions are defined by standards and cannot be changed as desired. The creation of a third portion III with an outer diameter that corresponds to the maximum outer diameter of plug connector 1 in the assembled state can be accomplished during or after the mounting of connecting element 30 on contact 10 and/or cable 20. In particular, as shown in
In addition, at least some of compression elements 102 have at least a portion of a recess 104. In the final compressed state, recesses 104 form shapes complementary to embossed formations 32 on connecting element 30. Embossed formations 32 may be created by recesses 104 during compression. In an alternative embodiment, embossed formations 32 were formed on connecting element 30 already prior to compression in star-type compression tool press 100, and recesses 104 in star-type compression tool press 100 allow the embossed formations 32 to be maintained and an even pressure force to be applied to connecting element 30.
While subject matter of the present disclosure has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. Any statement made herein characterizing the invention is also to be considered illustrative or exemplary and not restrictive as the invention is defined by the claims. It will be understood that changes and modifications may be made, by those of ordinary skill in the art, within the scope of the following claims, which may include any combination of features from different embodiments described above.
The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article “a” or “the” in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of “or” should be interpreted as being inclusive, such that the recitation of “A or B” is not exclusive of “A and B,” unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of “at least one of A, B and C” should be interpreted as one or more of a group of elements consisting of A, B and C, and should not be interpreted as requiring at least one of each of the listed elements A, B and C, regardless of whether A, B and C are related as categories or otherwise. Moreover, the recitation of “A, B and/or C” or “at least one of A, B or C” should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B and C.
| Number | Date | Country | Kind |
|---|---|---|---|
| 20 2021 100 405.3 | Jan 2021 | DE | national |
