Patent Application
20150311602
The subject matter herein relates generally to right angle connector assemblies.
A typical radio frequency (RF) connector assembly has a metal outer shell, an inner dielectric insert, and a center contact to carry an electrical signal which is secured within the inner dielectric insert. RF connector assemblies may be either plug connectors or jack connectors of either standard or reverse polarity configurations. RF connector assemblies may be either terminated to a cable or to a printed circuit board (PCB). For cable-mounted applications, the RF connector assembly may be used with coaxial cables in order to maintain the shielding around the electrical connection that the coaxial design offers.
Typical RF connector assemblies are not without disadvantages. For instance, some RF connector assemblies are right angle connector assemblies where mating and terminating ends of the right angle connectors are oriented generally perpendicular to one another. Such right angle connector assemblies are complex and costly to design, manufacture, and assemble. It is difficult to maintain the impedance of such connectors between the mating and terminating ends as the signal path turns 90° within the connector housing. Additionally, typical right angle RF connectors do not enable automated manufacturing. For example, in some existing right angle RF connectors, the center contact is inserted into the connector housing and then bent 90° manually using a tool in order to convey the signal path through the right angle corner. Furthermore, often the dielectric insert does not fully surround the center contact along the 90° bend, so shielding may be reduced and the electrical signal may be degraded.
In addition, housing components of typical RF connectors are often manufactured through a die cast process, which creates strong parts but is not as adapted for mass volume automated assembly as, for example, stamping and forming sheet metal to produce multiple identical parts on a carrier strip. Typical RF connectors also include many individual pieces, which makes automated assembly difficult. For example, the dielectric housing that surrounds the center contact along linear portions (e.g., not even along the right angle bend) may include two pieces that are each received in a respective corresponding shield and pressed together when the two shields are assembled. Thus, due to the complexity, number of different pieces, and manufacturing processes, typical right angle RF connectors are assembled by hand, which is time consuming.
A need remains for a right angle connector assembly that provides effective signal path shielding, reduces components, and allows for automatable manufacturing and assembly.
In an exemplary embodiment, a connector assembly includes a dielectric having a right angle body. The body includes a first segment and a second segment extending from the first segment at a right angle corner of the body. The body defines a right angle chamber extending through the first and second segments between a distal end of the first segment and a distal end of the second segment. The dielectric includes at least one door at the right angle corner. The door is rotatable between an open state and a closed state. The door provides access to the right angle chamber through a rear opening at the right angle corner in the open state. The door restricts access to the rear opening in the closed state. A female center contact is configured to be received in the right angle chamber in the first segment of the dielectric. The female center contact has a mating end configured to electrically connect to a mating contact of a mating connector and a terminating end configured to electrically connect to a cable conductor of a cable received in the right angle chamber in the second segment. A front shield receives a front of the dielectric. Upon loading the dielectric into the front shield, the front shield forces the door to move from the open state to the closed state. A rear shield receives a rear of the dielectric. The rear shield is configured to couple to the front shield.
Optionally, the front shield includes at least one closing tab configured to force the door to move from the open state to the closed state as the front of the dielectric is loaded into the front shield. The female center contact may be received into the right angle chamber through the rear opening at the right angle corner when the door is in the open state. The female center contact may be confined within the right angle chamber when the door is rotated to the closed state. The dielectric may include two doors and the front shield may include two closing tabs. The closing tabs may differ in length such that the closing tabs force the doors to close in a staggered sequence.
In an exemplary embodiment, a connector assembly includes a dielectric having a right angle body including a first segment and a second segment oriented at a right angle to the first segment. The body defines a right angle chamber extending through the first and second segments between a distal end of the first segment and a distal end of the second segment. A female center contact is configured to be received in the right angle chamber in the first segment of the dielectric. The female center contact has a mating end configured to electrically connect to a mating contact of a mating connector and a terminating end configured to electrically connect to a cable conductor of a cable received in the right angle chamber through an opening at the distal end of the second segment. The cable conductor is oriented perpendicular to the female center contact within the first segment. The terminating end includes a flared receptacle having first and second arms that engage opposite sides of the cable conductor to create a mechanical and electrical connection with the cable conductor.
The connector assembly 100 has a right angle shape. As used herein, “right angle” generally refers to two planes that are generally perpendicular and/or have a relative angle of approximately 90°, though the angle does not have to be exact. For example, a cross-sectional plane at the mating end 102 may be generally perpendicular to a cross-sectional plane at the terminating end 106. As such, the loading direction 108 of the mating connector (not shown) may be generally perpendicular to the loading direction 110 of the cable 104. The connector assembly 100 may also be referred to herein as “connector,” “right angle connector,” and/or “right angle RF connector.” In alternative embodiments, the connector 100 may be designed with a shape other than right angle, such as having an angle between the cable 104 and the mating connector in the range of 45° to 135°.
The connector 100 may be used in the automotive industry. For example, the connector 100 may electrically couple to an antenna within a key fob. Optionally, the connector 100 may be applied in various other industries that utilize RF communications, as known in the art. The connector 100 may be designed to operate at radio frequencies in the megahertz (MHz) range, as also known in the art.
The female center contact 202 is received in the right angle chamber 222 in the first segment 216 of the dielectric 204. The female center contact 202 has a mating end 228 configured to electrically connect to a mating contact (not shown) of the mating connector (not shown). The mating end 228 may define a socket that is designed to receive and mechanically connect to a male pin, blade, or the like, of the mating contact. In an alternative embodiment, the center contact 202 may have a different mating interface, such as a pin. The female center contact 202 also has a terminating end 230 that is configured to electrically connect to a cable conductor 232 of the cable 104, which is received in the right angle chamber 222 in the second segment 218. The female center contact 202 serves as a splice that provides a conductive link between the mating contact of the mating connector and the cable conductor 232 of the cable 104. The female center contact 202 may be a stamped (i.e. cut) and formed contact, such as from a panel of sheet metal. Stamped and formed contacts may be less expensive to manufacture than machined contacts.
The front shield 206 is configured to receive and provide shielding to a front 234 of the dielectric 204. The front shield 206 defines a cavity 238 that extends through the front shield 206 between a front 240 and a rear 242 of the shield 206. The cavity 238 is sized to receive the first segment 216 of the dielectric 204 therethrough when the front 234 of the dielectric 204 is received in the front shield 206. In an exemplary embodiment, the front shield 206 is manufactured using a die cast process. The front shield 206 may be die cast to provide strength to withstand the stresses of the mounted cable 104 being pulled in various directions. In an alternative embodiment, the front shield 206 may be stamped and formed. The rear shield 208 is designed to receive a rear 236 of the dielectric 204 and provide shielding along the rear 236. The rear shield 208 is configured to couple to the front shield 206 to at least partially surround the second segment 218 of the dielectric 204. In an exemplary embodiment, the rear shield 208 is made of sheet metal that is stamped and formed. For example, the rear shield 208 may be stamped and formed on a carrier strip for mass production and automated assembly. Alternatively, the rear shield 208 may be die cast.
The outer contact 210 is configured to be electrically connected to an outer mating contact (not shown) of the mating connector (not shown). The outer contact 210 may include multiple biased deflectable fingers 244 that retain electrical and mechanical contact with the outer mating contact when the mating connector is mated to the connector 100. The outer contact 210 is configured to be inserted at least partially within the cavity 238 of the front shield 206. For example, the outer contact 210 may include a mounting interface or end 246 that is received within the cavity 238 from the front 240 and couples to the front shield 206. The outer contact 210 also includes a mating end 248 that extends forwards of the front shield 206 and defines a socket for mating with the outer mating contact of the mating connector. The outer contact 210 has a hollow cylindrical shape configured to receive the first segment 216 of the dielectric 204 (and the female center contact 202 within) therein. The first segment 216 extends through the cavity 238 of the front shield 206 and is received within the outer contact 210. The outer contact 210 may be stamped and formed of a conductive material.
The outer housing 212 is configured to couple to the front 240 of the front shield 206 at least partially surrounding the outer contact 210. The outer housing 212 has a mating interface 250 at a front 258 that defines a socket for mating with the mating connector (not shown). The mating interface 250 forms the mating end 102 of the connector 100. The outer housing 212 defines a channel 254 that extends from the mating interface 250 to a rear 256 of the outer housing 212. The channel 254 is configured to receive the outer contact 210, first segment 216 of the dielectric 204, and female center contact 202 therein through the rear 256. The outer housing 212 may be manufactured from an electrically insulating material, such as a plastic and/or a composite. The outer housing 212 may include a lock 252 which hooks to the mating connector and supports retention of the mating connector within the mating interface 250 of the housing 212. The lock 252 may include one or more latches, tabs, and the like, to provide forces that oppose movement of the mating connector and/or connector 100 in a disconnecting direction.
The cable 104 includes a cable conductor 232 that is configured to be received in the right angle chamber 222 in the second segment 218 of the dielectric 204. A mating end 266 of the cable conductor 232 electrically connects to the terminating end 230 of the female center contact 202 within the right angle chamber 222. The cable 104 may be a coaxial cable. For example, the cable 104 may have an inner center conductor 259, a tubular insulating layer 260 surrounding the center conductor 259 along the length of the cable 104, a tubular conducting shield 262 surrounding the insulating layer 260, and an insulating outer sheath or jacket 264. The tubular insulating layer 260 and/or the insulating outer jacket 264 may be formed of a dielectric material. The tubular conducting shield 262 may be manufactured as woven or braided metal strands, such as copper. The center conductor 259 may be a conductive metal, such as copper as well. Optionally, the center conductor 259 may define the cable conductor 232 that is configured to be connected to the female center contact 202. For example, the distal end of the center conductor 259 may form the mating end 266 that connects to the female center contact 202 directly. Alternatively, as in the illustrated embodiment, the cable conductor 232 may include a separate terminal terminated to the end of the center conductor 259. For example, a pin or blade contact may be attached (e.g., crimped, soldered, etc.) to the center conductor 259 of the cable 104, where the pin or blade forms the mating end 266 of the cable conductor 232 that connects to the female center contact 202.
A ferrule 268 may be used to crimp the connector 100 to the cable 104. The ferrule 268 may be stamped and formed on a carrier strip. The ferrule 268 is an open-barrel shape with at least one crimping arm 270. Alternatively, the ferrule 268 may be formed as a closed-barrel. The ferrule 268 is used to mechanically and electrically connect the connector 100 to the cable 104. For example, the ferrule 268 may be positioned to clinch the coupled front and rear shields 206, 208 to the tubular conducting shield 262 of the cable 104 for both electrical and mechanical coupling.
During assembly, the at least one door 302 is positioned in the open state, and the female center contact 202 is loaded along loading direction 314 into the right angle chamber 222 through the rear opening 304. While loading, the female center contact 202 is oriented along an axis 316 that is parallel to the orientation of the first segment 216 of the dielectric 204. The female center contact 202 is received in the right angle chamber 222 in the first segment 216 of the dielectric 204. Optionally, the female center contact 202 includes at least one guide tab 318 that extends outward from the contact 202. The one or more guide tabs 318 may be used to guide the female center contact 202 during loading into the right angle chamber 222, so the female center contact 202 has the intended rotational orientation (e.g., rotation along the axis 316) for proper termination to the cable conductor 232 (shown in
During assembly, the dielectric-contact sub-assembly 402 is mounted to the front shield 206 along a loading direction 418. The front 234 of the dielectric 204 is loaded first such that the first segment 216 of the dielectric 204 extends through the cavity 238 of the shield 206. When the female center contact 202 and first segment 216 of the dielectric 204 are loaded into the outer contact 210, the center contact 202 is electrically isolated from the outer contact 210 by the material of the dielectric 204. Furthermore, upon loading, the second segment 218 is received in the groove 404. As the front 234 of the dielectric 204 is loaded into the front shield 206, each closing tab 414 forces a respective door 302 to move from the open state to the closed state. As shown, closing tab 414A forces door 302A, and tab 414B forces door 302B. The doors 302 and closing tabs 414 are positioned so the doors 302 close automatically when the dielectric 204 is assembled to the front shield 206.
In the embodiment in which the lengths of the closing tabs 414 are staggered, the staggered closing tabs 414 close the doors 302 in sequence to provide an overlapping cavity closure at the interface 506. For example, if closing tab 414A has a longer rearward length than closing tab 414B, the tab 414A would make contact with respective door 302A prior to closing tab 414B contacting door 302B when the dielectric 204 is being loaded into the front shield 206. As a result, door 302A rotates along direction 502 prior to door 302B rotating along direction 502, so door 302A reaches the closed state prior to door 302B reaching the closed state. The overlapping cavity closure may provide improved shielding at the interface 506, since the doors 302A, 302B at least partially overlap. Optionally, the closing tabs 414 may be the same length, such that the doors 302A, 302B close generally at the same time. In an alternative embodiment, the front shield 206 does not include separate closing tabs 414 that extend from the lip 410. Rather, the lip 410 serves the function of the closing tabs 414 to automatically force the doors 302 to the closed state upon loading the dielectric 204 into the groove 404 of the front shield 206.
The rotatable doors 302 provide an automatic mechanism for locking the female center contact 202 within the dielectric 204 during assembly, which improves the ease and efficiency of the assembly process. In addition, the doors 302 may be pre-assembled to the dielectric 204 prior to assembly of the connector 100, which reduces the number of individual components to assemble. For example, the dielectric 204 having attached doors 302 eliminates the need for a two-piece dielectric (e.g., dielectric and dielectric cover) during assembly as is typically used in the art. In addition, the one-piece dielectric 204 provides 360° shielding of the female center contact 202 at the right angle corner 220 (shown in
During assembly, the front shield 206A is moved in a loading direction 606 towards the rear shield 208A. The rear shield 208 may define a groove 614 that is configured to receive the rear 236 (shown in
When coupled, the rear shield 208 and the front shield 206 form a shield assembly 618. The rear shield 208 and the front shield 206 meet at an interface 616 that continuously stretches along a first side 620, a top 622, and a second side 624 of the shield assembly 618. However, the interface 616 does not extend along a bottom 626 of the shield assembly 618, which provides an opening 628 for the cable conductor 232 (shown in
After forming the shield assembly 618, the outer housing 212 may be mounted to the front 240 of the front shield 206. The outer housing 212 may be mounted either before or after the shield assembly 618 is removed from the carrier strip 602. The outer housing 212 may be coupled to the front shield 206 by various strategies known in the art, including threads, bayonets, latches, hooks, adhesives, deflectable extensions, rotation of the parts, or the like.
The cable 104 is moved in the loading direction 702 towards the terminating end 106 of the connector 100. At least part of the cable 104 is inserted through the opening 628 at the bottom 626 of the shield assembly 618. For example, the cable conductor 232 and the insulating layer 260 may be inserted through the opening 628, while the conducting shield 262 and the outer jacket 264 do not enter through the opening 628.
The shield assembly 618 includes a mounting portion 704 located proximate to the bottom 626 thereof. The mounting portion 704 may have a smaller outer diameter than other portions of the shield assembly 618. The mounting portion 704 is configured to be coupled to the cable 104. In an exemplary embodiment, the cable 104 couples to the shield assembly 618 of the connector 100 by dressing a braid 706 of the cable 104 around the mounting portion 704. The braid 706 may be a distal portion of the conducting shield 262. For example, the cable 104 is loaded in the loading direction 702 and the mounting portion 704 of the shield assembly 618 is received between the insulating layer 260 and the conducting shield 262 of the cable 104, at least along part of the length of the dressed braid 706.
The flared receptacle 902 includes a planar surface 912 having an aperture 914 at a center 920 thereof. The first and second arms 904, 906 curl from corresponding first and second edges 916, 918, of the planar surface 912 towards the center 920. As such, the planar surface 912 and the arms 904, 906 may be integrally connected. Optionally, the planar surface 912 may be a lower surface 912. The flared receptacle 902 may have first and second side walls 926, 928 that extend upwards from the lower surface 912. The first and second arms 904, 906 may extend generally downward from respective tops 932, 934 of the first and second side walls 926, 928 toward the lower surface 912 on opposing sides of the aperture 914 to define a contact region 930 therebetween. The mating end 266 of the cable conductor 232 extends through the aperture 914 and engages the first and second arms 904, 906 in the contact region 930. Additionally, the first and second arms 904, 906 may have flared tips 922, 924, respectively, at distal ends that are flared outward relative to the aperture 914. The flared tips 922, 924 define a guide section within the contact region 930 configured to guide the cable conductor 232 into an interference fit between the first and second arms 904, 906.
In an exemplary embodiment, the doors 302A, 302B may each be designed with a beveled edge 114A, 114B, respectively, to allow the doors 302A, 302B to overlap at the interface 506. For example, the door 302A that closes first may be beveled at the outer edge 114A, and the other door 302B may be beveled at the inner edge 114B. When the doors 302A, 302B are being closed, the door 302A closes first. The beveled edge 114B of the second door 302B interfaces with the beveled edge 114A of the first door 302A, allowing the second door 302B to partially overlap the first door 302A at the interface 506. The staggered closing tabs 414 and beveled edges 114 on the doors 302 provide an overlapping cavity closure that insulates the female center contact 202 and contains the female contact 202 within the dielectric 204.
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, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
