Electrical connector and manufacturing method thereof

Abstract

An electrical connector comprises an insulating shell, a conductive terminal retained in the insulating shell, a metal shell for accommodating the insulating shell, and a locking shell sleeved on the front end of the metal shell, wherein the insulating shell is injection molded on the outside of the conductive terminal, the conductive terminal comprises a first base extending in a front-to-back direction, a contact portion extending forward along the first base, a second base formed by extending vertically downward along the end of the first base, and a welding foot extending downward from the second base, the insulating shell comprises a first portion extending in a front-to-back direction and retained in the first base, and a second portion extending vertically from the end of the first portion and retained in the second base, the contact portion extending forward and extending out of the first portion, the cross-sectional dimensions of the first base and the second base being larger than the cross-sectional dimensions of the contact portion and the welding foot, the first portion or the second portion having a through hole arranged corresponding to the first base or the second base so that the first base or the second base is exposed to the air. The electrical connector of the present invention has a conductive terminal tail end exposed outside the insulating housing, so that after assembling the insulating housing, the terminal strip at the conductive terminal tail end can be broken off to realize automatic drawing production of the conductive terminal. Moreover, since the conductive terminal tail end is located in the accommodation space formed by the rear end of the insulating housing and the front end of the rear cover, it has a better characteristic impedance and shielding effect.

Description

Technical field

[0001] The present invention relates to an electrical connector and a manufacturing method thereof, and more particularly to an electrical connector and a manufacturing method thereof having better characteristic impedance and shielding effect. [Background Technology]

[0002] Chinese utility model patent No. CN205069951U discloses an electrical connector, including a centrally located pin, an insulator sleeved over the pin, a metal housing sleeved over one end of the insulator, and a locking housing sleeved over the outer side of the insulator. Because the pin and the insulator are assembled, the pin must be cut from the terminal strip and then assembled into the insulator during manufacturing, resulting in poor characteristic impedance and shielding effects.

[0003] Therefore, it is necessary to improve the existing electrical connector to overcome this defect. [Summary of the invention]

[0004] The object of the present invention is to provide an electrical connector which can realize automatic material drawing production and maintain better characteristic impedance and shielding effect.

[0005] The objectives of the present invention are achieved through the following technical solution 1: an electrical connector, comprising an insulating shell, a conductive terminal retained in the insulating shell, a metal shell for accommodating the insulating shell, and a locking shell sleeved on the front end of the metal shell, wherein the insulating shell is injection molded outside the conductive terminal, the conductive terminal comprises a first base extending in a front-to-back direction, a contact portion extending forward along the first base, a second base formed by extending vertically downward along the end of the first base, and a welding foot extending downward from the second base, the insulating shell comprises a first part extending in a front-to-back direction and retained in the first base, and a second part extending vertically from the end of the first part and retained in the second base, the contact portion extends forward and protrudes out of the first part, the cross-sectional dimensions of the first base and the second base are larger than the cross-sectional dimensions of the contact portion and the welding foot, the first part or the second part has a through hole arranged corresponding to the first base or the second base so that the first base or the second base is exposed to the air.

[0006] Furthermore, the rear end surface of the second portion is concavely formed with the through hole for exposing the second base body.

[0007] Furthermore, the second base of the conductive terminal includes a protrusion exposed from the through hole.

[0008] Furthermore, the conductive terminal is L-shaped, the cross-sections of the contact portion and the welding foot are circular, and the cross-sections of the first base and the second base are rectangular.

[0009] Furthermore, the surface of the contact portion is gold-plated, the surface of the soldering foot is tin-plated, and the first substrate and the second substrate are nickel-plated.

[0010] Furthermore, the metal shell includes a rectangular accommodating portion, a rectangular stop portion located at the front end surface of the rectangular accommodating portion, and a protruding portion extending forward from the rectangular stop portion, and the portion of the contact portion extending out of the first portion is accommodated in the protruding portion.

[0011] Furthermore, the surface of the protruding portion is provided with a first ring portion close to the rectangular blocking portion and a second ring portion located in front of the first ring portion, the diameter of the first ring portion is larger than that of the second ring portion, and a receiving groove is formed between the first ring portion and the second ring portion, and the lock shell is cylindrical and has an elastic arm protruding from the inside to be accommodated and supported in the receiving groove.

[0012] Furthermore, one end of the receiving groove close to the second ring portion is concave inward from the outer surface to form an annular groove, and the front end of the elastic arm is provided with a supporting portion that is supported and received in the groove.

[0013] Furthermore, the electrical connector further comprises a rear cover provided at the rear end of the metal shell, the rear cover comprising a recess provided on the front end surface of the rear cover, the recess and the through hole forming an accommodating space for accommodating the protrusion.

[0014] The object of the present invention is achieved by the following technical solution 2: A method for manufacturing an electrical connector, comprising the following steps:

[0015] Providing a conductive terminal, the conductive terminal comprising a contact portion and a soldering foot with a circular cross section, a first base with a rectangular cross section connecting the contact portion and the soldering foot, and a second base extending vertically downward from an end of the first base, wherein one of the first base and the second base is connected to a terminal strip;

[0016] An insulating housing is provided, the insulating housing comprising a first portion extending in a front-to-rear direction and fixed to the first base, and a second portion extending vertically from an end of the first portion and fixed to the second base, wherein one of the first portion and the second portion is provided with a through hole so that an end of one of the first base and the second base connected to the terminal strip is exposed to air;

[0017] Injection molding the conductive terminals of the connecting terminal strip and the insulating housing into a terminal module;

[0018] Breaking the terminal strip so that one end of the first base and the second base of the connecting terminal strip of the conductive terminal has a convex portion to expose the through hole;

[0019] Providing a metal shell for accommodating the insulating shell, and assembling the terminal module into the metal shell;

[0020] Providing a metal back cover with a notch, and sealing the rear end of the metal shell with the back cover so that the notch is arranged corresponding to the through hole;

[0021] A plastic lock shell is provided so that the lock shell is sleeved and fixed on the front end of the metal shell.

[0022] Compared with the prior art, the present invention has the following beneficial effects: since the tail end of the conductive terminal of the electrical connector of the present invention is exposed outside the insulating shell, the terminal strip at the tail end of the conductive terminal can be broken off after assembling the insulating shell to realize automatic drawing production of the conductive terminal, and since the front and rear end cross-sectional dimensions of the conductive terminal are inconsistent, its tail end is located in the accommodating space formed by the rear end of the insulating shell and the front end of the rear cover, and has better characteristic impedance and shielding effect.

Brief Description of the Drawings

[0023] Figure 1 It is a three-dimensional diagram of the electrical connector of the present invention.

[0024] Figure 2 yes Figure 1 A stereogram from another perspective.

[0025] Figure 3 It is a three-dimensional exploded view of the electrical connector of the present invention.

[0026] Figure 4 yes Figure 3 A three-dimensional exploded view from another perspective.

[0027] Figure 5 yes Figure 3 Further exploded perspective view.

[0028] Figure 6 yes Figure 5 A three-dimensional exploded view from another perspective.

[0029] Figure 7 yes Figure 1 Sectional view along line AA.

[0030]

Main component symbol description

[0031] Electrical connector 100 Conductive terminal 1

[0032] Contact portion 11 Connecting portion 12

[0033] First base 121 Second base 122

[0034] Protrusion 1221 welding foot 13

[0035] Insulation housing 2 Part 1 21

[0036] rib 211 second portion 22

[0037] Rear end surface 220 concave portion 221

[0038] Accommodating space 2210 through hole 2211

[0039] Metal shell 3 extension portion 31

[0040] Opening 310 First ring portion 311

[0041] Second ring portion 312 receiving groove 313

[0042] Rectangular accommodating portion 32

[0043] Cavity 320 Support column 321

[0044] Front end face 322 Rectangular stop 323

[0045] Rear end opening 324 lock housing 4

[0046] Accommodation space 40 elastic arm 401

[0047] Supporting portion 4011 Main body 41

[0048] Frame-shaped retaining portion 42 Rectangular rear end surface 421

[0049] Rectangular opening 422 Back cover 5

[0050] Notch 51

[0051] The following specific embodiments will further illustrate the present invention in conjunction with the above-mentioned drawings. [Specific implementation method]

[0052] Please refer to Figures 1 to 7 As shown, the electrical connector 100 of the present invention includes a conductive terminal 1, an insulating housing 2 injection-molded with the conductive terminal 1, a metal housing 3 that accommodates the insulating housing 2, a rear cover 5 that blocks the rear end of the metal housing 3, and a locking housing 4 that fits over the front end of the metal housing 3. The directions referred to in the present invention are based on the front-to-back direction of the conductive terminal 1.

[0053] Please refer to Figures 5 to 7The conductive terminal 1 is made of copper alloy and is L-shaped. It includes a first base 121 extending in the front-to-back direction, a contact portion 11 extending forward from the first base 121, a second base 122 extending vertically downward from the end of the first base 121, and a soldering foot 13 extending downward from the second base 122. The first base 121 and the second base 122 are referred to as the connecting portion 12. The cross-sections of the first and second bases 121, 122 are rectangular, while the cross-sections of the contact portion 11 and the soldering foot 13 are circular. The cross-sections of the first and second bases 121, 122 are larger than those of the contact portion 11 and the soldering foot 13. The cross-section diameter of the contact portion 11 is smaller than that of the soldering foot 13. The contact portion 11 is gold-plated to enhance wear and corrosion resistance during mating with the mating connector. The connecting portion 12 is tin-plated as a filler layer. The soldering foot 13 is nickel-plated to facilitate soldering. The cross-section of the connecting portion 12 is rectangular, which is convenient for stamping and positioning during processing and molding. It is convenient for fixing during the electroplating process at both ends, which simplifies the process, saves costs, and improves the overall strength of the electrical connector 100. When the conductive terminal 1 and the insulating shell 2 are injection molded, the connecting portion 12 of the conductive terminal 1 is connected to the terminal strip for automatic material drawing production. Theoretically, it is feasible to connect the terminal strip to the first substrate or the second substrate. Specifically, in this embodiment, the terminal strip is connected to the rear end of the second substrate 122. Therefore, after the conductive terminal 1 is injection molded with the insulating shell 2, the terminal strip is cut so that a protrusion 1221 is formed at the rear end of the second substrate 122 of the conductive terminal 1. The protrusion 1221 is a part of the terminal strip.

[0054] Please refer to Figures 5 and 6 The insulating housing 2 includes a first portion 21 extending in the front-to-back direction and fixed to the first base 121, and a second portion 22 extending vertically from the end of the first portion 21 and fixed to the second base 122. The first portion 21 is provided corresponding to the first base 121, and the second portion 22 is provided corresponding to the second base 122. The first portion 21 is cylindrical and accommodates the first base 121 and part of the contact portion 11, while the second portion 22 accommodates the second base 122 and part of the welding leg 13. A plurality of annular ribs 211 are provided on the surface of the first portion 21. The second portion 22 includes a rear end face 220 provided at the rear end, a recessed portion 221 recessed in the rear end face 220, and a through hole 2211 extending through the rear end of the recessed portion 221. The protrusion 1221 of the conductive terminal 1 is provided corresponding to the through hole 2211 to facilitate connection to the terminal strip. The contact portion 11 of the conductive terminal 1 extends forward and out of the first portion 21.

[0055] The metal shell 3 is made of zinc alloy, please refer to Figures 1 to 6 , the metal shell 3 includes a protruding portion 31 for accommodating the first part 21 and a rectangular accommodating portion 32 for accommodating the second part 22. An opening 310 is provided at the front end of the protruding portion 31. The contact portion 11 of the conductive terminal protrudes forward from the first part 21 and is accommodated in the protruding portion 31. The ribs 211 of the insulating shell interfere with the inner wall surface of the protruding portion 31. The rectangular accommodating portion 32 includes four support columns 321 provided at the bottom, a cavity 320 for accommodating the second part 22, a front end face 322 located at the front end, a rectangular stop 323 located in front of the front end face 322, and a rear end opening 324 passing through the bottom at the rear side of the rectangular accommodating portion 32. The second part 22 at the rear end of the insulating shell 2 is exposed at the rear end opening 324 so that the protrusion 1221 of the conductive terminal 1 is exposed to the air. Please refer to Figures 5 to 7 As shown, the metal shell 3 further includes a first ring portion 311 located on the surface of the extension 31 near the rectangular stop 323, a second ring portion 312 located in front of the first ring portion 311, and a receiving groove 313 located between the first and second ring portions 311, 312. The diameter of the first ring portion 311 is greater than the diameter of the second ring portion. The receiving groove 313 has a groove 3131 formed inwardly from the outer surface at one end near the second ring portion 312.

[0056] Please refer to Figures 4 to 7 As shown, the lock shell 4 is made of plastic and includes a cylindrical main body 41, a receiving space 40 provided in the inner cavity of the main body 41, and a frame-shaped stopper 42 provided at the rear end of the main body 41. The frame-shaped stopper 42 includes a rectangular rear end face 421 provided at the rear end and a rectangular opening 422 provided through the second rear end face 421. The receiving space 40 is in communication with the rectangular opening 422. The inner wall of the receiving space 40 is provided with an elastic arm 401 that is accommodated and abutted against the receiving groove 313. The elastic arm 401 extends in the front-to-back direction and is arranged around the inner wall of the receiving space 40, and four are arranged at equal distances. The front end of the elastic arm is provided with an abutting portion 4011 that is abutted and accommodated in the groove. The lock shell 4 is sleeved on the protruding portion 31 of the metal shell so that the rectangular rear end face 421 is attached to the front end face 322 and the rectangular stopper 323 is accommodated and abutted in the rectangular opening 422.

[0057] See also Figures 5 to 7The rear cover 5 is made of metal and is received within the rear opening 324 to shield the rear end of the electrical connector. A recess 21 is formed on the front surface of the rear cover 5. Because the rear end of the insulating housing 2 has a recess 221 and the protrusion 1221 is exposed within the recess 221, the recess 21 and the recess 221 form a receiving space 2210, allowing the protrusion 1221 to be received within the receiving space 2210 without contacting the rear cover 5, preventing the risk of a short circuit.

[0058] The conductive terminal 1 in this application is structured as follows: a front portion 11 with a smaller cross-section than the contact portion between the connecting portion 12 and the soldering foot 13; a rectangular connecting portion 12 with a larger cross-section than the soldering foot 13; and finally a circular soldering foot 13 with a smaller cross-section than the connecting portion 12. The inconsistent widths of these three portions can lead to sudden impedance changes at various points in the conductive terminal 1. To achieve impedance matching, reduce crosstalk, and optimize insertion loss, the protrusion 1221 connecting the conductive terminal to the connecting portion 12 is housed in a housing space 2210. The presence of air within the housing space allows the dielectric constant of air to be utilized to improve the impedance of the conductive terminal, thereby optimizing the signal integrity of the conductive terminal.

[0059] A method for manufacturing the above-mentioned electrical connector comprises the following steps:

[0060] The first step is to provide a conductive terminal 1. The conductive terminal 1 is L-shaped and includes a first base 121 extending in the front-to-back direction, a contact portion 11 extending forward along the first base 121, a second base 122 extending vertically downward from the end of the first base 121, and a soldering leg 13 extending downward from the second base 122. The first base 121 and the second base 122 are referred to as the connecting portion 12. The cross-sections of the first base 121 and the second base 122 are rectangular, while the cross-sections of the contact portion 11 and the soldering leg 13 are circular. The cross-sections of the first base 121 and the second base 122 are larger than the cross-sections of the contact portion 11 and the soldering leg 13. The cross-section diameter of the contact portion 11 is smaller than the cross-section diameter of the soldering leg 13. In theory, either the first base 121 or the second base 122 can be connected to the terminal strip. In this embodiment, the rear end of the second base 122 is connected to the terminal strip.

[0061] The second step is to provide an L-shaped insulating shell 2, and injection mold the conductive terminal 1 of the connecting terminal strip and the insulating shell 2 into a terminal module, so that the first base 121 or the second base 122 of the connecting terminal strip of the conductive terminal is exposed from the insulating shell. In this embodiment, the end of the second base 122 is exposed from the insulating shell 2 to connect the terminal strip. The insulating shell 2 includes a first part 21 extending in the front-to-back direction and fixed to the first base 121, and a second part 22 extending vertically from the end of the first part 21 and fixed to the second base 122. A plurality of ribs 211 are arranged around the surface of the first part 21. The second part 22 includes a rear end face 220, a recessed portion 221 recessed in the rear end face 220, and a through hole 2211 provided in the recessed portion 221 and passing through the rear end face 220.

[0062] In the third step, the terminal strip is broken to form a protrusion 1221 at the rear end of the second base 122 exposed from the insulating housing 2; the protrusion 1221 is located on the second base 122. The protrusion 1221 is exposed at the rear end surface 220 and further exposed from the through hole 2211.

[0063] The fourth step involves providing a metal housing 3 to house the insulating housing 2. The terminal module, after breaking off the terminal strip, is assembled into the metal housing 3. The metal housing 3 is made of zinc alloy and includes an extension 31 that houses the first portion 21 and a rectangular accommodating portion 32 that houses the second portion 22. The extension 31 has an opening 310 at its front end. The contact portion 11 of the conductive terminal extends forward from the first portion 21 of the insulating housing and is accommodated within the extension 31. The ribs 211 of the insulating housing interfere with the inner wall of the extension 31. The rectangular accommodating portion 32 includes four support columns 321 at the bottom, a cavity 320 that accommodates the second portion 22, a front face 322 at the front end, a rectangular stop 323 in front of the front face 322, and a rear opening 324 extending through the bottom of the rectangular accommodating portion 32. The rear second portion 22 of the insulating housing 2 is exposed through the rear opening 324, exposing the protrusion 1221 of the conductive terminal 1 to air. The metal housing 3 further includes a first ring portion 311 disposed in an annular manner on the surface of the extension 31 near the rectangular stop 323, a second ring portion 312 located in front of the first ring portion 311, and a receiving groove 313 located between the first and second ring portions 311, 312. The diameter of the first ring portion 311 is greater than that of the second ring portion. The receiving groove 313 has a recessed groove 3131 formed inwardly from the outer surface at one end near the second ring portion 312.

[0064] A metal back cover 5 having a recess 51 is provided. The back cover 5 covers the rear end of the metal housing 1, such that the recess 21 and the rear end of the insulating housing 2 form a receiving space 2210 to accommodate the protrusion 1221. The back cover 5 is received within the rear opening 324 to shield the rear end of the electrical connector. Because the rear end of the insulating housing 2 has a recess 221 and the protrusion 1221 is exposed within the recess 221, the recess 51 and the recess 221 form a receiving space 2210, allowing the protrusion 1221 to be received within the receiving space 2210 without contacting the back cover 5, thereby preventing the risk of a short circuit.

[0065] A plastic lock shell 4 is provided so that the lock shell 4 is sleeved and fixed on the front end of the metal shell 3. The lock shell 4 includes a cylindrical main body 41, a receiving space 40 provided in the inner cavity of the main body 41, and a frame-shaped stopper 42 provided at the rear end of the main body 41. The frame-shaped stopper 42 includes a rectangular rear end face 421 provided at the rear end and a rectangular opening 422 provided through the rectangular rear end face 421. The receiving space 40 is in communication with the rectangular opening 422. The lock shell 4 is sleeved on the protruding portion 31 of the metal shell so that the second rear end face 421 is attached to the front end face 322 and the rectangular stopper 323 is received and abutted in the rectangular opening 422. The inner wall of the receiving space 40 is provided with an elastic arm 401 that is received and abutted against the receiving groove 313. The elastic arm 401 extends in the front-to-back direction and is arranged around the inner wall of the receiving space 40, and four are arranged at equal distances. The front end of the elastic arm is provided with a supporting portion 4011 which is received in the groove.

[0066] In the present invention, by connecting the conductive terminal 1 to the terminal strip and injection molding it with the insulating shell, rapid drawing production can be achieved. In addition, since the terminal strip is broken after the conductive terminal and the insulating shell are injection molded, the rear end of the conductive terminal must be exposed to the rear end of the insulating shell. Since the structure of the conductive terminal 1 in this application is a contact portion 11 with a front cross-section smaller than the connecting portion 12 and the welding foot 13, followed by a rectangular connecting portion 12 with a cross-section larger than the welding foot 13, and then a circular welding foot 13 with a cross-section smaller than the connecting portion 12. Due to the inconsistent widths of the three parts, the impedance of each part of the conductive terminal 1 will suddenly change. In order to achieve impedance matching, reduce crosstalk and optimize insertion loss, it is necessary to provide a recess 51 at the rear end of the back cover 5, which together with the recess 221 at the rear end of the insulating shell 2 forms an accommodating space 2210 to accommodate the protrusion 1221, and improve the impedance and insertion loss of the conductive terminal by the dielectric constant of the air in the accommodating space.

[0067] The above descriptions are only some embodiments of the present invention, not all embodiments. Any equivalent changes made to the technical solution of the present invention by ordinary technicians in this field after reading the specification of the present invention are covered by the claims of the present invention.

Claims

1. An electrical connector comprising an insulating housing, a conductive terminal held within the insulating housing, a metal housing for receiving the insulating housing, and a locking housing sleeved on a front end of the metal housing, wherein: The insulating shell is injection molded outside the conductive terminal, and the conductive terminal includes a first base extending in the front-to-back direction, a contact portion extending forward along the first base, a second base extending vertically downward along the end of the first base, and a welding foot extending downward from the second base. The insulating shell includes a first part extending in the front-to-back direction and fixed to the first base, and a second part extending vertically from the end of the first part and fixed to the second base. The contact portion extends forward and protrudes out of the first part. The cross-sectional dimensions of the first base and the second base are greater than the cross-sectional dimensions of the contact portion and the welding foot. A convex portion is formed at the end of the first base or the rear end of the second base of the conductive terminal, and a through hole is formed on the end surface of the first part or the second part corresponding to the position of the convex portion. The first base and the second base are respectively covered as a whole by the first part and the second part, and the convex portion is exposed to the air from the through hole.

2. The electrical connector according to claim 1, wherein: The conductive terminal is L-shaped, the cross-sections of the contact portion and the welding foot are circular, and the cross-sections of the first base and the second base are rectangular.

3. The electrical connector according to claim 2, wherein: The surface of the contact portion is gold-plated, the surface of the welding foot is tin-plated, and the first substrate and the second substrate are nickel-plated.

4. The electrical connector according to claim 1, wherein: The metal shell includes a rectangular accommodating portion, a rectangular blocking portion located at the front end surface of the rectangular accommodating portion, and a protruding portion extending forward from the rectangular blocking portion. The portion of the contact portion extending out of the first portion is accommodated in the protruding portion.

5. The electrical connector according to claim 4, wherein: The surface of the protruding portion is provided with a first ring portion close to the rectangular blocking portion and a second ring portion located in front of the first ring portion. The diameter of the first ring portion is larger than that of the second ring portion. A receiving groove is formed between the first ring portion and the second ring portion. The lock shell is cylindrical and has an elastic arm protruding from the inside for receiving and resisting the receiving groove.

6. The electrical connector according to claim 5, wherein: An end of the receiving groove close to the second ring portion is concave inwardly from the outer surface to form an annular groove, and a front end of the elastic arm is provided with a supporting portion that is supported and received in the groove.

7. The electrical connector according to claim 1, wherein: The electrical connector further comprises a rear cover provided at the rear end of the metal shell, the rear cover comprising a recess provided at the front end surface of the rear cover, the recess and the through hole forming an accommodating space for accommodating the protrusion.

8. A method for manufacturing an electrical connector, characterized in that: The following steps are involved: A conductive terminal is provided, the conductive terminal comprising a contact portion and a soldering foot with a circular cross section, a first base body with a rectangular cross section connecting the contact portion and the soldering foot, and a second base body extending vertically downward from an end of the first base body, wherein a protrusion is provided at the end of one of the first base body and the second base body for connecting to a terminal strip; An insulating housing is provided, the insulating housing comprising a first portion extending in a front-to-rear direction and fixed to the first base, and a second portion extending vertically from an end of the first portion and fixed to the second base, wherein one of the first portion and the second portion is provided with a through hole so that a protrusion of one of the first base and the second base connected to the terminal strip is exposed to air; Injection-molding the conductive terminals of the connecting terminal strip and the insulating housing into a terminal module, wherein the insulating housing entirely covers and holds the first substrate and the second substrate; Breaking the terminal strip so that the protrusion at the end of one of the first base body and the second base body of the connecting terminal strip of the conductive terminal is exposed to the through hole; Providing a metal shell for accommodating the insulating shell, and assembling the terminal module into the metal shell; Providing a metal back cover with a notch, and sealing the rear end of the metal shell with the back cover so that the notch is arranged corresponding to the through hole; A plastic lock shell is provided so that the lock shell is sleeved and fixed on the front end of the metal shell.

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