Coaxial electrical connector

Abstract

The electrical connector (100) includes a terminal (103) having a first surface (108) defining a plurality of ridges (112) protruding from the first surface. A first ridge (112) of the plurality of ridges (112) has a different height above the first surface (108) than a second ridge (112) of the plurality of ridges (112). The plurality of ridges (112) are configured to provide a plurality of electrical contact points between the terminal (102) and a corresponding mating terminal (104). A method (200) of manufacturing the electrical connector (100) includes the steps of providing a terminal preform (106) formed from sheet metal having a first surface (108), and forming the plurality of ridges (112) protruding from the first surface (108).

Description

Technical Field

[0001] The present invention relates generally to electrical connectors, and more particularly to an electrical connector suitable for use with a coaxial cable. Background Art

[0002] Coaxial cable connector assemblies are used in many automotive applications, such as navigation systems, infotainment systems, airbag systems, and other data transmission systems. A coaxial cable typically consists of an outer shield conductor, an inner center conductor, a dielectric, and an insulating jacket. The outer and inner conductors of a coaxial cable are typically electrically connected to a mating coaxial cable using a coaxial connector.

[0003] Coaxial connectors are commonly used to connect coaxial cables while providing a degree of radio frequency (RF) shielding. With the continued proliferation of devices requiring high-speed data communications, the use of coaxial connectors for coaxial cables has increased significantly in automotive applications.

[0004] Coaxial connectors have become so common in automotive applications that standards for signal loss and contact impedance have been established. Some coaxial connectors that meet these specifications use high-cost, cold-drawn, tubular shield terminals. Lower-cost stamped male and female shield terminals are also available; however, these generally provide less effective shielding because cantilevered contact springs, contact bumps on the shield terminals, or separate contact springs inserted between the shield terminals provide limited contact points between the terminals.

[0005] Coaxial connectors also need to be correctly seated to provide adequate shielding; incorrect seating or air gaps between the shield terminals can result in significant RF leakage. Consequently, these coaxial connectors require tight manufacturing tolerances to ensure proper seating, which drives up the cost of each coaxial connector. A modern car may have more than 40 such coaxial connectors.

[0006] Therefore, a low-cost coaxial connector having stamped terminal connectors that meets all performance specifications and has improved shielding performance remains desirable.

[0007] The subject matter discussed in the Background section should not be considered prior art simply because it is mentioned in the Background section. Similarly, problems mentioned in the Background section or related to the subject matter in the Background section should not be considered to have been previously discovered in the prior art. The subject matter in the Background section merely represents different approaches and may themselves be inventions. Summary of the Invention

[0008] According to one embodiment of the present invention, an electrical connector is provided. The electrical connector includes a terminal having a first surface, the first surface defining a plurality of ridges protruding from the first surface. A first ridge of the plurality of ridges has a different height above the first surface than a second ridge of the plurality of ridges. The plurality of ridges is configured to provide a plurality of electrical contact points between the terminal and a corresponding mating terminal.

[0009] In an exemplary embodiment of the electrical connector having one or more features of the preceding paragraph, when the terminal is received within the corresponding mating terminal, there is an air gap of less than 0.1 mm between the terminal and the corresponding mating terminal.

[0010] In an exemplary embodiment having one or more features of the electrical connector of the preceding paragraph, the first surface defines a plurality of indentations recessed below the first surface.

[0011] In an exemplary embodiment having one or more features of the electrical connector of the preceding paragraph, the plurality of ridges are arranged around a perimeter of the plurality of indentations.

[0012] In an exemplary embodiment having one or more features of the electrical connector of the preceding paragraph, the plurality of ridges are formed from material displaced from the plurality of indentations.

[0013] In an exemplary embodiment having one or more features of the electrical connector of the preceding paragraph, the first surface is curved.

[0014] In an exemplary embodiment having one or more features of the electrical connector of the preceding paragraph, the first surface has a generally cylindrical shape.

[0015] In an exemplary embodiment having one or more features of the electrical connector of the preceding paragraph, the first surface does not define an aperture therethrough.

[0016] In an exemplary embodiment having one or more features of the electrical connector of the preceding paragraph, the first surface is an exterior surface.

[0017] In an exemplary embodiment of an electrical connector having one or more features of the preceding paragraph, the terminal is an inner shield terminal. The first surface defines an outer surface of the inner shield terminal. The corresponding mating terminal is an outer shield terminal having an inner surface and configured to receive the inner shield terminal therein.

[0018] In an exemplary embodiment of the electrical connector having one or more features of the preceding paragraph, at least a portion of the plurality of ridges interfaces with the interior surface when the inner shield terminal is configured within the outer shield terminal.

[0019] In an exemplary embodiment of the electrical connector having one or more features of the preceding paragraph, the first surface defines a slot extending longitudinally along a length of the first surface, and wherein the first surface is configured to apply a spring force against an interior surface of the outer shield terminal.

[0020] According to another embodiment of the present invention, a method for manufacturing an electrical connector is provided. The method includes the steps of providing a terminal preform formed from sheet metal. The terminal preform has a first surface. The method also includes forming a plurality of ridges in the first surface, the ridges protruding from the first surface. A first ridge among the plurality of ridges has a different height above the first surface than a second ridge among the plurality of ridges.

[0021] In an exemplary embodiment having one or more features of the method of the preceding paragraph, the plurality of ridges are formed by a knurling process.

[0022] In an exemplary embodiment having one or more features of the method of the preceding paragraph, the method further comprises the step of forming a plurality of indentations in the first surface that are recessed below the first surface.

[0023] In an exemplary embodiment having one or more features of the method of the preceding paragraph, the plurality of ridges and the plurality of dimples are simultaneously formed by the knurling process.

[0024] In an exemplary embodiment having one or more features of the method of the preceding paragraph, the method further comprises the step of arranging a plurality of ridges between the first surface and the plurality of indentations.

[0025] In an exemplary embodiment having one or more features of the method of the preceding paragraph, the method further comprises the step of arranging a plurality of ridges on a perimeter of the plurality of indentations.

[0026] In an exemplary embodiment of an electrical connector having one or more features of the preceding paragraph, the plurality of ridges are formed from material of the terminal preform displaced from the plurality of indentations.

[0027] In an exemplary embodiment having one or more features of the method of the previous paragraph, the method further comprises the step of bending the terminal preform such that the first surface has a generally cylindrical shape.

[0028] In an exemplary embodiment having one or more features of the method of the preceding paragraph, the method further includes the step of bending the terminal preform such that an edge of the first surface defines a slit extending longitudinally along a length of the first surface.

[0029] According to another embodiment of the present invention, an electrical connector is provided. The electrical connector includes a terminal having a device for providing a plurality of contact points between the terminal and a corresponding mating terminal. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0031] Figure 1 FIG. 1 is a perspective view of an electrical connector assembly in a connection structure according to a first embodiment of the present invention.

[0032] Figure 2 According to the first embodiment of the present invention Figure 1 A cross-sectional view of the electrical connector assembly taken along section line 4-4 in a connected configuration.

[0033] Figure 3 According to the first embodiment of the present invention Figure 1 A perspective view of an electrical connector of an electrical connector assembly.

[0034] Figure 4A According to the first embodiment of the present invention Figure 1 A cross-sectional view of an electrical connector and a corresponding mating electrical connector along section line 4A-4A in a connected configuration.

[0035] Figure 4B According to the first embodiment of the present invention Figure 4A An enlarged portion of a cross-sectional view of FIG.

[0036] Figure 5 is a flowchart of a method for manufacturing an electrical connector according to a second embodiment of the present invention.

[0037] Figure 6 FIG. 1 is a partial top view of a terminal preform according to a second embodiment of the present invention.

[0038] Figure 7 is a perspective view of a mold according to a second embodiment of the present invention; and

[0039] Figure 8 According to the second embodiment of the present invention Figure 7 A cross-sectional view of the mold along section line 8-8. DETAILED DESCRIPTION

[0040] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other cases, well-known methods, processes, components, circuits, and networks have not been described in detail in order to avoid unnecessarily obscuring aspects of the embodiments.

[0041] Figure 1 and Figure 2An example of a coaxial connector assembly, hereinafter referred to as assembly 100, is shown, configured to interconnect two coaxial cables. Assembly 100 includes a male electromagnetic shield terminal, hereinafter referred to as terminal 102, configured to be attached to the outer shield conductor of a first coaxial cable (not shown), and a female electromagnetic shield terminal, hereinafter referred to as mating terminal 104, configured to be attached to the outer shield conductor of a second coaxial cable (not shown) and to receive terminal 102. Terminal 102 and mating terminal 104 are configured to surround an inner terminal (not shown) attached to the inner conductors of the first and second coaxial cables and provide shield continuity between the first and second coaxial cables.

[0042] like Figure 3 As shown, the terminal 102 has a generally cylindrical shape formed by bending or rolling a terminal preform 106 made of a metal sheet. A first surface, hereinafter referred to as an outer surface 108 of a contact portion 110 of the terminal 102, defines a plurality of ridges 112 and dimples 114 formed by a knurling process performed on the terminal preform 106 before the terminal preform 106 is bent into the cylindrical shape. Figure 4A and 4B As shown, the ridges 112 are arranged on a perimeter 116 of the indentation 114. The ridges 112 are configured to provide multiple electrical contact points between the terminal 102 and the mating terminal 104. In the illustrated example, the indentation 114 and the ridges 112 have a diamond shape, ie, are in the shape of a diamond.

[0043] The ridges 112 protrude above the exterior surface 108, while the dimples 114 are recessed below the exterior surface 108. Without being bound by any particular theory of operation, the ridges 112 are formed by sheet material that is displaced when the dimples 114 are formed in the terminal 102 preform by the knurling process. Due to the diamond shape of the dimples 114, the height of the ridges 112 above the exterior surface 108 varies around the perimeter 116 of the dimples 114 because more material is displaced near the obtuse angles 118 of the dimples 114 than at the acute angles of the dimples 114. The height of the ridges 112 above the exterior surface 108 may also vary due to tolerance variations in the knurling process.

[0044] When the terminal 102 is received within the mating terminal 104, at least a portion of the ridges 112 on the outer surface 108 of the terminal 102 interfaces with the inner surface 120 of the mating terminal 104. The tallest ridges 112 of the terminal 102 make mechanical and electrical contact with the inner surface 120 of the mating terminal 104, thereby providing multiple electrical connections between the terminal 102 and the mating terminal 104, reducing connection resistance and improving shielding effectiveness. The ridges 112 protrude from the outer surface 108 and typically have a height between 0.03 and 0.07 mm. The air gap between the terminal 102 and the mating terminal 104 is reduced to less than 0.1 mm, preferably less than 0.08 mm, more preferably less than 0.05 mm, and even more preferably 0.03 mm, further improving shielding effectiveness. The presence of ridges 112 of varying heights also improves the assembly 100's resistance to fretting corrosion, as taller ridges 112 that may have been degraded by fretting are replaced by ridges 112 of lower height than the initial ridges 112 that made contact. The indentation 114 also serves as a reservoir for corrosion debris so that it does not interfere with the connector between the terminal 102 and the mating terminal 104 .

[0045] The terminal 102 defines a slit 122 in the exterior surface 108 that extends longitudinally along the length of the exterior surface 108. The terminal 102 is configured such that when the terminal 102 is inserted into the mating terminal 104, the slit 122 narrows, causing the exterior surface 108 of the terminal 102 to exert a normal spring force on the interior surface 120 of the mating terminal 104, thereby providing lower resistance and a more reliable connection between the terminal 102 and the mating terminal 104, thereby improving shielding. When the terminal 102 is inserted into the mating terminal 104, the width of the slit is reduced to less than 0.1 mm, preferably less than 0.08 mm, and more preferably less than 0.05 mm. The slit 122 is the only opening, hole, gap, break, or aperture in the exterior surface 108 of the terminal 102.

[0046] Although Figures 3 to 4B The illustrated example connector assembly 100 is arranged generally parallel to or in line with the cable, but alternative embodiments of the connector are contemplated in which one or both terminals are arranged generally at right angles to the cable. In other alternative embodiments of the connector assembly 100, the connector assembly 100 can be configured to interconnect with conductive traces on a printed circuit board.

[0047] Although Figures 3 to 4B The illustrated example of has the dimples and ridges 112 defining a diamond shape, but alternative embodiments may have other shapes, such as square, rectangular, triangular, circular, oval, etc.

[0048] Method 200 of manufacturing electrical connector assembly 100, such as in Figure 5 The above method shown in , comprises the following steps:

[0049] Step 202: providing a terminal preform formed of a metal plate having a first surface; this step includes providing a terminal preform 106 formed of a sheet metal having a first surface 108, such as Figure 6 As shown in;

[0050] Step 204: forming a plurality of ridges in the first surface, the ridges protruding from the first surface, such that a first ridge in the plurality of ridges has a different height above the first surface than a second ridge in the plurality of ridges; this step includes forming a plurality of ridges 112 in the first surface 108, the ridges protruding from the first surface 108, using a knurling die 124 having a plurality of protrusions 126 that are pressed into the terminal preform 106 to form the plurality of ridges 112, as shown. Figure 7 and 8 The plurality of ridges 112 are formed such that a first ridge 112 of the plurality of ridges 112 has a different height above the first surface 108 than a second ridge 112 of the plurality of ridges 112 .

[0051] Step 206: forming a plurality of indentations on the first surface that are recessed below the first surface. This step includes forming a plurality of indentations 114 in the first surface 108 by pressing a plurality of protrusions 126 of a knurling die 124 that is pressed into the terminal preform 106 and recessed below the first surface 108 to form the plurality of indentations 114.

[0052] Step 208: Arranging a plurality of ridges between the first surface and the plurality of indentations; this step includes arranging the plurality of ridges 112 so that they are located between the first surface 108 and the plurality of indentations 114;

[0053] Step 210 : Arranging a plurality of ridges on a perimeter of the plurality of dimples; this step includes arranging the plurality of ridges 112 to be located on a perimeter of the plurality of dimples 114 .

[0054] Step 212: bending the terminal preform so that the first surface has a generally cylindrical shape. This step includes bending or rolling the terminal preform 106 so that the first surface 108 has a generally cylindrical shape.

[0055] Step 214 : bending the terminal preform so that the edge of the first surface defines a slit extending longitudinally along the length of the first surface; this step includes bending the terminal preform 106 so that the edge of the first surface 108 defines a slit 122 extending longitudinally along the length of the first surface 108 .

[0056] Thus, an electrical connector assembly 100 and a method 200 for manufacturing an electrical connector are provided. Compared to prior art connector assemblies, the assembly 100 and method 200 provide benefits such as improved shielding effectiveness due to lower connection resistance and reduced air gaps between the terminal 102 and the mating terminal 104. The assembly 100 and method 200 also improve the fretting corrosion resistance of the assembly 100.

[0057] While the present invention has been described with reference to preferred embodiments thereof, the present invention is not intended to be limited thereto, but rather is limited only by the scope set forth in the claims below. For example, the embodiments described above (and / or various aspects thereof) may be used in combination with one another. Furthermore, various modifications may be made to adapt specific circumstances or materials to the teachings of the present invention without departing from its broad scope. The sizes, types, orientations of the various components, and the number and position of the various components described herein are intended to define parameters of specific embodiments and are not intended to be limiting, but rather are merely prototype embodiments.

[0058] After reading the above description, many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of ordinary skill in the art. Therefore, the scope of the present invention is limited only by the appended claims and the full range of equivalents encompassed by these claims.

[0059] As used herein, “one or more” includes functions performed by one element, functions performed by more than one element, such as in a distributed fashion, several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0060] It should also be understood that, although in some cases the terms first, second, etc. are used to describe various elements in this article, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the various described embodiments, the first contact can be referred to as the second contact, and similarly, the second contact can be referred to as the first contact. The first contact and the second contact are both contacts, but they are not the same contact.

[0061] The terms used in the description of the various embodiments herein are for the purpose of describing the particular embodiments only and are not intended to be limiting. As used in the description of the various described embodiments and in the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the terms and / or "include any and all combinations of one or more of the associated listed items." It should also be understood that the term "comprising" as used herein specifically refers to the presence of the stated features, wholes, steps, operations, elements, and / or parts, but does not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts, and / or combinations thereof.

[0062] As used herein, the term “if” is optionally interpreted to mean “when” or “upon or in response to determining or in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if “[the stated condition or event] is detected” is optionally interpreted to mean “upon deciding” or “in response to deciding” or “upon [the condition or event] is detected” or “in response to detecting [the stated condition or event],” depending on the context.

[0063] In addition, although the terms of regulations or orientations may be used herein, these elements should not be limited by these terms. Unless otherwise specified, all regulations or orientations are used to distinguish one element from another element and do not imply any particular sequence, order of operation, direction or orientation unless otherwise specified.

Claims

1. An electrical connector assembly (100), comprising: A terminal (102) having a first surface (108) defining a plurality of ridges (112) projecting from the first surface (108), wherein a first ridge (112) of the plurality of ridges (112) has a first height above the first surface (108) and is configured to form a first electrical contact point between the terminal (102) and a corresponding mating terminal (104), and a second ridge (112) of the plurality of ridges (112) has a second height above the first surface (108), the second height being greater than the first height. The present invention relates to a terminal (102) having a plurality of ridges (112) and a plurality of ridges (112) having a low degree of contact, and wherein a second ridge (112) of the plurality of ridges (112) is configured to provide a plurality of second electrical contact points between the terminal (102) and the corresponding mating terminal (104) after the first electrical contact point is degraded due to micromotion, wherein the first surface (108) defines a plurality of indentations (114) recessed below the first surface (108), wherein the plurality of ridges (112) are disposed on a perimeter (116) of the plurality of indentations (114), and wherein the plurality of ridges (112) are formed of material displaced from the plurality of indentations (114).

2. The electrical connector assembly (100) according to claim 1, characterized in that: When the terminal (102) is received in the corresponding mating terminal (104), an air gap of less than 0.1 mm exists between the terminal (102) and the corresponding mating terminal (104).

3. The electrical connector assembly (100) according to claim 1, characterized in that: The first surface (108) is curved.

4. The electrical connector assembly (100) according to claim 1, characterized in that: The first surface (108) does not define an aperture extending through the first surface.

5. The electrical connector assembly (100) according to claim 4, characterized in that: The first surface (108) is an exterior surface.

6. The electrical connector assembly (100) according to claim 5, characterized in that: The terminal (102) is an inner shield terminal, wherein the first surface (108) defines an outer surface of the inner shield terminal, and the corresponding mating terminal (104) is an outer shield terminal having an inner surface (120) and configured to receive the inner shield terminal therein.

7. The electrical connector assembly (100) according to claim 6, characterized in that: When the inner shield terminal is disposed within the outer shield terminal, at least a portion of the plurality of ridges (112) interface with the inner surface (120).

8. The electrical connector assembly (100) according to claim 7, characterized in that: The first surface (108) defines a slot (122) extending longitudinally along a length of the first surface (108), wherein a width of the slot (122) is less than 0.1 mm when the terminal (102) is inserted into the corresponding mating terminal (104), and wherein the first surface (108) is configured to apply a spring force to the interior surface (120) of the outer shield terminal.

9. A method (200) of manufacturing an electrical connector assembly (100), comprising the following steps: Providing a terminal preform (106) formed of sheet metal, the terminal preform (106) having a first surface (108); forming a plurality of ridges (112) in the first surface (108), the ridges protruding from the first surface (108), wherein a first ridge of the plurality of ridges (112) has a first height above the first surface (108), and a second ridge of the plurality of ridges (112) has a second height above the first surface (108), the second height being lower than the first height; forming a plurality of dimples (114) in the first surface (108), the plurality of dimples being recessed below the first surface (108); disposing the plurality of ridges (112) on a perimeter (116) of the plurality of dimples (114), wherein the plurality of ridges (112) are formed from material displaced from the plurality of dimples (114); providing a first electrical contact point between the terminal (102) and a corresponding mating terminal (104) via a first ridge of the plurality of ridges (112); as well as A second electrical contact point is provided between the terminal (102) and the corresponding mating terminal (104) by a second ridge of the plurality of ridges (112) after the first electrical contact point is degraded due to micromotion.

10. The method (200) according to claim 9, characterized in that The plurality of ridges (112) are formed by a knurling process.

11. The method (200) according to claim 9, characterized in that The plurality of ridges (112) and the plurality of dimples (114) are simultaneously formed by a knurling process.

12. The method (200) according to claim 9, characterized in that The following steps are also included: The plurality of ridges (112) are disposed between the first surface (108) and the plurality of dimples (114).

13. The method (200) according to claim 9, characterized in that The plurality of ridges (112) are formed from material of the terminal preform (106) displaced from the plurality of indentations (114) by a knurling process.

14. The method (200) according to claim 9, characterized in that The following steps are also included: The terminal preform (106) is bent so that the first surface (108) has a substantially cylindrical shape.

15. The method (200) according to claim 14, characterized in that The following steps are also included: The terminal preform (106) is bent such that an edge of the first surface (108) defines a slit (122) extending longitudinally along a length of the first surface (108).

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