Electrical connector assembly and method of manufacturing the same

Abstract

An electrical connector assembly (100) includes an electrical terminal (102) having a connecting portion (104) and an attachment portion (106) angled relative to the connecting portion (104). The assembly (100) also includes a cylindrical inner housing (110) formed of a polymer material, in which the connecting portion (104) of the electrical terminal (102) is disposed, and an outer connector housing (112) formed of a polymer material, the outer connector housing (112) having a smooth bore (114) configured to receive the inner housing (110) containing the electrical terminal (102). The inner housing (110) and the bore (114) are sized such that the inner housing (110) is in an interference fit when received in the bore (114). The assembly process of the electrical connector assembly (100) includes the following steps: inserting the inner housing sleeve (110) into the hole (114) of the outer connector housing (112) and attaching the inner housing sleeve (110) to the outer connector housing (112) by welding the inner housing sleeve (110) to the outer connector housing (112).

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 091,373, filed on October 14, 2020, the entire contents of which are incorporated herein by reference. Background Art

[0003] The terminals of a right-angle electrical connector for terminating wires and cables have a connecting end that is designed to interconnect with a corresponding mating terminal, and an attachment end that is attached to the wire and cable is arranged at a right angle to the connecting end. In certain applications, it is desired that the wire and cable be in a specific orientation relative to the connector housing that holds the terminal. In previous connector designs, the terminals and housing were designed to position the cable in a fixed orientation, such as the 6 o'clock position, or in one of four orientations, such as the 12 o'clock, 3 o'clock, 6 o'clock, or 9 o'clock positions. Changing these fixed orientations requires an investment of time and money to develop new connector tooling to manufacture connectors with different cable orientations. Summary of the Invention

[0004] According to one or more aspects of the present disclosure, an electrical connector assembly includes an electrical terminal having a connection portion configured to mate with a corresponding mating electrical connector and an attachment portion configured to mate with a cable. The connection portion is angled relative to the attachment portion. The electrical connector assembly also includes a cylindrical inner housing formed of a polymer material, the connection portion of the electrical terminal being disposed within the cylindrical inner housing, and an outer connector housing formed of a polymer material having a smooth bore configured to receive the inner housing containing the electrical terminal. The bore and the inner housing are sized such that the inner housing forms an interference fit when received within the bore. The electrical connector assembly is assembled through a process that includes inserting the inner housing into the bore of the outer connector housing and attaching the inner housing to the outer connector housing by welding the inner housing to the outer connector housing.

[0005] In one or more embodiments of the electrical connector assembly according to the preceding paragraph, welding may be performed by selectively melting a portion of the polymer material of the inner housing shell and a portion of the polymer material of the outer connector housing.

[0006] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the welding may be performed using a sonic welding process.

[0007] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the curved first rib can extend radially from the inner housing sleeve.

[0008] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the first rib can be sized to provide an interference fit between the inner housing sleeve and the aperture when the inner housing sleeve is received within the aperture, and wherein the first rib is welded to the outer connector housing.

[0009] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the curved second rib can extend radially from the inner housing sleeve, and the second rib can be sized to be in an interference fit when the inner housing sleeve is received in the aperture.

[0010] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the inner housing sleeve and the aperture can be configured to allow the attachment portion to be arranged in any radial orientation relative to the longitudinal axis of the aperture.

[0011] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the connecting portion can be angled perpendicularly relative to the attachment portion.

[0012] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the outer connector housing and the inner housing sleeve are formed of the same polymer material.

[0013] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the polymer material forming the outer connector housing and the inner housing sleeve is 20% glass-filled polybutylene terephthalate.

[0014] According to one or more aspects of the present disclosure, a method for assembling an electrical connector assembly is provided. The electrical connector assembly having electrical terminals comprises a connecting portion, an attachment portion, and a cylindrical inner housing sleeve. The connecting portion is configured to mate with a corresponding mating electrical connector, and the attachment portion is configured to mate with a cable. The cylindrical inner housing sleeve is formed of a polymer material, in which the connecting portion of the electrical terminal is disposed, and the outer connector housing is formed of a polymer material and has a smooth bore configured to receive the inner housing sleeve containing the electrical terminal. The connecting portion is angled relative to the attachment portion. The bore and the inner housing sleeve are sized so that the inner housing sleeve is in an interference fit when received in the bore. The method comprises the steps of inserting the inner housing sleeve into the bore of the outer connector housing and attaching the inner housing sleeve to the outer connector housing by welding a portion of the inner housing sleeve to a portion of the outer connector housing.

[0015] In one or more embodiments of the method according to the preceding paragraph, the method may further comprise the step of selectively melting a portion of the polymer material of the inner housing sleeve and a portion of the polymer material of the outer connector housing.

[0016] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the welding is performed using a sonic welding process.

[0017] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the curved first rib may extend radially from the inner housing shell. The first rib may be sized such that the inner housing shell forms an interference fit with the aperture when the inner housing shell is received within the aperture. The method may further include welding the first rib to the outer connector housing.

[0018] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the inner housing shell may define a curved second rib extending radially from the inner housing shell. The second rib may be sized to be in an interference fit when the inner housing shell is received within the aperture.

[0019] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, prior to the attaching step, the inner housing sleeve and the aperture can be configured to allow the attachment portion to be arranged in any radial orientation relative to the longitudinal axis of the aperture.

[0020] In one or more embodiments of the electrical connector assembly according to any of the preceding paragraphs, the connecting portion can be angled perpendicularly relative to the attachment portion.

[0021] According to one or more aspects of the present disclosure, a coaxial connector assembly includes a coaxial terminal having a connecting portion extending along a first axis and configured to mate with a corresponding mating coaxial connector, and an attachment portion extending along a second axis and attached to a coaxial cable. The first axis is arranged at a ninety-degree angle relative to the second axis. The coaxial connector assembly further includes a cylindrical inner housing sleeve formed of a polymer material, in which the connecting portion of the coaxial terminal is disposed, and an outer connector housing formed of a polymer material, the housing having a hole extending through the outer connector housing along the first axis. A first side of the outer connector housing extends parallel to the first axis, and a second side extends parallel to the first axis and is arranged substantially perpendicular to the first side. The inner housing sleeve is fixed within the outer connector housing so that the second axis of the connecting portion is not parallel to the first side of the outer connector housing and is not parallel to the second side of the outer connector housing.

[0022] In one or more embodiments of the coaxial connector assembly according to the preceding paragraph, the inner surface of the bore may be smooth.The inner housing sleeve may be welded to the outer connector housing.

[0023] In one or more embodiments of the coaxial connector assembly according to any of the preceding paragraphs, the first rib can be sized such that the inner housing sleeve is in an interference fit with the aperture when the inner housing sleeve is received into the aperture, and wherein the first rib is sonic welded to the outer connector housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a perspective view of an electrical connector according to some embodiments;

[0025] Figure 2 According to some embodiments Figure 1 An exploded perspective view of an electrical connector;

[0026] Figure 3A According to some embodiments Figure 1 A rear perspective view of an outer connector housing of an electrical connector;

[0027] Figure 3B According to some embodiments Figure 1 A front perspective view of the inner housing sleeve of the electrical connector;

[0028] Figure 4A According to some embodiments Figure 1 The electrical connector will Figure 3B Insert the inner shell Figure 3A a cross-sectional side view of the outer connector housing;

[0029] Figure 4B According to some embodiments Figure 1 The electrical connector will Figure 3B Insert the inner shell Figure 3A a cross-sectional side view of the outer connector housing;

[0030] Figure 5 yes Figure 1 , illustrating various possible "clock positions" of the terminals according to some embodiments; and

[0031] Figure 6 is formed Figure 1 A flowchart of a process or method for an electrical connector assembly. DETAILED DESCRIPTION

[0032] The present application relates to an electrical connector. This connector is designed so that right-angle terminals and the cables attached thereto can be positioned at any angle relative to the connector's outer connector housing. This is achieved through a smooth bore in the outer connector housing that receives an inner housing sleeve that houses the right-angle terminals. Once the inner housing sleeve is positioned within the bore, it forms an interference fit with the outer connector housing. After the inner housing sleeve is positioned within the bore, aligning the right-angle terminals with the desired "clock position" relative to the outer connector housing, the inner housing sleeve is sonically welded to the inner wall of the bore through the outer connector housing to secure the "clock position" of the right-angle terminals.

[0033] Figure 1 and Figure 2A non-limiting example of a right-angle coaxial electrical connector assembly that complies with the FAKRA standard is shown, hereinafter referred to as assembly 100. FAKRA is the abbreviation of the German Fachnormenausschuss Kraftfahrzeugindustrie, used by the automotive standards committee of the German Institute for Standardization [Deutsches Institut für Normung (DIN)], and represents international standardization interests in the automotive field. The FAKRA standard provides a system for correct connector attachment, key connection and color coding for coaxial electrical connectors. In a FAKRA connector, similar socket keys can only be connected to similar plug keyways. With the help of FAKRA-defined snaps on the socket housing and cooperating latches on the plug housing, safe positioning and locking of the connector housing are facilitated. The FAKRA standard is incorporated into the United States Council for Automotive Research (USCAR) USCAR-18 standard.

[0034] The assembly 100 includes an electrical terminal 102 having a connecting portion 104 extending along a first axis X and configured to interface with a coaxial cable (not shown), the connecting portion 104 being configured to interface with a corresponding mating electrical connector (not shown). In the illustrated example, the electrical terminal 102 is an outer shield terminal that is connected to the outer shield of the coaxial cable. The connecting portion 104 extends along a second axis Y that is non-coaxial with the first axis X, thereby causing the connecting portion 104 to be angled relative to the attaching portion 106. In the illustrated embodiment, the attaching portion 106 is generally perpendicular to or arranged at a right angle to the connecting portion 104 of the electrical terminal 102. Alternative embodiments are contemplated in which the attaching portion 106 and the cable are arranged at an angle between 0 and 90 degrees relative to the connecting portion 104 of the electrical terminal 102.

[0035] The connecting portion 104 of the electrical terminal 102 is secured within a cylindrical inner housing sleeve 110. The inner housing sleeve 110 is formed from an insulating polymer material, such as 20% glass-filled polybutylene terephthalate.

[0036] The assembly 100 also includes an outer connector housing 112 having a smooth bore 114, such as Figure 3AAs shown, the outer connector housing 112 includes an attachment hole 116 extending from a rear surface 118 of the outer connector housing 112 to a connection hole 120 on a front surface 122 of the outer connector housing 112. The smooth bore 114 is configured to receive the inner housing sleeve 110, which includes the electrical terminals 102, through the attachment hole 116. The rear surface 118 of the outer connector housing 112 is generally flat. The outer connector housing 112 is also formed from an insulating polymer material, such as the same 20% glass-filled polybutylene terephthalate material that forms the inner housing sleeve 110. The smooth bore 114 and the inner housing sleeve 110 are sized to provide an interference fit when the inner housing sleeve 110 is received within the smooth bore 114.

[0037] The inner housing 110 has first and second ribs 124, 126 that are concentrically curved. Figure 3B and 4A As shown, it extends radially from the inner housing sleeve 110. Figure 4B As shown, when the inner housing 110 is inserted into the smooth hole 114 , the first and second ribs 124 , 126 are in an interference fit state with the inner wall 128 of the smooth hole 114 .

[0038] The smooth bore 114 and the flat rear surface 118 of the outer connector housing 112 cooperate with the curved first and second ribs 124, 126 of the inner housing shell 110 to allow the attachment portion 106 of the electrical terminal 102 to be arranged at any radial angle or "clock position" relative to the outer connector housing 112, such as Figure 5 shown.

[0039] Once the connection portion 106 is positioned at the desired clock position, the inner housing sleeve 110 is attached to the outer connector housing 112 by welding the inner housing sleeve 110 to the inner wall 128 of the smooth bore 114, thereby permanently positioning the attachment portion 106 of the electrical terminal 102 at the desired clock position. The rearmost first rib 124 defines a raised ridge 130 that extends across the first rib 124, as shown. Figure 4A and 4B It is this ridge 130 that primarily forms the weld between the inner housing sleeve 110 and the outer connector housing 112.

[0040] Figure 6 The method 200 of assembling the assembly 100 is shown in FIG. The various steps of the method 200 are summarized as follows:

[0041] Step 202 , inserting the inner housing sleeve into the hole of the outer connector housing, which includes inserting the inner housing sleeve 110 into the smooth hole 114 of the outer connector housing 112 .

[0042] Step 204 , attaching the inner housing sleeve to the outer connector housing by welding a portion of the inner housing sleeve to a portion of the outer connector housing, includes securing the inner housing sleeve 110 to the outer connector housing 112 by welding a portion of the inner housing sleeve to a portion of the outer connector housing 112 .

[0043] Step 206, selectively melting a portion of the polymer material of the inner housing sleeve and a portion of the polymer material of the outer connector housing, which step includes selectively melting a portion of the polymer material of the inner housing sleeve 110 and a portion of the polymer material of the outer connector housing 112, such as by using a sonic welding process; and

[0044] Step 208 , welding the first rib to the outer connector housing, includes welding the first rib 124 to the outer connector housing 112 .

[0045] While the exemplary embodiment is a coaxial electrical connector assembly, other connector assembly embodiments are contemplated that are suitable for use with single conductor stranded or solid cable, fiber optic cable, pneumatic tubing, hydraulic tubing, or hybrid connector assemblies including two or more of the items listed above.

[0046] Although the present invention has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, various modifications may be made to adapt a particular situation or material to the teachings of the present invention without departing from its broad scope. Therefore, the present invention is not intended to be limited to the disclosed embodiment or embodiments, but is intended to include all embodiments falling within the scope of the appended claims.

Claims

1. An electrical connector assembly (100), comprising: an electrical terminal (102) having a connection portion (104) configured to interface with a corresponding mating electrical connector, and an attachment portion (106) configured to interface with a cable, wherein the connection portion (104) is angled relative to the attachment portion (106); a cylindrical inner housing (110) formed of a polymer material, wherein the connecting portion (104) of the electrical terminal (102) is disposed; as well as an outer connector housing (112) formed of a polymeric material, the outer connector housing (112) having a smooth bore (114) configured to receive an inner housing sleeve (110) containing the electrical terminal (102), wherein the bore (114) and the inner housing sleeve (110) are sized to provide an interference fit when the inner housing sleeve (110) is received within the bore (114), The inner housing sleeve (110) has a curved first rib (124) and a curved second rib (126) radially extending from the inner housing sleeve (110), and the sizes of the first rib (124) and the second rib (126) are set so that when the inner housing sleeve (110) is received in the hole (114), the inner housing sleeve (110) and the hole (114) are in an interference fit state; The first rib (124) defines a raised ridge (130) extending across the first rib (124); The electrical connector assembly (100) is assembled through the following process, including: arranging the attachment portion (106) of the electrical terminal (102) at any angle relative to the outer connector housing (112); inserting the inner housing sleeve (110) into the hole (114) of the outer connector housing (112); and The inner housing sleeve (110) is attached to the outer connector housing (112) by welding the raised ridge (130) of the inner housing sleeve (110) to the outer connector housing (112), wherein the smooth bore (114) and the flat rear surface (118) of the outer connector housing (112) cooperate with the curved first rib (124) and the curved second rib (126) of the inner housing sleeve (110) to allow the attachment portion (106) of the electrical terminal (102) to be arranged at any radial angle relative to the outer connector housing (112).

2. The electrical connector assembly (100) according to claim 1, characterized in that The welding is performed by selectively melting a portion of the polymer material of the inner housing sleeve (110) and a portion of the polymer material of the outer connector housing (112).

3. The electrical connector assembly (100) according to claim 1, characterized in that The welding is performed using a sonic welding process.

4. The electrical connector assembly (100) according to claim 1, characterized in that The connecting portion (104) is angled perpendicularly relative to the attachment portion (106).

5. The electrical connector assembly (100) according to claim 1, characterized in that The inner housing sleeve (110) and the outer connector housing (112) are formed from the same polymer material.

6. The electrical connector assembly (100) according to claim 5, characterized in that The polymer material forming the inner housing sleeve (110) and the outer connector housing (112) is a 20% glass filled polybutylene terephthalate material.

7. A method (200) of assembling an electrical connector assembly (100), the electrical connector assembly (100) comprising: An electrical terminal (102) having a connection portion (104) configured to interface with a corresponding mating electrical connector and an attachment portion (106) configured to interface with a cable, wherein the connection portion (104) is angled relative to the attachment portion (106); a cylindrical inner housing (110) formed of a polymeric material in which the connection portion (104) of the electrical terminal is disposed, and an outer connector housing (112) formed of a polymeric material, the outer connector housing (112) having a smooth bore (114) configured to receive the inner housing (110) containing the electrical terminal (102), and wherein the bore (114) and the inner housing (110) are sized such that the inner housing (110) is in an interference fit when received within the bore (114). The inner housing sleeve (110) has a curved first rib (124) and a curved second rib (126) radially extending from the inner housing sleeve (110), and the sizes of the first rib (124) and the second rib (126) are set so that when the inner housing sleeve (110) is received in the hole (114), the inner housing sleeve (110) and the hole (114) are in an interference fit state; The first rib (124) defines a raised ridge (130) extending across the first rib (124); The method (200) comprises: arranging the attachment portion (106) of the electrical terminal (102) at any angle relative to the outer connector housing (112); inserting (202) the inner housing sleeve (110) into the aperture (114) of the outer connector housing (112); and The inner housing sleeve (110) is attached (204) to the outer connector housing (112) by welding the raised ridge (130) of the inner housing sleeve (110) to the outer connector housing (112), wherein the smooth bore (114) and the flat rear surface (118) of the outer connector housing (112) cooperate with the curved first rib (124) and the curved second rib (126) of the inner housing sleeve (110) to allow the attachment portion (106) of the electrical terminal (102) to be arranged at any radial angle relative to the outer connector housing (112).

8. The method (200) according to claim 7, characterized in that: Further including: A portion of the polymer material of the inner housing sleeve (110) and a portion of the polymer material of the outer connector housing (112) are selectively melted (206).

9. The method (200) according to claim 7, characterized in that The welding is performed using a sonic welding process.

10. The method (200) according to claim 7, characterized in that The inner housing sleeve (110) and the aperture (114) are configured to allow the attachment portion (106) to be positioned in any radial orientation relative to a longitudinal axis (X) of the aperture (114) prior to the attaching step (204).

11. The method (200) according to claim 7, characterized in that The connecting portion (104) is angled perpendicularly relative to the attachment portion (106).

12. A coaxial connector assembly (100), comprising: A coaxial terminal (102) having a connecting portion (104) extending along a first axis (X), the connecting portion (104) being configured to mate with a corresponding mating coaxial connector, and an attachment portion (106) extending along a second axis (Y) and attached to a coaxial cable, wherein the first axis (X) is arranged at a ninety-degree angle relative to the second axis (Y); a cylindrical inner housing (110) formed of a polymer material, wherein the connecting portion (104) of the coaxial terminal (102) is disposed; as well as an outer connector housing (112) formed of a polymeric material, the outer connector housing (112) having a bore (114) extending therethrough along a first axis (X), a first side extending parallel to the first axis (X), and a second side extending parallel to the first axis (X) and disposed generally perpendicular to the first side, wherein the inner housing sleeve (110) has a curved first rib (124) and a curved second rib (126) extending radially therefrom, the first rib (124) and the second rib (126) being sized to provide an interference fit between the inner housing sleeve (110) and the bore (114) when the inner housing sleeve (110) is received therein, and wherein the first rib (124) defines a raised ridge (130) extending across the first rib (124); as well as The inner housing sleeve (110) is secured within the outer connector housing (112) by welding the raised ridge (130) of the inner housing sleeve (110) to the outer connector housing (112) such that the second axis (Y) of the attachment portion (106) is non-parallel to the first side of the outer connector housing (112) and non-parallel to the second side of the outer connector housing (112).

13. The coaxial connector assembly (100) according to claim 12, characterized in that: The inner surface of the hole (114) is smooth.

14. The coaxial connector assembly (100) according to claim 12, characterized in that The first rib (124) is sonic welded to the outer connector housing (112).

Images