Electrical connector assembly and method of manufacturing the same using an additive manufacturing process

Abstract

An electrical connector is presented herein. The electrical connector includes an insulator (10) formed of a dielectric material and defining a cavity (18) passing through the insulator (10). The cavity (18) has a plurality of cylindrical portions (20A, 20B, 20C). The diameter of a first cylindrical portion (20B) among the plurality of cylindrical portions (20A, 20B, 20C) is greater than the diameters of adjacent second and third cylindrical portions (20A, 20C) on each side of the first cylindrical portion (20B) among the plurality of cylindrical portions (20A, 20B, 20C). The insulator (10) is preferably formed using an additive manufacturing process, such as stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selective thermal sintering, multi-jet modeling, multi-jet fusion, electron beam melting, layered object manufacturing, or 3D printing.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. application No. 17 / 344,498, filed on June 10, 2021, the entire disclosure of which is incorporated herein by reference. Background Art

[0003] Electrical insulators configured to receive electrical terminals are typically formed from a plastic insulating material using an injection molding process. The geometry of insulator features, particularly internal features within the terminal cavity, is limited by the requirements of the injection molding process. For example, it can be difficult or impossible to create a one-piece insulator in which the diameter of an internal cavity portion is larger than the diameter of two adjacent cavity portions because the features formed in the mold required to create the cavity cannot be removed from the cavity once the plastic injected into the mold hardens. Summary of the Invention

[0004] The present patent application relates to an electrical connector assembly and a method for manufacturing the electrical connector assembly using an additive manufacturing process.

[0005] According to one or more aspects of the present disclosure, an electrical connector includes an insulator formed of a dielectric material and defining a cavity therethrough. The cavity has a plurality of cylindrical portions. A first cylindrical portion of the plurality of cylindrical portions has a diameter greater than the diameters of adjacent second and third cylindrical portions of the plurality of cylindrical portions on either side of the first cylindrical portion.

[0006] In one or more embodiments of the electrical connector according to the preceding paragraph, the cavity has a frustoconical portion.

[0007] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the insulator has bilateral symmetry about a plane extending along a longitudinal axis of the insulator.

[0008] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the insulator defines a channel extending from a side wall of the cavity to an outer wall of the insulator.

[0009] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the channel is defined on an end portion of the insulator.

[0010] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the insulator and the cavity are formed using an additive manufacturing process.

[0011] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the additive manufacturing process is selected from the list consisting of stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selective thermal sintering, multi-jet modeling, multi-jet fusion, electron beam melting, layered object manufacturing, and 3D printing.

[0012] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the insulator has a plurality of cylindrical shaped portions having different diameters.

[0013] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the insulator has a frustoconical shaped portion.

[0014] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the cavity is configured to receive and retain the electrical terminal therein.

[0015] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the cavity and the electrical terminal are configured to cooperatively receive and retain the electrical terminal within the cavity at any angular orientation relative to a longitudinal axis of the insulator.

[0016] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the electrical connector further includes an electrical terminal disposed within the cavity and a substantially cylindrical shield terminal, wherein the insulator is disposed within the shield terminal.

[0017] According to one or more aspects of the present disclosure, a method for manufacturing an electrical connector includes the steps of forming an insulator formed of a dielectric material using an additive manufacturing process, and forming a cavity extending through the insulator using the additive manufacturing process. The cavity includes a plurality of cylindrical portions formed using the additive manufacturing process. A first cylindrical portion of the plurality of cylindrical portions has a diameter greater than the diameters of adjacent second and third cylindrical portions of the plurality of cylindrical portions on either side of the first cylindrical portion.

[0018] In one or more embodiments of the method according to the preceding paragraph, the method further comprises the step of forming a frustoconical portion in the cavity using an additive manufacturing process.

[0019] In one or more embodiments of the method according to any of the preceding paragraphs, the method further comprises the step of forming a channel extending from a sidewall of the cavity to an outer wall of the insulator using an additive manufacturing process.

[0020] In one or more embodiments of the method according to any of the preceding paragraphs, the channel is defined on an end of the insulator.

[0021] In one or more embodiments of the method according to any of the preceding paragraphs, the additive manufacturing process is selected from the list consisting of stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selective thermal sintering, multi-jet modeling, multi-jet fusion, electron beam melting, layered object manufacturing, and 3D printing.

[0022] In one or more embodiments of the method according to any of the preceding paragraphs, the insulator has bilateral symmetry about a plane extending along a longitudinal axis of the insulator. The method further comprises the steps of disposing the electrical terminal in the cavity at any angular orientation relative to the longitudinal axis of the insulator and retaining the electrical terminal in the cavity.

[0023] According to one or more aspects of the present disclosure, an electrical connector assembly includes an insulator formed of a dielectric material and defining a cavity therethrough. The cavity has a plurality of cylindrical portions, and wherein a first cylindrical portion of the plurality of cylindrical portions has a diameter greater than a diameter of adjacent second and third cylindrical portions of the plurality of cylindrical portions on each side of the first cylindrical portion. The electrical connector assembly includes an electrical terminal disposed within the cavity. The insulator includes means for retaining the electrical terminal within the cavity at any angular orientation relative to a longitudinal axis of the insulator. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

[0025] Figure 1 is a perspective view of an electrical insulator according to some embodiments;

[0026] Figure 2 are electrical terminals according to some embodiments and Figure 1 Exploded view of an electrical insulator;

[0027] Figure 3 According to some embodiments Figure 1 A cross-sectional side view of an electrical insulator;

[0028] Figure 4 According to some embodiments Figure 1 A cross-sectional side view of an electrical insulator, wherein Figure 2 The electrical terminal is disposed in the cavity; and

[0029] Figure 5 is a flow chart of a method of manufacturing an electrical connector assembly according to some embodiments. DETAILED DESCRIPTION

[0030] This article describes an electrical connector having an insulator configured to contain electrical terminals. The insulator is formed of a dielectric material (such as an engineering plastic). The insulator defines a cavity that is configured to hold and retain the electrical terminals within the insulator. The cavity extends longitudinally from one end of the insulator to the other end and is oriented parallel to the longitudinal axis of the insulator. The cavity has multiple cylindrical portions with different diameters. The diameter of the first cylindrical portion is larger than the diameters of the adjacent second and third cylindrical portions of the cavity on each side of the first cylindrical portion. The cavity is formed using an additive manufacturing process, the cavity being formed so that the diameter of the first cylindrical portion is larger than the diameters of the adjacent second and third cylindrical portions on each side of the first cylindrical portion. Examples of additive manufacturing processes that can be used to manufacture the insulator include: stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selective thermal sintering, multi-jet modeling, multi-jet fusion, electron beam melting, layered object manufacturing, and 3D printing.

[0031] Figures 1-4 A specific example of a generally cylindrical insulator 10 is shown for use within a shield terminal (not shown) of a coaxial shielded electrical connector to electrically insulate a center signal terminal 12 from the shield terminal. The insulator 10 has the advantage of being small enough that up to 1,000 insulators can be produced at a time using existing additive manufacturing processes, making it cost-competitive with insulators for shielded electrical connectors produced using conventional injection molding processes.

[0032] like Figure 1 As shown, the outer surface of the insulator 10 has a plurality of cylindrical portions 14A, 14B, 14C having different diameters. The outer surface of the insulator also has a frustoconical portion 16. The insulator defines a cavity 18, which is configured to hold and retain the signal terminal 12 inside the insulator 10. The cavity 18 extends longitudinally from one end of the insulator 10 to the other end and is oriented parallel to or coaxially with the longitudinal axis X of the insulator 10. The cavity 18 has a plurality of cylindrical portions 20A, 20B, 20C, 20D having different diameters. The insulator 10 defines a plurality of channels 22 extending from the cavity 18 to the outer surface of the insulator 10. During the manufacturing process, these channels 22 serve as drains and / or vents to allow cleaning fluids used in the manufacturing process to exit the cavity 18. Some of the channels 22 are arranged on an end of the insulator 10 where the insulator 10 contacts a deposition platform (not shown) during the additive manufacturing process, thereby being used for the discharge of cleaning fluids. Figure 2As shown in FIG, the "teeth" 24 between these channels 22 on one end of the insulator 10 can also serve as crush ribs for securing the insulator 10 within the shield terminal. These channels 22 can also be placed at specific locations in the insulator 10 to tune the capacitance between the signal terminal 12 and the shield terminal to improve the RF performance of the connector assembly.

[0033] like Figure 3 As shown, the cavity 18 in the insulator 10 has various cylindrical portions 20A, 20B, 20C, 20D that are larger than the adjacent portions 20B, 20D. One cylindrical portion 20C of the cavity 18 cooperates with the resilient cantilever locking tang feature 28 on the signal terminal 12 to retain the signal terminal 12 within the cavity 18. Figure 4 In the illustrative example of FIG, when the locking tang feature 28 is inserted into the cavity 18, the locking tang feature 28 protrudes at an acute angle relative to the longitudinal axis X. When the signal terminal 12 is pushed into the cavity 18, the signal terminal 12 passes through the first cylindrical portion 20A and the second cylindrical portion 20B, which has a smaller diameter than the first cylindrical portion 20A. There is a frustoconical portion 26 of the cavity 18 positioned between the first cylindrical portion 20A and the second cylindrical portion 20B. When the terminal 12 passes through the frustoconical portion 26, the locking tang feature 28 is compressed so that the terminal 12 can fit through the smaller cylindrical portion 20B.

[0034] Without subscribing to any particular theory of operation, after passing through the frustoconical portion 26, the locking tang feature 28 of the signal terminal 12 enters the third cylindrical portion 20C of the cavity 18, which has a larger diameter than the second cylindrical portion 20B. Once within the third cylindrical portion 20C, the locking tang feature 28 returns to its original uncompressed state. Figure 4 As shown in FIG, the locking tang feature 28 engages a wall 30 of the third cylindrical portion 20C adjacent the frustoconical portion 26 and prevents the signal terminal from being removed from the cavity 18. The terminal 12 also defines a transversely extending (i.e., perpendicular to the longitudinal axis X) protrusion 32 disposed within the first cylindrical portion 20A. The protrusion 32 cooperates with the locking tang feature 28 to position the terminal within the cavity.

[0035] Because the first, second, and third cylindrical portions 20A-20C and the frusto-conical portion 26 of the cavity 18 are symmetrical about the longitudinal axis X, the signal terminal 12 can be inserted and retained within the insulator 10 at any angular orientation relative to the longitudinal axis X of the insulator 10. This is particularly beneficial when the small size of the insulator 10 and the signal terminal makes it difficult to align the terminal retention features in a particular orientation.

[0036] Although the illustrated examples relate to an insulating body 10 in a shielded coaxial connector, other embodiments of the present invention may be included in other connector types, such as an insulating multi-cavity connector body.

[0037] Figure 5 A flow chart of a method 100 for forming the electrical connector described above is shown. The method 100 comprises the following steps:

[0038] Step 102, forming an insulator from a dielectric material using an additive manufacturing process, includes forming the insulator 10 from a dielectric material using an additive manufacturing process, for example, the additive manufacturing process is selected from the list consisting of stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selective thermal sintering, multi-jet modeling, multi-jet fusion, electron beam melting, layered object manufacturing, or 3D printing;

[0039] Step 104, forming a cavity extending through the insulator using an additive manufacturing process, includes forming a cavity 18 extending through the insulator 10 using an additive manufacturing process. The cavity 18 has a plurality of cylindrical portions 20A-20D formed using the additive manufacturing process. A cylindrical portion 20C of the plurality of cylindrical portions has a diameter greater than the diameters of adjacent portions 20B, 20D on each side of the cylindrical portion 20C.

[0040] Step 106 , forming a frustoconical portion in the cavity using an additive manufacturing process, including forming the frustoconical portion 26 in the cavity using an additive manufacturing process;

[0041] Step 108, using an additive manufacturing process to form a channel extending from the sidewall of the cavity to the outer wall of the insulator, including using an additive manufacturing process to form a channel 22 extending from the sidewall of the cavity 18 to the outer wall of the insulator 10. The channel can be defined on the end of the insulator 10 and form a tooth pattern;

[0042] Step 110 , disposing the electrical terminal in the cavity, including disposing the electrical terminal 12 (such as the center signal terminal) in the cavity 18 ;

[0043] Step 112, retaining the electrical terminal within the cavity at any angular orientation relative to the longitudinal axis of the insulator, includes retaining the electrical terminal 12 within the cavity 18 at any angular orientation relative to the longitudinal axis X of the insulator 10. This is possible because the locking tang feature 28 on the terminal 12 and the insulator 10 have bilateral symmetry about a plane extending along the longitudinal axis X of the insulator; and

[0044] Step 114, placing the insulator and the electrical terminal in a generally cylindrical shield terminal, including placing the insulator 10 and the electrical terminal 12 in a generally cylindrical shield terminal (not shown);

[0045] Although the embodiments shown herein relate to an insulator 10 for a shielded electrical connector, other embodiments are contemplated in which the insulator is a connector body having a different shape, which may contain multiple cavities aligned in a linear, rectangular, or circular array.

[0046] Thus, an electrical connector and a method of manufacturing the electrical connector using an additive manufacturing process are provided. The electrical connector includes an insulator 10 that provides the benefit of receiving and retaining a terminal 12 when the terminal 12 is inserted into a cavity 18 in the insulator 10 at any angular orientation relative to the longitudinal axis X of the insulator 10. A channel 22 extending from the cavity 18 to the outer wall of the insulator 10 provides the benefit of allowing cleaning fluid to escape from the cavity 18 during the manufacturing process. When the insulator 10 is used in a coaxial shielded electrical connector application, the channel 22 also provides the benefit of tuning the capacitance between the signal terminal 12 within the insulator 10 and the shield terminal surrounding the insulator 10. The method of additively manufacturing the insulator 10 also provides the benefit of being cost-competitive with insulators manufactured using conventional injection molding techniques.

[0047] 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. Furthermore, many modifications may be made to adapt a particular situation or material to the teachings of the present invention without departing from the essential scope of the invention. Therefore, the present invention is not limited to the disclosed embodiment or embodiments, but is intended to encompass all embodiments falling within the scope of the appended claims.

Claims

1. An electrical connector, comprising: An insulator (10) formed of a dielectric material and defining a cavity (18) extending through the insulator (10), wherein the cavity (18) has a plurality of cylindrical portions (20A, 20B, 20C), and wherein a first cylindrical portion (20B) of the plurality of cylindrical portions (20A, 20B, 20C) has a diameter that is smaller than a diameter of an adjacent second and third cylindrical portions (20A, 20C) of the plurality of cylindrical portions (20A, 20B, 20C) on each side of the first cylindrical portion (20B), and wherein the cavity (18) defines a frustoconical portion (26) located between the first cylindrical portion (20B) and the second cylindrical portion (20A); and An electrical terminal (12) having a resilient cantilevered locking tang feature (28) projecting at an acute angle relative to a longitudinal axis (X) and configured to retain the electrical terminal (12) within the cavity (18), wherein the locking tang feature (28) is configured to be compressed by the frustoconical portion (26) when the electrical terminal (12) is inserted into the cavity (18) to enable the electrical terminal (12) to fit through the smaller first cylindrical portion (20B).

2. The electrical connector according to claim 1, wherein: The locking tang feature (28) is configured to return to an original, uncompressed shape of the locking tang feature (28) after the locking tang feature (28) passes through the frustoconical portion (26) and enters the third cylindrical portion (20C).

3. The electrical connector according to claim 1, wherein: The insulator (10) has bilateral symmetry about a plane extending along the longitudinal axis (X) of the insulator.

4. The electrical connector according to claim 1, wherein The insulator (10) defines a channel (22) extending from a side wall of the cavity (18) to an outer wall of the insulator.

5. The electrical connector according to claim 4, wherein: The passage (22) is defined on an end of the insulator (10).

6. The electrical connector according to claim 1, wherein: The insulator (10) and the cavity (18) are formed using an additive manufacturing process.

7. The electrical connector according to claim 6, wherein: The additive manufacturing process is selected from the list consisting of stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selective thermal sintering, multi-jet modeling, multi-jet fusion, electron beam melting, layered object manufacturing and 3D printing.

8. The electrical connector according to claim 1, wherein: The insulator (10) has a plurality of cylindrical shaped portions (14A, 14B, 14C) having different diameters.

9. The electrical connector according to claim 8, wherein: The insulator (10) has a frustoconical shaped portion (16).

10. The electrical connector according to claim 1, wherein: The electrical terminal (12) is retained within the cavity (18) at any angular orientation relative to the longitudinal axis (X) of the insulator.

11. The electrical connector according to claim 1 , further comprising: A generally cylindrical shield terminal wherein the insulator (10) is disposed within the shield terminal.

12. A method of manufacturing an electrical connector, comprising: forming an insulator (10) formed of a dielectric material using an additive manufacturing process; as well as forming a cavity (18) extending through the insulator (10) using the additive manufacturing process, wherein the cavity (18) has a plurality of cylindrical portions (20A, 20B, 20C) formed using the additive manufacturing process, and wherein a first cylindrical portion (20B) of the plurality of cylindrical portions (20A, 20B, 20C) has a diameter that is smaller than a diameter of an adjoining second and third cylindrical portions (20A, 20C) of the plurality of cylindrical portions (20A, 20B, 20C) on each side of the first cylindrical portion (20B), and wherein the cavity (18) defines a frustoconical portion (26) located between the first cylindrical portion (20B) and the second cylindrical portion (20A) formed using the additive manufacturing process; inserting an electrical terminal (12) into the second cylindrical portion (20A), wherein the electrical terminal (12) has a resilient cantilevered locking tang feature (28) projecting at an acute angle relative to the longitudinal axis (X) and configured to retain the electrical terminal (12) within the cavity (18); and When the electrical terminal (12) is inserted into the cavity (18), the locking tang feature (28) is compressed using the frustoconical portion (26) to enable the electrical terminal (12) to fit through the smaller first cylindrical portion (20B).

13. The method of claim 12, further comprising: After the locking tang feature (28) passes through the frustoconical portion (26) and enters the third cylindrical portion (20C), the locking tang feature (28) is returned to the original uncompressed shape of the locking tang feature (28).

14. The method of claim 12, further comprising: A channel (22) is formed using the additive manufacturing process to extend from a sidewall of the cavity (18) to an outer wall of the insulator.

15. The method according to claim 14, wherein The passage (22) is defined on an end of the insulator (10).

16. The method according to claim 12, wherein The additive manufacturing process is selected from the list consisting of stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selective thermal sintering, multi-jet modeling, multi-jet fusion, electron beam melting, layered object manufacturing and 3D printing.

17. The method according to claim 12, wherein The insulator (10) has bilateral symmetry about a plane extending along a longitudinal axis (X) of the insulator (10), and wherein the method further comprises: disposing an electrical terminal (12) within the cavity (18); and The electrical terminal (12) is retained within the cavity (18) at any angular orientation relative to the longitudinal axis (X) of the insulator (10).

18. The method of claim 17, further comprising: The insulator (10) and the electrical terminal (12) are disposed within a generally cylindrical shield terminal, wherein the cavity (18) and the electrical terminal (12) are configured to cooperatively receive and retain the electrical terminal (12) within the cavity (18) at any angular orientation relative to a longitudinal axis (X) of the insulator.

19. An electrical connector assembly, comprising: An insulator (10) formed of a dielectric material and defining a cavity (18) extending through the insulator (10), wherein the cavity (18) has a plurality of cylindrical portions (20A, 20B, 20C), and wherein a first cylindrical portion (20B) of the plurality of cylindrical portions (20A, 20B, 20C) has a diameter that is smaller than a diameter of an adjacent second and third cylindrical portions (20A, 20C) of the plurality of cylindrical portions (20A, 20B, 20C) on each side of the first cylindrical portion (20B), and wherein the cavity (18) defines a frustoconical portion (26) located between the first cylindrical portion (20B) and the second cylindrical portion (20A); and An electrical terminal (12) is disposed within the cavity (18), wherein the insulator (10) includes means for retaining the electrical terminal (12) within the cavity (18) at any angular orientation relative to a longitudinal axis (X) of the insulator (10), wherein when the electrical terminal (12) is inserted into the cavity (18), the means for retaining the electrical terminal (12) within the cavity (18) is compressed by the frustoconical portion (26) to enable the electrical terminal (12) to fit through the smaller first cylindrical portion (20B).

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