Electrical connector for automotive applications
By using a support structure design for grounding and signal conductors in the electrical connector, combined with cold welding and stamping features, the problem of unstable conductor position in automotive applications is solved, achieving constant impedance and signal reliability in vibration environments, and simplifying the manufacturing process.
Patent Information
- Application Number
- CN202511115560.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2024-08-12
- Filing Date
- 2025-08-11
- Publication Date
- 2026-02-13
AI Technical Summary
In automotive applications, the relative positions of the terminals or conductors of electrical connectors become unstable under vibration or shock, leading to impedance mismatch and signal reflection, especially in the case of differential pairs.
The design employs grounding and signal conductors within the housing, with the conductors fixed by a support structure. Combined with cold welding connections and stamping features, this ensures the stability and alignment of the conductors within the housing, reduces relative movement, and achieves constant differential impedance.
Maintaining constant impedance of differential pairs under strong vibration or shock reduces signal reflection, improves the stability and reliability of electrical connections, simplifies the installation process, and reduces manufacturing tolerances.
Smart Images
Figure CN121529261A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present invention relates to an electrical connector for automotive applications. BACKGROUND
[0002] Electrical connectors are used in automotive applications to electrically connect different modules of a vehicle. Examples include actuators, sensors and control modules. The connectors typically comprise one or more electrical terminals or conductors, a housing and related parts, which terminate a cable to provide a suitable electrical connection and disconnection. The electrical connection can support a power voltage, but can also support data lines that operate at high frequencies, e.g. up to 20 GHz. Therefore, electrical connectors for automotive applications require a housing that forms an electromagnetic shield to protect the electrical connection from the environment. Typically, such a housing also acts as a signal ground for data applications.
[0003] It is important that the relative position between the terminals or conductors and the signal ground provided, for example, by the housing or another terminal / conductor, remains stable even in the case of vibrations or shocks found in automotive applications, in particular truck applications. This is because the distance has an influence on the impedance of the terminals or conductors, but should be kept as constant as possible to avoid impedance mismatches that can cause signal reflections. Likewise, if the terminals or conductors are implemented as a differential pair, their relative distance also needs to remain stable to achieve a constant differential impedance. Again, mismatches in the differential impedance can lead to impedance mismatches and thus to signal reflections. SUMMARY
[0004] The above-mentioned aspects are solved by the electrical connector for automotive applications defined in claim 1. Advantageous embodiments are the subject of the dependent claims.
[0005] The electrical connector for automotive applications according to the invention comprises a housing, at least one signal conductor arranged at least partially in the housing and comprising a first end protruding from the housing, wherein the at least one signal conductor is electrically insulated from the housing, and at least one ground conductor arranged at least partially in the housing and comprising a first end protruding from the housing, wherein the at least one ground conductor is in electrical contact with the housing.
[0006] By having ground and signal conductors in the housing, the impedance of a differential pair or the differential impedance can remain substantially constant even in the case of strong vibrations or shocks. Furthermore, the first ends of the signal and ground conductors can be used as solder pins, so that the housing itself does not need to be soldered to attach the connector to a printed circuit board. Further advantages of the invention will be described further below.
[0007] The electrical connector according to the present application can comprise two signal conductors and two ground conductors, each conductor being configured as described above, wherein the signal conductors are arranged between the ground conductors. This arrangement enables an optimal differential impedance matching and minimizes crosstalk between the multiple coaxial and / or differential pair conductors.
[0008] The at least one signal conductor and the at least one ground conductor can be at least partially arranged in a support structure, which mechanically connects the conductors to the housing and is electrically insulating, wherein a portion of each conductor protrudes from the support structure. Thus, the support structure fixes the conductors within the housing and minimizes movements of the conductors relative to the housing, but also relative to each other, which is advantageous for a constant (differential) impedance.
[0009] The support structure can be overmolded around the at least one signal conductor and the at least one ground conductor. Overmolding is a rather cost-efficient process, which can form the support structure with very small tolerances in size and distance between the conductors.
[0010] The housing can be press-fitted onto the at least one ground conductor, preferably wherein the housing and / or the at least one ground conductor comprises a tin finish, such that a cold weld is formed by the press-fitting connection. Thus, an electrical connection with low contact resistance between the at least one ground conductor and the housing can be made without additional process steps. For example, an additional thermal soldering or brazing step can be omitted.
[0011] The connector can comprise a front ground conductor and a rear ground conductor, and a portion of the rear side of the housing can be press-fitted onto the rear ground conductor. This enables an electrical connection between the rear ground conductor and the housing. Furthermore, if the front ground conductor and the rear ground conductor are both arranged in a support structure, the front ground conductor is pressed against the front of the housing when pressure is applied to the rear ground conductor. In this way, the front ground conductor can also form a cold weld with the housing.
[0012] The housing can comprise at least one protrusion, which is adapted to rest on a printed circuit board when the electrical connector is mounted on the printed circuit board. This is particularly advantageous during the mounting of the connector to the printed circuit board, for example to press the protruding first ends of the conductors into corresponding printed circuit board holes or vias, since a high pressure applied to the printed circuit board during such a process can be distributed by the protrusion, which can avoid a breaking or cracking of the printed circuit board. Furthermore, the protrusion also stabilizes the connector in operation, in particular during vibrations or impacts.
[0013] The at least one signal conductor and / or the at least one ground conductor can be made of the same material as the housing. Thus, the housing and the conductors have the same coefficient of thermal expansion, which enables a more stable relative alignment even in case of temperature changes. This again increases the constant (differential) impedance.
[0014] The at least one signal conductor or and / or the at least one ground conductor and / or the housing can be a stamped part. Stamped features are more accurate than molded features. Thus, minimizing the role of a support structure, such as an overmold, in the positioning of the conductors will reduce tolerances and enable a more stable and narrower (differential) impedance match.
[0015] The first end of the at least one ground conductor can protrude further from the housing than the first end of the at least one signal conductor. In this way, the solder tails of the ground conductors can be used for pre-alignment when mounting the connector to a printed circuit board. Thus, a tight PCB hole around the thinner and shorter solder tails of the signal conductors can be achieved. The smaller the hole or via on the printed circuit board for the signal leads, the better the (differential) impedance match of the signal lines.
[0016] The at least one signal conductor can comprise a smaller diameter than the at least one ground conductor. As mentioned above, a small conductor diameter is beneficial for the (differential) impedance match, thereby minimizing signal reflections.
[0017] The second end of the at least one signal conductor can be adapted to electrically contact an electrical conductor of a complementary electrical connector. Thus, the second end of the signal conductor establishes electrical contact with a corresponding conductor in the complementary connector.
[0018] The second end of the at least one ground conductor can protrude from the housing. This allows positioning and alignment of the connector in a housing comprising multiple connectors as described herein. Furthermore, it allows electrical connection of the ground conductors (and optionally the housing) of one connector to another connector or multiple other connectors as described herein. For example, it is only necessary to snap a metal comb onto these protrusions, in which case the spacing between two such connectors will be very precise.
[0019] Another aspect of the invention relates to a kit comprising multiple electrical connectors as described herein. The kit can further comprise a housing, wherein the multiple electrical connectors are arranged in the housing, preferably wherein the electrical connectors are configured such that the second end of the at least one ground conductor protrudes from the housing and each ground conductor second end is received by a corresponding slot in the housing. The advantages described above and herein with respect to the connector according to the invention also apply to a kit of such connectors. BRIEF DESCRIPTION OF DRAWINGS
[0020] Possible embodiments of the invention are described in more detail in the following detailed description with reference to the drawings. The drawings show:
[0021] Figure 1A and Figure 1B : shows an embodiment of an electrical connector for automotive applications according to the invention;
[0022] Figure 2: Showed in more detail Figure 1A and Figure 1B The internal parts of the connector; and
[0023] Figure 3 : Demonstrates manufacturing Figure 1A , Figure 1B and Figure 2 An exemplary method of an exemplary embodiment of a connector. Detailed Implementation
[0024] For the sake of brevity, only a few embodiments will be described below. Those skilled in the art will recognize that the features described with reference to these specific embodiments can be modified and combined in different ways, and individual features may be omitted. The general interpretations in the foregoing sections also apply to the more detailed explanations below.
[0025] Figure 1A and Figure 1B An embodiment of an electrical connector 1 for automotive applications according to the present invention is shown. The connector 1 in this example is a data connector for automotive applications such as cars or trucks. Therefore, the connector 1 is adapted to be mounted on a printed circuit board. The connector 1 includes a housing 2. The housing is made of a metallic material to provide electrical shielding for the connector 1. Examples of suitable metallic materials include steel, copper, aluminum, and suitable alloys.
[0026] Figure 1A The internal parts of connector 1 are also shown. For illustrative and clarity reasons, these parts are shown before insertion into housing 2, while Figure 1B The finished connector 1 is shown, with its internal components inserted into the housing. These internal components include two signal conductors 3a and 3b. In other embodiments, the number of signal conductors may vary. Figure 1A and Figure 1B In the example, signal conductors 3a and 3b are designed as a differential pair, i.e., suitable for differential signal transmission, and have matched differential impedances to avoid signal reflections that are detrimental to reliable data transmission. In other examples, the conductors will form one or more coaxial transmission lines.
[0027] like Figure 1B As shown, the internal components are inserted into the housing 2, and the first ends 4a and 4b of each of the signal conductors 3a and 3b protrude from the housing 2. These ends are adapted to be received in corresponding holes or through-holes on a printed circuit board. In this way, the first ends 4a and 4b of the signal conductors 3a and 3b can be soldered to the printed circuit board. When the signal conductors 3a and 3b are arranged in the housing 2, they are electrically insulated from the housing 2. The signal conductors 3a and 3b can be made of, for example, steel, copper, aluminum, and suitable alloys. For reasons of thermal and dimensional stability, they are made of the same material as the housing 2.
[0028] The second end of the signal conductors 3a, 3b, as shown in Figure 1A , is adapted for electrical contact with electrical conductors of a complementary electrical connector. Thus, the second end of the signal conductors 3a, 3b establishes electrical contact with corresponding conductors in the complementary connector.
[0029] In the example of Figure 1A and Figure 1B , the connector further comprises two ground conductors 5a and 5b, which are arranged in the vicinity of the signal conductors 4a and 4b. Again, in other embodiments, the number of ground conductors can be different. The ground conductors 5a and 5b comprise respective first ends 6a and second ends 6b protruding from the housing 2. Like the first ends 4a and 4b of the signal conductors 3a and 3b, the first ends 6a and 6b of the ground conductors 5a and 5b are adapted to be received in corresponding holes or vias of a printed circuit board. In this way, the first ends 6a and 6b of the ground conductors 5a and 5b can be soldered to the printed circuit board. The ground conductors 5a and 5b can for example be made of steel, copper, aluminum and suitable alloys. For reasons of thermal stability and dimensional stability, they are made of the same material as the housing 2 and / or the signal conductors 3a and 3b.
[0030] Unlike the signal conductors 3a and 3b, the ground conductors 5a and 5b are in electrical contact with the housing 2. For the rear ground conductor 5b, as shown in Figure 1B , where the Figure 1A , the tab 7 of the housing 2 is closed and presses firmly against the ground conductor 5a. For example, the tab 7 can be press-fitted onto the ground conductor 5b. If the housing 2 and / or the ground conductor 5b comprises a tin finish, a cold weld can be formed by the press-fitting.
[0031] In the example of Figure 1A and Figure 1B , as shown in Figure 1B , a portion of the rear ground conductor 5b protrudes from the housing 2. This allows the connector 1 to be positioned and aligned in a housing comprising a plurality of connectors 1 as described herein. Furthermore, it allows the ground conductors 5a, 5b (and optionally the housing 2) of one connector to be electrically connected with another connector or a plurality of other connectors as described herein. For example, it is only necessary to clip a metal comb onto the protruding portion of the rear ground connector 5b, in which case the spacing between two such connectors will be very precise.
[0032] In the example of Figure 1A and Figure 1B , the diameter of the signal conductors 3a, 3b is smaller than the diameter of the ground conductors 5a, 5b. A small conductor diameter is generally advantageous for (differential) impedance matching, thereby minimizing signal reflections. In the example of Figure 1A and Figure 1BIn the exemplary embodiment of the signal conductors 3a, 3b have a rectangular cross section with dimensions of 0.285 mm by 0.285 mm. The ground conductors 5a, 5b have a rectangular cross section with dimensions of 0.5 mm by 0.55 mm.
[0033] Figure 1A and Figure 1B One particular feature of the exemplary connector 1 is that the first ends 6a, 6b of the ground conductors 5a, 5b protrude further from the housing 2 than the first ends of the signal conductors 3a and 3b. In this way, the solder tails of the ground conductors 5a, 5b can be used for pre-alignment when the connector 1 is mounted to a printed circuit board. Thus, a tight PCB hole around the thinner and shorter solder tails of the signal conductors 3a, 3b can be achieved compared to thicker ground conductors 5a, 5b.
[0034] In Figure 1A and Figure 1B The exemplary connector 1 further comprises a support structure 8 in which parts of the signal conductors 3a, 3b and the ground conductors 5a, 5b are arranged. The support structure 8 mechanically connects the conductors 3a, 3b, 5a and 5b to the housing 2 and is electrically insulating. Parts of the conductors 3a, 3b, 5a and 5b, for example their first ends 4a, 4b, 6a and 6b, protrude from the support structure 8. Thus, the support structure fixes the conductors 3a, 3b, 5a and 5b within the housing 2 and minimizes movements of the conductors 3a, 3b, 5a and 5b relative to the housing 2 and movements of the conductors relative to each other. Figure 1A and Figure 1B The support structure 8 in the exemplary embodiment is obtained by overmolding parts of the conductors 3a, 3b, 5a and 5b.
[0035] The support structure 8 also has the effect that, if the tab 7 of the housing 2 presses against the rear ground connector 5b as described above, the front ground connector 5a presses against the front side of the housing 2, thereby establishing an electrical connection between the two. If the housing 2 and / or the front ground connector 5a comprises a tin finish, a cold weld can be formed under sufficient pressure.
[0036] In Figure 1B and Figure 2 The housing 2 comprises a protrusion 11 in the exemplary embodiment, which is adapted to rest on a printed circuit board when the electrical connector 1 is mounted on the printed circuit board. This is particularly advantageous during the mounting of the connector 1 to a printed circuit board, for example to press the protruding first ends 4a, 4b, 6a and 6b of the conductors 3a, 3b, 5a and 5b into corresponding printed circuit board holes or vias, because a high pressure applied to the printed circuit board during such a process is distributed by the protrusion 11, which can avoid a breakage or fracture of the printed circuit board. Furthermore, the protrusion 11 also stabilizes the connector 1 in operation, in particular during vibrations or impacts.
[0037] It is noted that in Figure 1A the additional components, i.e. the mounting frame 9 and the spacers 10, are shown, which are auxiliary parts for manufacturing the inner parts of the connector 1, which are removed before the inner parts, i.e. the signal conductors 3a, 3b, the ground conductors 5a, 5b and the support structure 8, are inserted into the housing 2.
[0038] The at least one signal conductor or and / or the at least one ground conductor and / or the housing can be a stamped part. Stamped features are more accurate than molded features. Thus, minimizing the role of the support structure (such as an overmold) in the positioning of the conductors will reduce tolerances and achieve a more stable and narrower (differential) impedance match.
[0039] Figure 1B The inner parts of the connector 1 of Figure 2 and Figure 1A are shown in more detail. For illustrative reasons, the support structure 8 is shown as semi-transparent, so that the signal conductors 3a, 3b and the ground conductors 5a, 5b embedded in the overmolded support structure 8 can be seen. As Figure 1B depicted, the shape of the ground connectors 5a, 5b closely follows the shape of the signal connectors 3a, 3b, which facilitates the differential impedance match between the signal conductors 3a, 3b. Thus, the rear ground conductor 5b fills a considerable part of the interior of the housing 2 (as Figure 1B and Figure 2 shown). As Figure 1A , Figure 1B the additional parts, i.e. the mounting frame 9 and the spacers 10, are shown in Figure 3 and Figure 1A , which are auxiliary parts for manufacturing the inner parts of the connector 1, which are removed before the inner parts, i.e. the signal conductors 3a, 3b, the ground conductors 5a, 5b and the support structure 8, are inserted into the housing 2 (as
[0040] Figure 1B The method 100 of manufacturing the connector 1 described in Figure 2 , and is shown. In a first step 110, the signal conductors 3a, 3b and the ground conductors 5a, 5b are stamped from a metal sheet, such as steel, copper, aluminum or a suitable alloy. This is done in a single stamping step, which allows a good definition of the dimensions and mutual distances. Furthermore, stamping allows the conductors to be manufactured with minimal tolerances. In order to maintain the mutual positions between the conductors in the subsequent steps, spacers 10 are arranged between the conductors and the conductors are arranged in a mounting frame 9.
[0041] In a step 120, the signal conductors 3a and 3b are twisted 90°.
[0042] In step 130, the spacers 10 of the inner part front side of the connector are removed, i.e. the spacers between the ground conductor 5a, the signal conductor 3a, the signal conductor 3b and the ground conductor 5b are removed, in preparation for the subsequent overmolding step.
[0043] In step 140, the signal conductors 3a, 3b and the ground conductors 5a, 5b are overmolded in order to form the support structure 8.
[0044] In step 150, the spacers 10 of the bottom side of the inner part of the connector are removed, i.e. the spacers between the ground conductor 5a, the signal conductor 3a, the signal conductor 3b and the ground conductor 5b.
[0045] In step 160, the parts of the mounting frame 9 are removed in preparation for the subsequent press-fitting step.
[0046] In step 170, the inner part is press-fitted into the housing 2. The remaining parts of the mounting frame 9 and the remaining spacers 10 are removed.
[0047] Finally, in step 180, the baffle 7 is bent and press-fitted against the rear ground conductor 5b.
[0048] List of reference signs
[0049] 1 connector
[0050] 2 housing
[0051] 3a, 3b signal conductor
[0052] 4a, 4b first end of the signal conductor
[0053] 5a, 5b ground conductor
[0054] 6a, 6b first end of the ground conductor
[0055] 7 baffle
[0056] 8 support structure
[0057] 9 mounting frame
[0058] 10 spacer
[0059] 100 manufacturing method
[0060] 110 stamping
[0061] 120 twisting
[0062] 130 removing spacers
[0063] 140 overmolding
[0064] 150 removing spacers
[0065] 160 removing portions of the mounting frame
[0066] 170 press-fitting inner parts
[0067] 180 press-fitting stopper
Claims
1. An electrical connector (1) for automotive applications, comprising: Shell (2); At least one signal conductor (3a, 3b), said at least one signal conductor being at least partially disposed within said housing (2) and including a first end (4a, 4b) protruding from said housing (2), wherein said at least one signal conductor (3a, 3b) is electrically insulated from said housing (2); and At least one grounding conductor (5a, 5b) is arranged at least partially in the housing (2) and includes a first end (6a, 6b) protruding from the housing (2), wherein the at least one grounding conductor (5a, 5b) is in electrical contact with the housing.
2. The electrical connector (1) according to claim 1, characterized in that, It includes two signal conductors (3a, 3b) and two ground conductors (5a, 5b), each constructed as described in claim 1, wherein the signal conductors (3a, 3b) are arranged between the ground conductors (5a, 5b).
3. The electrical connector (1) according to any one of claims 1 or 2, characterized in that, The at least one signal conductor (3a, 3b) and the at least one ground conductor (5a, 5b) are at least partially arranged in a support structure (8) that mechanically connects the conductors to the housing (2) and is electrically insulated, wherein portions of the conductors protrude from the support structure (8).
4. The electrical connector (1) according to claim 3, characterized in that, The support structure (8) is molded around the at least one signal conductor (3a, 3b) and the at least one ground conductor (5a, 5b).
5. The electrical connector (1) according to any one of claims 1 to 4, characterized in that, The housing (2) is press-fitted onto the at least one grounding conductor (5a, 5b), preferably wherein the housing and / or the at least one grounding conductor (5a, 5b) are tin-finished such that the press-fit connection forms a cold solder joint.
6. The electrical connector (1) according to claim 5, characterized in that, The connector (1) includes a front grounding conductor (5a) and a rear grounding conductor (5b), wherein a portion of the rear side of the housing (2) is press-fitted onto the rear grounding conductor (5b).
7. The electrical connector (1) according to any one of claims 1 to 6, characterized in that, The housing (2) includes at least one protrusion (11) adapted to rest on the printed circuit board when the electrical connector (1) is mounted on the printed circuit board.
8. The electrical connector (1) according to any one of claims 1 to 7, characterized in that, The at least one signal conductor (3a, 3b) and / or the at least one ground conductor (5a, 5b) are made of the same material as the housing (2).
9. The electrical connector (1) according to any one of claims 1 to 8, characterized in that, The at least one signal conductor (3a, 3b) and / or the at least one ground conductor (5a, 5b) and / or the housing (2) are stamped parts.
10. The electrical connector (1) according to any one of claims 1 to 9, characterized in that, The first end (6a, 6b) of the at least one grounding conductor (5a, 5b) protrudes further from the housing (2) than the first end (4a, 4b) of the at least one signal conductor (3a, 3b).
11. The electrical connector (1) according to any one of claims 1 to 10, characterized in that, The diameter of the at least one signal conductor (3a, 3b) is smaller than the diameter of the at least one grounding conductor (5a, 5b).
12. The electrical connector (1) according to any one of claims 1 to 11, characterized in that, The second end of the at least one signal conductor (3a, 3b) is adapted to make electrical contact with the electrical conductor of the complementary electrical connector (2).
13. The electrical connector (1) according to any one of claims 1 to 12, characterized in that, The second end of at least one grounding conductor (5a, 5b) protrudes from the housing (2).
14. A set comprising a plurality of electrical connectors (1) according to any one of claims 1 to 13.
15. The set according to claim 14, characterized in that, It also includes a housing in which the plurality of electrical connectors (1) are arranged, preferably wherein the electrical connectors (2) are constructed as described in claim 13, and the second end of each grounding conductor (5a, 5b) is received by a corresponding slot in the housing.