Electric connector and manufacturing method thereof

Abstract

The invention provides an electric connector with excellent waterproof performance and a manufacturing method of the electric connector. A method for manufacturing an electrical connector includes: a step for pressing a contact pin into a cylindrical housing and holding the contact pin by the housing; a step of pressing the housing into the outer contact and holding the housing by the outer contact; the outer contact includes a base portion holding the housing therein, a first cylindrical portion extending linearly from a front end surface of the base portion toward a front end side and contacting the outer contact of the first plug connector, and a second cylindrical portion extending linearly from the base portion toward a base end side and contacting the outer contact of the second plug connector. And a through hole which penetrates through the base part, the first cylindrical part and the second cylindrical part in the insertion and extraction direction and is internally provided with the contact pin and the housing. And forming a first sealing member for sealing a gap between the contact pin and the housing and a gap between the housing and the outer contact in the second cylindrical portion of the outer contact. The electric connector is manufactured by the manufacturing method.

Description

Technical Field

[0001] This invention generally relates to an electrical connector and a method of manufacturing the electrical connector, and more specifically, to an electrical connector for providing a coaxial connection between a plug connector for providing a coaxial cable connection to an electronic device such as a vehicle camera and a plug connector for providing a coaxial cable connection to a control device for receiving input from the electronic device. Background Technology

[0002] In recent years, in-vehicle cameras have been installed in vehicles, and the images captured by these cameras are used for autonomous driving and driver assistance systems. An in-vehicle camera typically includes a camera housing, a circuit board inside the housing, imaging elements such as a CCD (charge-coupled device) or CMOS (complementary metal-oxide-semiconductor) sensor mounted on the circuit board, and an optical system positioned in front of the imaging elements. These in-vehicle cameras are installed in various parts of the car (e.g., front bumper, rear bumper) and connect to the ECU (Electronic Control Unit) that controls the car's movements. The camera sends the captured images to the ECU and receives power and commands from it.

[0003] To provide a connection between the vehicle-mounted camera and the ECU, an electrical connection is required between a connecting cable extending from the circuit board of the vehicle-mounted camera and a connecting cable extending from the ECU. At this point, to achieve the environmental resistance requirements of the vehicle-mounted camera, such as improved connection reliability, waterproofing, and shock resistance, an electrical connector (adapter connector) is used to relay the electrical connection between the connecting cable of the vehicle-mounted camera's circuit board and the connecting cable of the ECU.

[0004] Furthermore, with the increasing pixel count of automotive cameras in recent years, the amount of data transmitted from the cameras to the ECU has increased. To transmit large amounts of data in a short time, high-frequency signals need to be exchanged between the automotive camera and the ECU, thus creating a need to improve the electrical characteristics of the connection between the automotive camera and the ECU, especially the transmission characteristics in the high-frequency band. To address this need, Patent Document 1 discloses... Figure 1 The electrical connector 500 is shown. Electrical connector 500 is an adapter connector that provides a coaxial connection between a plug connector for connecting to the end of a coaxial cable of the vehicle-mounted camera and a plug connector for connecting to the end of a coaxial cable of the ECU. It is well known that coaxial connections using coaxial cables have higher transmission characteristics in the high-frequency band compared to connections using multiple terminals. By using such a coaxial connection using coaxial cables to connect the vehicle-mounted camera and the ECU, the transmission characteristics of the connection between the vehicle-mounted camera and the ECU in the high-frequency band can be improved.

[0005] like Figure 1 As shown, the electrical connector 500 includes: a contact pin 510; a cylindrical insulating housing 520 that holds the contact pin 510 inside; a metal outer contact 530 that holds the insulating housing 520 inside; a metal flange 540 that extends outward from the outer peripheral surface of the outer contact 530; a metal cover 550 that extends from the flange 540 to surround the outer contact 530 from the outside via a gap; a through hole 560 formed in the flange 540; a fixing bolt 570; and a gasket 580 provided on the outer contact 530.

[0006] The electrical connector 500 is mounted on the support member 600 by inserting an external contact 530 into the through hole 610 formed in the plate-shaped support member 600. Thus, one end of the pin 51 and the external contact 530 is exposed relative to the left side of the support member 600 in the figure, and the other end of the pin 510 and the external contact 530 is exposed relative to the right side of the support member 600 in the figure. Therefore, by having the pins and external contacts of the plug connector connected to the coaxial cable of the vehicle camera, and the pins and external contacts of the plug connector connected to the coaxial cable of the ECU, respectively, contact the pin 510 and the external contact 530, a coaxial connection between the coaxial cable of the vehicle camera and the coaxial cable of the ECU can be provided. Furthermore, with the fixing bolt 570 inserted into the through hole 560, the electrical connector 500 is fixed on the support member 600 by pressing it into the through hole 620 formed in the support member 600. Furthermore, the gap between the through hole 610 of the support member 600 and the outer contact 530 of the electrical connector 500 is liquid-tightly sealed by the gasket 580, providing the electrical connector 500 with waterproof performance.

[0007] Thus, the gap between the through hole 610 of the support member 600 and the outer contact 530 of the electrical connector 500 is liquid-tightly sealed by the gasket 580. However, in the structure of the electrical connector 500, the gaps between the contact pin 510 and the insulating housing 520, and between the insulating housing 520 and the outer contact 530, are not liquid-tightly sealed, failing to provide waterproof performance inside the outer contact 530. The intrusion of water and dust from one side to the other inside the outer contact 530 will reduce the connection reliability and product life of the electrical connector 500.

[0008] Furthermore, with the increase in the pixel count of automotive cameras, the amount of data transmitted from the camera to the ECU is also increasing, requiring a higher communication speed between the camera and the ECU. To address this need, Mini Coaxial connectors have been introduced instead of the FAKRA standard connectors currently used in the coaxial connection between the camera and the ECU. Mini Coaxial connectors are smaller than FAKRA connectors and can transmit signals at much higher speeds.

[0009] Figure 2 A simplified cross-sectional view showing the construction of an electrical connector 700 as specified in the Mini Coaxial standard. Figure 2 The diagram shows a portion of one side of the electrical connector 700. A plug connector is connected to the side of the illustrated electrical connector 700 to a coaxial cable that communicates with an ECU (Electronic Control Unit) and an onboard camera. The miniature coaxial standard requires the following: On the side connected to the coaxial cable with the ECU, an insulating housing 730, which holds the contact pin 710 and is held within an outer contact 720, has a cylindrical retaining portion 740 that holds the contact pin 710 and a protrusion 750 that protrudes from the front end face of the retaining portion 740 toward the front end side. The protrusion 750 covers the base end portion of the exposed portion of the contact pin 710 from the outside. The miniature coaxial standard specifies the shape of the protrusion 750 and the amount of protrusion (e.g., 0.15 mm) from the retaining portion 740 toward the front end side. Thus, the miniature coaxial standard strictly specifies the construction of one side of the electrical connector 700 that connects to the plug connector connected to the coaxial cable with the ECU. Therefore, on the side connected to the coaxial cable of the ECU, no additional components can be provided inside the outer contact 720 for liquid-tightly sealing the gap between the contact pin 710 and the insulating housing 730, and the gap between the insulating housing 730 and the outer contact 720.

[0010] Furthermore, in Figure 1 In the construction of the electrical connector 500, the gaps between the fixing bolt 570 and the through hole 560 and the through hole 620 of the support member 600 are not liquid-tightly sealed, resulting in insufficient waterproof performance of the electrical connector 500. Furthermore, in the structure of the electrical connector 500, the cover 550 is formed of metal and is integrally formed with the flange 540. Therefore, when a prying operation, tilting operation, or vibration is applied to the plug connector inserted into the cover 550, the cover 550 may deform, or the flange 540 may float from the support member 600, leading to a decrease in the connection reliability of the electrical connector 500 and a reduction in product lifespan.

[0011] Existing technical documents

[0012] Patent documents

[0013] Patent Document 1: Japanese Patent Application Publication No. 2001-326017 Summary of the Invention

[0014] The problem that the invention aims to solve

[0015] In view of the above-mentioned existing problems, the present invention aims to provide an electrical connector with excellent waterproof performance and a method for manufacturing the electrical connector.

[0016] Solution for solving the problem

[0017] Such an objective is achieved by the present invention as defined in (1) and (2) below.

[0018] (1) An electrical connector for providing a coaxial connection between a first plug connector inserted from a front end side and a second plug connector inserted from a base end side, characterized in that it comprises contact pins, an insulating housing, an outer contact, and a first sealing member.

[0019] The aforementioned contact pin includes: a first contact portion that extends linearly along the insertion / removal direction of the first plug connector and the second plug connector and contacts the contact pin of the first plug connector; a press-in portion that extends from the first contact portion toward the base end side; and a second contact portion that extends linearly from the press-in portion toward the base end side and contacts the contact pin of the second plug connector.

[0020] The aforementioned insulating housing comprises: a retaining portion into which the pressing portion of the stylus is pressed; a protrusion that protrudes from the front end face of the retaining portion toward the front end side and covers the base end side portion of the first contact portion of the stylus from the outside; and a through hole that passes through the retaining portion and the protrusion in the insertion / removal direction, and the stylus is inserted through the through hole.

[0021] The aforementioned external contact comprises: a base that internally holds the retaining portion of the housing; a first cylindrical portion that extends linearly from the front end face of the base toward the front end side and contacts the external contact of the first plug connector; a second cylindrical portion that extends linearly from the base toward the base end side and contacts the external contact of the second plug connector; and a through hole that penetrates the base, the first cylindrical portion, and the second cylindrical portion in the insertion / removal direction, wherein the contact pin and the housing are located internally.

[0022] The first sealing component is disposed inside the second cylindrical portion of the outer contact and seals the gap between the contact pin and the housing, as well as the gap between the housing and the outer contact.

[0023] (2) A method for manufacturing an electrical connector, which is used to provide a coaxial connection between a first plug connector inserted from the front end side and a second plug connector inserted from the base end side, characterized in that it includes the following steps:

[0024] The process of pressing a stylus into a cylindrical housing, thereby holding the stylus in place by the housing;

[0025] The process of pressing the housing into the outer contact to hold the housing is described. The outer contact includes a base that holds the housing internally; a first cylindrical portion extending linearly from the front end face of the base toward the front end side and contacting the outer contact of the first plug connector; a second cylindrical portion extending linearly from the base toward the base end side and contacting the outer contact of the second plug connector; and a through-hole of the base, the first cylindrical portion, and the second cylindrical portion penetrating in the insertion / removal direction of the first and second plug connectors, with the contact pin and the housing located internally.

[0026] The process of forming a first sealing member within the second cylindrical portion of the outer contact to seal the gap between the stylus and the housing, and the gap between the housing and the outer contact.

[0027] The effects of the invention are as follows.

[0028] In the electrical connector of this invention, the construction is not defined according to the miniature coaxial standard. A first sealing member is provided within the second cylindrical portion of the outer contact, which offers greater design freedom, to seal the gaps between the contact pin and the housing, as well as the gaps between the housing and the outer contact. Therefore, the waterproof performance of the electrical connector can be improved. Attached Figure Description

[0029] Figure 1 This is a simplified cross-sectional view of an existing electrical connector.

[0030] Figure 2 This is a simplified cross-sectional view of the construction of an electrical connector as specified in the miniature coaxial standard.

[0031] Figure 3 This is a perspective view showing the electrical connector of the present invention and a vehicle-mounted camera on which the electrical connector is mounted.

[0032] Figure 4 yes Figure 3 A 3D view of the electrical connector shown.

[0033] Figure 5 yes Figure 3 A perspective view of the electrical connector as seen from another angle.

[0034] Figure 6 yes Figure 3 The electrical connector shown is viewed from the +Z direction in a top view.

[0035] Figure 7 yes Figure 3 The electrical connector shown is viewed from the -Z direction as a top view.

[0036] Figure 8 yes Figure 6 The AA-line sectional view shown.

[0037] Figure 9 yes Figure 7 The BB line section view shown.

[0038] Figure 10 yes Figure 3 An exploded perspective view of the electrical connector shown.

[0039] Figure 11 yes Figure 10 A three-dimensional view of the base plate as seen from other angles.

[0040] Figure 12 yes Figure 10 The stylus shown is a three-dimensional view viewed from other angles.

[0041] Figure 13 yes Figure 10 The shell shown is a three-dimensional view viewed from other angles.

[0042] Figure 14 yes Figure 10 The diagram shows a cross-sectional perspective view of the shell.

[0043] Figure 15 yes Figure 10 The cross-sectional view of the external contact shown.

[0044] Figure 16 yes Figure 10 The image shown is a three-dimensional view of the cover from other angles.

[0045] Figure 17 This is a flowchart illustrating a method for manufacturing the electrical connector of the present invention.

[0046] Symbol Explanation

[0047] 1—Electrical connector; 2—Base plate; 21—Main body; 22—Through hole; 23—Fixing hole; 24—Flange; 25—Circular recess; 26—Riveting area; 3—Contact pin; 31—First contact; 32—Press-in; 321—Small diameter; 322—Large diameter; 33—Second contact; 4—Housing; 411—Small diameter; 412—Large diameter; 42—Protrusion; 43—Rib; 44—Through hole 441—First section, 442—Second section, 443—Third section, 444—Fourth section, 5—Outer contact, 51—Base, 511—Main body, 512—Retaining groove, 513—Matching protrusion, 52—First cylindrical part, 53—Second cylindrical part, 54—Through hole, 541—First section, 542—Second section, 543—Third section, 544—Fourth section, 6—Pad, 7—Cover, 71—Base 72—Cylindrical portion, 73—Through hole, 731—Straight-in portion, 732—Abutting portion, 74—Protrusion, 8a—First sealing component, 8b—Second sealing component, 8c—Third sealing component, 100—Vehicle-mounted camera, 110—Camera housing, 120—Back plate, 130—Through hole, 500—Electrical connector, 510—Contact pin, 520—Insulating housing, 530—Outer contact, 540—Flange portion, 550—Cover portion 560—Through hole, 570—Fixing bolt, 580—Gasket, 600—Support component, 610—Through hole, 620—Through hole, 700—Electrical connector, 710—Pin, 720—Outer contact, 730—Insulating housing, 740—Retaining part, 750—Protrusion, S100—Manufacturing method, S110, S120, S130, S140, S150, S160, S170—Process. Detailed Implementation

[0048] The electrical connector and its manufacturing method according to the present invention will now be described based on the preferred embodiments shown in the accompanying drawings. Furthermore, the figures referred to below are schematic diagrams prepared for illustrating the present invention. The dimensions (length, width, thickness, etc.) of the constituent elements shown in the drawings do not necessarily reflect the actual dimensions. Also, in the figures, the same or corresponding elements are labeled with the same symbols. Furthermore, in the following description, the positive direction of the Z-axis is sometimes referred to as the "front end side," the negative direction of the Z-axis as the "base end side," and the Z-direction as the "insertion / removal direction of the plug connector."

[0049] <Electrical Connectors>

[0050] First, refer to Figures 3 to 16 The electrical connector of the present invention will be described in detail. Figure 3 This is a perspective view showing the electrical connector of the present invention and a vehicle-mounted camera on which the electrical connector is mounted. Figure 4 yes Figure 3 A 3D view of the electrical connector shown. Figure 5 yes Figure 3 A perspective view of the electrical connector as seen from another angle. Figure 6 yes Figure 3 The electrical connector shown is viewed from the +Z direction in a top view. Figure 7 yes Figure 3 The electrical connector shown is viewed from the -Z direction as a top view. Figure 8 yes Figure 6 The AA-line sectional view shown.

[0051] Figure 9 yes Figure 7 The BB line section view shown. Figure 10 yes Figure 3 An exploded perspective view of the electrical connector shown. Figure 11 yes Figure 10 A three-dimensional view of the base plate as seen from other angles. Figure 12 yes Figure 10 The stylus shown is a three-dimensional view viewed from other angles. Figure 13 yes Figure 10 The shell shown is a three-dimensional view viewed from other angles. Figure 14 yes Figure 10 The diagram shows a cross-sectional perspective view of the shell. Figure 15 yes Figure 10 The cross-sectional view of the external contact shown. Figure 16 yes Figure 10 The image shown is a three-dimensional view of the cover from other angles.

[0052] like Figure 3 As shown, the electrical connector 1 of the present invention is mounted on the back plate 120 of the camera housing 110 of the vehicle-mounted camera 100 by any fixing method such as adhesive, adhesive tape, retainer, threaded parts, etc. The electrical connector 1 is an adapter connector for providing a coaxial connection between a first plug connector for coaxial cable connection to a control device such as an ECU (Electronic Control Unit) of a vehicle (not shown) and a second plug connector for coaxial cable connection to the vehicle-mounted camera 100.

[0053] One end of the coaxial cable of the control device is connected to the first plug connector, and the other end of the coaxial cable of the control device is connected to the circuit board of the control device. Similarly, one end of the coaxial cable of the vehicle-mounted camera 100 is connected to the second plug connector, and the other end of the coaxial cable of the vehicle-mounted camera 100 is connected to the circuit board of the vehicle-mounted camera 100. The first plug connector connected to the coaxial cable of the control device is connected to the electrical connector 1 from the front end side (+Z direction side). And the second plug connector connected to the coaxial cable of the vehicle-mounted camera 100 is connected to the electrical connector 1 from the base end side (-Z direction side). As a result, the electrical connector 1 provides a coaxial connection between the first plug connector connected to the coaxial cable of the control device and the second plug connector connected to the coaxial cable of the vehicle-mounted camera 100.

[0054] Figure 4 and Figure 5 The electrical connector 1 shown is an electrical connector conforming to the miniature coaxial standard. As an example, electrical connector 1 has a width of 13.4 mm in the X and Y directions and a height of 18.5 mm in the Z direction. Figures 8-10 As shown, the electrical connector 1 includes: a base plate 2; contact pins 3; a housing 4 that maintains the insulation of the contact pins 3 internally; an outer contact 5 that maintains the housing 4 internally; an annular gasket 6 mounted on the outer peripheral surface of the outer contact 5; a cover 7 that covers the outer contact 5 from the outside; and a first sealing member 8a (see reference) that seals the gaps between the components of the electrical connector 1 to provide waterproof performance. Figure 8 ), second sealing component 8b (refer to) Figure 9 ), and the third sealing component 8c (refer to Figure 8 With the electrical connector 1 assembled, the contact pin 3, housing 4, and outer contact 5 are coaxially arranged to form a coaxial structure.

[0055] like Figure 10 and Figure 11 As shown, the base plate 2 is a plate-shaped component made of a metal material such as aluminum. The base plate 2 includes: a plate-shaped main body 21; a through hole 22 formed on the main body 21; four fixing holes 23 formed on the outside of the through hole 22; a flange 24 that protrudes linearly from the front end face of the main body 21 toward the front end side (+Z direction); four circular recesses 25 formed on the base end face of the main body 21 in a manner that surrounds the four fixing holes 23 respectively; and four riveting areas 26 formed on the base end face of the main body 21 in a manner that are adjacent to the through hole 22.

[0056] The main body 21 is a plate-shaped portion having a front end face and a base end face perpendicular to the Z direction (the insertion and removal direction of the first plug connector and the second plug connector). When the electrical connector 1 is mounted on the back plate 120 of the vehicle-mounted camera 100, the base end face of the main body 21 is fixed to the back plate 120 by any fixing method such as adhesive, adhesive tape, retainer, or threaded parts. Furthermore, when the electrical connector 1 is mounted on the back plate 120 of the vehicle-mounted camera 100, the external contact 5 passes through a through hole 130 formed in the back plate 120 (see reference). Figure 3 It extends into the camera housing 110. The through hole 22 is a circular through hole formed in a straight line along the Z direction, penetrating the main body 21. Figure 8 As shown, with the outer contact 5 inserted into the through hole 22, the outer contact 5 is held by the base plate 2.

[0057] Return to Figure 10 and Figure 11 Four fixing holes 23 are arranged separately on the outside of the through hole 22 and are formed in a circular manner through the main body 21 in a straight line along the Z direction. The four fixing holes 23 are formed at equal 90-degree intervals on the outside of the through hole 22. Figure 5 As shown, the four protrusions 74 of the cover 7 are inserted through the four fixing holes 23 respectively, and are heat-pressed to the main body 21, so that the cover 7 is held by the base plate 2.

[0058] Return to Figure 10 The flange portion 24 is a square annular portion that protrudes linearly from the front end face of the main body portion 21 toward the front end side. The flange portion 24 is formed to surround the through hole 22 and four fixing holes 23 from the outside. (Example...) Figure 8 As shown, the cover 7 is fitted inside the flange 24 to support the cover 7 from the outside and prevent the cover 7 from swinging or rotating on the base plate 2.

[0059] Return to Figure 11 Four circular recesses 25 are formed on the base end face of the main body 21, respectively surrounding four fixing holes 23. Therefore, the four fixing holes 23 connect the bottom surfaces (faces opposite the base end side) of the four circular recesses 25 to the front end face of the main body 21. Four riveting regions 26 are arc-shaped recesses formed on the base end face of the main body 21, spaced at equal 90-degree angles and adjacent to the through holes 22, in a separated state. The four riveting regions 26 extend in an arc shape with a constant width and adjacent to the through holes 22. As explained below, with the outer contact 5 inserted into the through hole 22, the four riveting regions 26 are riveted inwards to press the outer contact 5 from the outside, and the outer contact 5 is fixedly held by the base plate 2.

[0060] Return to Figure 10The contact pin 3 functions as an electrical path between the contact pin of the first plug connector inserted into the electrical connector 1 from the front end side and the contact pin of the second plug connector inserted into the electrical connector 1 from the base end side. The contact pin 3 is a rod-shaped component made of a metal material such as brass. Figure 12 As shown, the contact pin 3 includes: a first contact portion 31 located at the front end and in contact with the contact pin of the first plug connector; a pressing portion 32 extending from the first contact portion 31 toward the base end and pressed into the housing 4; and a second contact portion 33 extending linearly from the pressing portion 32 toward the base end and in contact with the contact pin of the second plug connector. The first contact portion 31, the pressing portion 32, and the second contact portion 33 are formed concentrically as a single unit.

[0061] The first contact portion 31 is a cylindrical part that extends linearly along the Z direction. For example... Figure 8 As shown, with the electrical connector 1 assembled, the first contact portion 31 protrudes from the housing 4 towards the front end and is exposed within the outer contact 5. Therefore, the first contact portion 31 contacts the pins of the first plug connector inserted into the electrical connector 1 from the front end. Return to Figure 12 The pressing portion 32 is a portion that extends from the first contact portion 31 toward the base end side. The pressing portion 32 has a small diameter portion 321 that extends from the first contact portion 31 toward the base end side and a large diameter portion 322 that extends linearly from the small diameter portion 321 toward the base end side.

[0062] The small-diameter portion 321 is a cylindrical portion extending linearly from the base end of the first contact portion 31 towards the base end side. The diameter of the small-diameter portion 321 is larger than the diameter of the first contact portion 31. The large-diameter portion 322 is a cylindrical portion extending linearly from the base end of the small-diameter portion 321 towards the base end side. The diameter of the large-diameter portion 322 is larger than the diameter of the small-diameter portion 321. Furthermore, the connection between the small-diameter portion 321 and the large-diameter portion 322 forms a tapered surface whose diameter increases from the front end side towards the base end side. The second contact portion 33 is a cylindrical portion extending linearly from the base end of the large-diameter portion 322 towards the base end side. The diameter of the second contact portion 33 is smaller than the diameter of the large-diameter portion 322, but larger than the diameter of the small-diameter portion 321. Figure 8 As shown, with the electrical connector 1 assembled, the second contact portion 33 protrudes from the housing 4 toward the base end side and is exposed within the outer contact 5. Therefore, the second contact portion 33 contacts the pin of the second plug connector that is inserted into the electrical connector 1 from the base end side.

[0063] Return to Figure 10 The housing 4 is a cylindrical component made of elastic insulating materials such as liquid crystal polymer and nylon. The contact pin 3 is pressed into the housing 4 and held in place by the housing 4. Figure 13 and Figure 14As shown, the housing 4 includes: a cylindrical retaining portion 41 that holds the press-in portion 32 of the stylus 3 inside; a cylindrical protrusion 42 that protrudes from the front end face of the retaining portion 41 toward the front end side; four ribs 43 formed on the outer peripheral surface of the retaining portion 41; and a through hole 44 that extends linearly through the retaining portion 41 and the protrusion 42 in the Z direction and inserts the stylus 3.

[0064] The retaining portion 41 is a cylindrical portion into which the press-in portion 32 of the stylus 3 is pressed and held from the outside. The retaining portion 41 includes a cylindrical small-diameter portion 411 located at the front end and extending linearly along the Z direction, and a cylindrical large-diameter portion 412 extending linearly from the base end of the small-diameter portion 411 toward the base end side. The front end face of the small-diameter portion 411 and the base end face of the large-diameter portion 412 are flat surfaces orthogonal to the Z direction. Furthermore, the small-diameter portion 411 and the large-diameter portion 412 are formed concentrically as a single unit. The outer diameter of the large-diameter portion 412 is larger than the outer diameter of the small-diameter portion 411.

[0065] The protrusion 42 is a cylindrical portion formed concentrically with the small-diameter portion 411 on the front end face of the protrusion 42. The front end face of the protrusion 42 is a flat surface orthogonal to the Z direction. Furthermore, the outer diameter of the protrusion 42 is smaller than the outer diameter of the small-diameter portion 411, and gradually increases from the front end side towards the base end side. Figure 8 As shown, the protrusion 42 protrudes from the front end face of the small diameter portion 411 toward the front end side, and covers the base end side portion of the first contact portion 31 of the stylus 3 from the outside.

[0066] Return to Figure 13 Four ribs 43 are protrusions formed at equal angular intervals on the outer peripheral surface of the small-diameter portion 411 and extending linearly along the Z direction. The through hole 44 is a circular hole formed to extend linearly along the Z direction through the central portion of the retaining portion 41 and the protrusion 42. (Example) Figure 14 As shown, the through hole 44 has a first section 441, a second section 442, a third section 443, and a fourth section 444 arranged concentrically from the front end side.

[0067] The first section 441 is a cylindrical space that extends through the protrusion 42 in the Z direction and communicates with the outside. The first section 441 is defined by the inner circumferential surface of the protrusion 42 and has a constant diameter in the Z direction. Furthermore, the diameter of the first section 441 is approximately equal to the diameter of the first contact portion 31 of the stylus 3. The second section 442 is a cylindrical space located at the base end side of the first section 441 and communicates with the first section 441. The second section 442 is defined by the inner circumferential surface of the small-diameter portion 411 and has a constant diameter in the Z direction. The diameter of the second section 442 is larger than the diameter of the first section 441 and is approximately equal to the diameter of the small-diameter portion 321 of the stylus 3. Furthermore, the connection between the first section 441 and the second section 442 forms a tapered surface with a diameter that gradually increases from the front end side towards the base end side.

[0068] The third segment 443 is a cylindrical space located on the base end side of the second segment 442 and communicating with the second segment 442. The third segment 443 is defined by the inner circumferential surfaces of the small-diameter portion 411 and the large-diameter portion 412, and has a constant diameter along the Z direction. The diameter of the third segment 443 is larger than the diameter of the second segment 442, and is approximately equal to the diameter of the large-diameter portion 322 of the stylus 3. Furthermore, the connection between the second segment 442 and the third segment 443 forms a conical surface with a diameter that gradually increases from the front end side towards the base end side. The fourth segment 444 is a conical space located on the base end side of the third segment 443 and communicating with the third segment 443. The fourth segment 444 penetrates the base end surface of the large-diameter portion 412 in the Z direction and communicates with the outside. The fourth segment 444 has a conical shape with a diameter that gradually increases from the front end side towards the base end side. Furthermore, the maximum diameter of the fourth section 444, i.e. the diameter of the fourth section 444 on the base end face of the large diameter portion 412, is larger than the diameter of the large diameter portion 322.

[0069] like Figure 8 As shown, the stylus 3 is inserted into the through hole 44 of the housing 4, and the pressing part 32 of the stylus 3 is pressed into the holding part 41 of the housing 4, thereby holding the stylus 3 by the housing 4. In this state, the protrusion 42 of the housing 4 covers the base end portion of the first contact part 31 from the outside. Furthermore, the first contact part 31 of the stylus 3 is inserted into the first section 441 and protrudes towards the front end, while the second contact part 33 of the stylus 3 protrudes towards the base end from the fourth section 444.

[0070] With the stylus 3 held in place by the housing 4, the small-diameter portion 321 of the stylus 3 is pressed into the second section 442, and the large-diameter portion 322 of the stylus 3 is pressed into the third section 443. Friction between the small-diameter portion 321 and the inner circumferential surface of the small-diameter portion 411 of the designated second section 442, and friction between the large-diameter portion 322 and the inner circumferential surfaces of the small-diameter portions 411 and 412 of the designated third section 443, prevents the stylus 3 from detaching from the housing 4.

[0071] Furthermore, although the stylus 3 is pressed into the through hole 44 of the housing 4, the stylus 3 is made of a metallic material, while the housing 4 is made of an elastic insulating material. When two components made of different materials with different hardnesses are pressed together, a tiny gap is created between the two components. Therefore, a gap exists between the stylus 3 and the through hole 44 of the housing 4.

[0072] Return to Figure 10 The outer contact 5 is a cylindrical component made of a metal material such as zinc alloy. The outer contact 5 functions as an external conductor layer that holds the contact pin 3 and the housing 4 internally. Figure 10 and Figure 15 As shown, the outer contact 5 includes: a cylindrical base 51 that holds the retaining portion 41 of the housing 4 inside; a first cylindrical portion 52 extending from the base 51 toward the front end side; a second cylindrical portion 53 extending from the base 51 toward the base end side; and a through hole 54 that extends linearly through the base 51, the first cylindrical portion 52, and the second cylindrical portion 53 in the Z direction, with the contact pin 3 and the housing 4 located inside. Furthermore, the base 51, the first cylindrical portion 52, and the second cylindrical portion 53 are formed concentrically as a single unit.

[0073] The base 51 is a cylindrical portion that inserts into the through hole 22 in the base plate 2. The base 51 includes a cylindrical main body 511, a retaining groove 512 formed on the outer peripheral surface of the main body 511, and a fitting protrusion 513 protruding from the front end face of the main body 511 toward the front end side. The main body 511 is a cylindrical portion that extends linearly along the Z direction with a constant diameter. The front end face and base end face of the main body 511 are flat surfaces orthogonal to the Z direction. The retaining groove 512 is a recess formed around the outer peripheral surface of the main body 511. A gasket 6 made of an elastic material such as silicone rubber is installed inside the retaining groove 512. Figure 8 As shown, when the outer contact 5 is inserted into the through hole 22 of the base plate 2, the main body 511 is located inside the through hole 22. In this state, the gasket 6 installed in the retaining groove 512 contacts the inner circumferential surface of the through hole 22, liquid-tightly sealing the gap between the outer contact 5 and the through hole 22.

[0074] Return to Figure 10 and Figure 15 The fitting protrusion 513 is an annular portion extending from the front end face of the main body 511 toward the front end side. The fitting protrusion 513 is formed on the front end face of the main body 511 in a manner that surrounds the first cylindrical portion 52. The front end face of the fitting protrusion 513 is a flat surface orthogonal to the Z direction. Furthermore, the outer diameter of the fitting protrusion 513 is smaller than the outer diameter of the main body 511.

[0075] The first cylindrical portion 52 is a cylindrical portion extending linearly from the front end face of the main body portion 511 of the base 51 toward the front end side. The outer diameter of the first cylindrical portion 52 is smaller than the outer diameter of the main body portion 511 of the base 51 and the outer diameter of the fitting protrusion 513. The second cylindrical portion 53 is a cylindrical portion extending linearly from the base end face of the main body portion 511 of the base 51 toward the base end side. The outer diameter of the second cylindrical portion 53 is larger than the outer diameter of the first cylindrical portion 52 and smaller than the outer diameter of the base 51.

[0076] The through hole 54 is a circular hole that extends linearly through the base 51, the first cylindrical portion 52, and the second cylindrical portion 53 in the Z direction. The through hole 54 has a first segment 541, a second segment 542, a third segment 543, and a fourth segment 544 arranged concentrically from the front end side.

[0077] The first section 541 is a cylindrical space that extends linearly through the first cylindrical portion 52 in the Z direction and communicates with the outside. The first section 541 is defined by the inner circumferential surface of the first cylindrical portion 52 and has a constant diameter in the Z direction. Furthermore, the diameter of the first section 541 is slightly larger than the small diameter portion 411 of the housing 4. Therefore, when the housing 4 is held by the outer contact 5, a gap exists between the inner circumferential surface of the first cylindrical portion 52 defining the first section 541 and the small diameter portion 411.

[0078] The second section 542 is a cylindrical space located at the base end of the first section 541 and communicating with the first section 541. The second section 542 is located inside the main body 511. The second section 542 is defined by the inner circumferential surface of the main body 511 and has a constant diameter along the Z direction. The diameter of the second section 542 is approximately equal to the large diameter of the shell 4. Furthermore, the connection between the first section 441 and the second section 442 is a tapered surface whose diameter gradually increases from the front end side towards the base end side. The third section 543 is a cylindrical space located at the base end of the second section 542 and communicating with the second section 542. The third section 543 is defined by the inner circumferential surfaces of the main body 511 and the second cylindrical section 53 and has a constant diameter along the Z direction. The diameter of the third section 543 is larger than the diameter of the second section 542 and the outer diameter of the large diameter of the large diameter of the large diameter of the shell 412. Furthermore, the connection between the second segment 542 and the third segment 543 forms a flat surface orthogonal to the Z direction. The fourth segment 544 is a conical space located on the base side of the third segment 543 and connected to the third segment 543.

[0079] The housing 4 is inserted into the through hole 54 of the outer contact 5 from the base end side, and the large diameter portion 412 of the housing 4 is pressed into the second section 542. Thus, the housing 4 is held by the outer contact 5. Figure 8As shown, with the housing 4 held by the outer contact 5, the front end portion of the small-diameter portion 411 of the housing 4 is located within the first section 541, and the large-diameter portion 412 of the housing 4 is located within the second section 542. In this state, the four ribs 43 of the housing 4 abut against the connection between the first section 541 and the second section 542, and the large-diameter portion 412 contacts the second section 542. Friction between the large-diameter portion 412 and the inner circumferential surface of the main body portion 511 of the second section 542 prevents the housing 4 from detaching from the outer contact 5. Furthermore, in this state, the base end face of the large-diameter portion 412 of the housing 4 and the connection between the second section 542 and the third section 543 are approximately on the same plane.

[0080] Furthermore, although the large-diameter portion 412 of the housing 4 is pressed into the second section 542, the housing 4 is formed of an elastic insulating material, while the outer contact 5 is formed of a metallic material. As described above, when two components made of different types of materials with different hardness are pressed together, a small gap is generated between the two components. Therefore, a gap exists between the large-diameter portion 412 and the inner circumferential surface of the main body portion 511 of the second section 542. In this state, the first contact portion 31 of the stylus 3 is exposed within the first cylindrical portion 52 in a state separated from the first cylindrical portion 52, and the second contact portion 33 of the stylus 3 is exposed within the second cylindrical portion 53 in a state separated from the second cylindrical portion 53.

[0081] With the contact pin 3 and housing 4 held by the outer contact 5, the outer contact 5 is inserted from the base end side into the through hole 22 of the base plate 2. Then, the outer contact 5 is fixedly held by the base plate 2 by riveting the riveting area 26 of the base plate 2 inwards. In this state, the gasket 6 installed in the retaining groove 512 of the outer contact 5 liquid-tightly seals the gap between the base 51 of the outer contact 5 and the through hole 22.

[0082] Return to Figure 10 The cover 7 is a cylindrical component that covers the first cylindrical portion 52 of the outer contact 5 in a separated state from the outside. The cover 7 is formed of resin materials such as nylon or polyamide resin and is mounted on the base plate 2 to guide the connection of the first plug connector relative to the electrical connector 1 from the front end side. Figure 10 and Figure 16 As shown, the cover 7 has a plate-shaped base 71, a cylindrical portion 72 extending from the front end of the base 71 toward the front end side, a through hole 73 extending through the base 71 in a straight line in the Z direction, and four protrusions 74 protruding from the base end of the base 71 toward the base end side.

[0083] The base 71 is a plate-shaped portion having a planar shape corresponding to the inner space of the flange 24 of the base plate 2. With the cover 7 installed on the base plate 2, the base 71 is held within the inner space of the flange 24. The front end face and the base end face of the base 71 are flat surfaces orthogonal to the Z direction. The cylindrical portion 72 is a square cylindrical portion extending linearly from the front end face of the base 71 towards the front end side. Figure 8 As shown, with the electrical connector 1 assembled, the cylindrical portion 72 covers the first cylindrical portion 52 of the outer contact 5 from the outside in a separated state. When the first plug connector is connected to the electrical connector 1 from the front end side, the first plug connector slides on the inner circumferential surface of the cylindrical portion 72, thereby guiding the connection of the first plug connector relative to the electrical connector 1.

[0084] Furthermore, when the first plug connector is connected to the electrical connector 1, the cylindrical portion 72 supports the first plug connector from the outside. Therefore, even if a prying operation, tilting operation, or vibration is applied to the first plug connector, large displacement or vibration of the first plug connector can be prevented. Moreover, since the cover 7 is separate from the base plate 2 and is formed of a resin material that is more flexible than metal, even if a prying operation, tilting operation, or vibration is applied to the first plug connector, the elastic deformation of the cylindrical portion 72 can absorb the displacement or vibration of the first plug connector. As a result, strong loads can be prevented from being applied to the base plate 2 and the outer contact 5. Therefore, it is possible to prevent the base plate 2 from floating off the back plate 120 of the vehicle camera 100 and the outer contact 5 from deforming, thereby improving the connection reliability of the electrical connector 1 and extending the product life of the electrical connector 1.

[0085] Return to Figure 16 The through hole 73 is a circular hole formed in a straight line in the Z direction, penetrating the central portion of the base 71. The through hole 73 includes a straight section 731 extending in the Z direction and an annular abutment portion 732 protruding inward from the inner circumferential surface of the straight section 731. The straight section 731 is a circular hole extending straight in the Z direction with a constant diameter. The diameter of the straight section 731 is approximately equal to the outer diameter of the main body 511 of the outer contact 5. The abutment portion 732 is an annular portion protruding inward from the front end portion of the inner circumferential surface of the straight section 731. The inner diameter of the abutment portion 732 is smaller than the outer diameter of the main body 511 and is approximately equal to the outer diameter of the engaging protrusion 513 of the outer contact 5. Furthermore, the front end surface of the abutment portion 732 is continuous with the front end surface of the base 71.

[0086] like Figure 8As shown, with the electrical connector 1 assembled, the main body 511 of the outer contact 5 abuts against the contact portion 732 from the base end side, fitting into the straight-in portion 731, and the fitting protrusion 513 of the outer contact 5 fits into the contact portion 732. Furthermore, in this state, the base 71 of the cover 7, the front end face of the contact portion 732, and the front end face of the fitting protrusion 513 of the outer contact 5 are approximately on the same plane.

[0087] Return to Figure 16 The four protrusions 74 are cylindrical portions formed on the base end face of the base 71 at positions corresponding to the four fixing holes 23 of the base plate 2. For example... Figure 9 As shown, when the cover 7 is installed on the base plate 2, the four protrusions 74 are respectively inserted into the four fixing holes 23 and protrude towards the base end. With the cover 7 installed on the base plate 2, the four protrusions 74 are flattened by heat pressing the portions of the four protrusions 74 protruding from the main body 21 of the base plate 2 towards the base end to prevent the cover 7 from detaching from the base plate 2. Furthermore, the four protrusions 74 are formed of resin material, and the base plate 2 is formed of metal material. When heat pressing is performed between two components made of such different materials, a small gap is generated between the two components. Therefore, even after heat pressing the cover 7 onto the base plate 2, a gap exists between each protrusion 74 and its corresponding fixing hole 23.

[0088] Return to Figure 8 and Figure 9 The first sealing component 8a, the second sealing component 8b, and the third sealing component 8c are components that liquid-tightly seal the gaps between the components of the electrical connector 1. After applying a curable material such as thermosetting resin or photocurable resin to predetermined locations, a curing treatment such as heat treatment or light irradiation treatment is performed to cure the material, thereby forming the first sealing component 8a, the second sealing component 8b, and the third sealing component 8c.

[0089] like Figure 8As shown, a first sealing member 8a is disposed within the second cylindrical portion 53 of the outer contact 5, liquid-tightly sealing the gap between the large-diameter portion 322 of the contact needle 3 and the third section 443 of the through hole 44 of the housing 4, and the gap between the large-diameter portion 412 of the housing 4 and the second section 542 of the through hole 54 of the outer contact 5. The first sealing member 8a is formed within the second cylindrical portion 53 according to the following steps: A sufficient amount of curable material is applied from the base end side to the base end face of the large-diameter portion 412 located within the second cylindrical portion 53 and to the connection between the second section 542 and the third section 543, filling the gap between the large-diameter portion 322 and the third section 443, and the gap between the large-diameter portion 412 and the second section 542 with the curable material. Then, the applied curable material is cured to form the first sealing member 8a to seal the gap between the large-diameter portion 322 and the third section 443, and the gap between the large-diameter portion 412 and the second section 542. The first sealing member 8a liquid-tightly seals the gap between the contact pin 3 and the housing 4, as well as the gap between the housing 4 and the outer contact 5, within the second cylindrical portion 53. This prevents the intrusion of water, dust, water vapor, etc., from the front end side to the base end side or from the base end side to the front end side within the outer contact 5, thereby improving the waterproof performance of the electrical connector 1.

[0090] As explained in the background section, the structure of the front end portion of the electrical connector 1, which is connected to the first plug connector for connection with the coaxial cable of the control device, i.e., the first cylindrical portion 52 of the outer contact 5, is strictly regulated by the micro-coaxial standard, leaving virtually no design freedom. Therefore, according to the micro-coaxial standard, it is impossible to provide an additional sealing member such as the first sealing member 8a within the first cylindrical portion 52. On the other hand, in the electrical connector 1 of the present invention, the structure is not regulated according to the micro-coaxial standard, and the first sealing member 8a is provided within the base end portion of the electrical connector 1, i.e., the second cylindrical portion 53 of the outer contact 5, where the design freedom is higher. With this structure, the micro-coaxial standard is satisfied, and the waterproof performance of the electrical connector 1 is improved.

[0091] like Figure 9 As shown, the second sealing member 8b is disposed in each of the four circular recesses 25 formed on the base end face of the main body portion 21 of the base plate 2, and liquidally seals the gap between the protrusion 74 of the cover 7 and the circular recesses 25. Furthermore, in each figure, the portions of the four protrusions 74 protruding from the main body portion 21 toward the base end are not flattened; however, note that when the cover 7 is installed on the base plate 2, the portions of the four protrusions 74 protruding from the main body portion 21 toward the base end are flattened by heat pressing.

[0092] The second sealing member 8b is formed in each of the four circular recesses 25 according to the following steps: The four protrusions 74 of the cover 7 are heat-pressed together. With the cover 7 mounted on the base plate 2, a curable material is applied from the base end side to the bottom surface of the four circular recesses 25, filling the gap between the fixing hole 23 and the corresponding protrusion 74 in each circular recess 25. Then, the applied curable material is cured, thereby forming the second sealing member 8b in each of the four circular recesses 25 to seal the gap between the fixing hole 23 and the corresponding protrusion 74 in each circular recess 25. The second sealing member 8b liquid-tightly seals the gap between the base plate 2 and the cover 7. This prevents water, dust, water vapor, etc., from entering through the base plate 2 from the front end side to the base end side, or from the base end side to the front end side, thus improving the waterproof performance of the electrical connector 1.

[0093] Return to Figure 8 A third sealing member 8c is disposed within the cylindrical portion 72 of the cover 7, and liquid-tightly seals the gap between the mating protrusion 513 of the base 51 of the outer contact 5 and the abutment portion 732 of the through hole 73 of the cover 7. The third sealing member 8c is formed within the cylindrical portion 72 according to the following steps: A sufficient amount of curable material is applied from the front end side to the front end face of the mating protrusion 513 of the outer contact 5 and the front end faces of the base 71 and the abutment portion 732 of the cover 7, filling the gap between the mating protrusion 513 and the abutment portion 732 with the curable material. Then, the applied curable material is cured to form the third sealing member 8c to seal the gap between the mating protrusion 513 and the abutment portion 732. The third sealing member 8c liquid-tightly seals the gap between the outer contact 5 and the cover 7 within the cylindrical portion 72. Therefore, the waterproof performance of the electrical connector 1 can be improved by preventing water, dust, water vapor, etc. inside the cover 7 from entering from the front end to the base end or from the base end to the front end.

[0094] Furthermore, as described above, the gasket 6 liquid-tightly seals the gap between the base 51 of the outer contact 5 and the through hole 22 of the base plate 2. Therefore, in the electrical connector 1 of the present invention, all gaps between the components of the electrical connector 1 are liquid-tightly sealed by the gasket 6, the first sealing member 8a, the second sealing member 8b, and the third sealing member 8c. With this structure, it is possible to prevent the intrusion of water, dust, water vapor, etc., from the front end side to the base end side or from the base end side to the front end side, thereby improving the waterproof performance of the electrical connector 1.

[0095] Furthermore, in the electrical connector 1 of the present invention, the cover 7 is formed of a resin material that is more flexible than a metal material, and the cover 7 and the base plate 2 are formed separately. Therefore, when the first plug connector is connected to the electrical connector 1, even if a prying operation, tilting operation, or vibration is applied to the first plug connector, the cover 7 can elastically deform and absorb the displacement and vibration of the first plug connector. As a result, it is possible to prevent strong loads from being applied to the base plate 2 and the outer contact 5. Therefore, it is possible to prevent the base plate 2 from floating off the back plate 120 of the vehicle camera 100 and the outer contact 5 from deforming, thereby improving the connection reliability of the electrical connector 1 and further extending the product life of the electrical connector 1.

[0096] <Manufacturing Method of Electrical Connectors>

[0097] Next, the manufacturing method of the above-mentioned electrical connector 1 will be described in detail. Figure 17 This is a flowchart illustrating a method for manufacturing the electrical connector of the present invention.

[0098] The manufacturing method S100 of the electrical connector 1 of the present invention is performed by a manufacturing machine that automatically manufactures the electrical connector 1 or by an operator who manufactures it manually. First, in step S110, the contact pin 3 is held by the housing 4. Specifically, the contact pin 3 is pressed into the through hole 44 of the housing 4 from the base end side. When the small diameter portion 321 of the contact pin 3 is pressed into the second section 442 of the housing 4, and the large diameter portion 322 of the contact pin 3 is pressed into the third section 443 of the housing 4, the pressing of the contact pin 3 into the through hole 44 is completed. Figure 8 As shown, in this state, the first contact portion 31 of the stylus 3 protrudes from the holding portion 41 of the housing 4 toward the front end side, and the second contact portion 33 of the stylus 3 protrudes from the holding portion 41 toward the base end side. Furthermore, the protrusion 42 of the housing 4 covers the base end side portion of the first contact portion 31 from the outside.

[0099] Return to Figure 17 In step S120, the housing 4, which holds the contact pin 3 internally, is held by the outer contact 5. Specifically, the housing 4 is pressed into the through hole 54 of the outer contact 5 from the base end side. The four ribs 43 of the housing 4 abut against the connection between the first section 541 and the second section 542 of the outer contact 5 from the base end side, thus completing the pressing of the housing 4 into the through hole 54. Figure 8 As shown, in this state, the base end face of the large diameter portion 412 of the housing 4 and the connection between the second section 542 and the third section 543 of the outer contact 5 are approximately on the same plane.

[0100] Return to Figure 17In step S130, a first sealing member 8a is formed inside the second cylindrical portion 53 of the outer contact 5. Specifically, a sufficient amount of curable material is applied from the base end side to the base end face of the large-diameter portion 412 of the housing 4 located inside the second cylindrical portion 53 and to the connection between the second section 542 and the third section 543 of the outer contact 5, filling the gaps between the large-diameter portion 322 of the stylus 3 and the third section 443 of the housing 4, and between the large-diameter portion 412 and the second section 542 of the outer contact 5 with the curable material. Then, the applied curable material is cured to form the first sealing member 8a, thereby sealing the gaps between the large-diameter portion 322 and the third section 443, and between the large-diameter portion 412 and the second section 542. In this state, the first sealing member 8a liquid-tightly seals the gaps between the stylus 3 and the housing 4, and between the housing 4 and the outer contact 5, within the second cylindrical portion 53 of the outer contact 5. Furthermore, at any time before process S140, a gasket 6 is installed in the retaining groove 512 of the outer contact 5.

[0101] Next, in step S140, the cover 7 is installed on the outer contact 5. Specifically, the outer contact 5 is inserted into the through hole 73 of the cover 7 from the base end side. The main body 511 of the outer contact 5 abuts against the abutment portion 732 of the cover 7 from the base end side, with the body portion 511 fitted into the straight-in portion 731 of the cover 7, and the fitting protrusion 513 of the outer contact 5 fits into the abutment portion 732, thus completing the insertion of the outer contact 5 into the through hole 73. Figure 8 As shown, in this state, the base 71 and the front end face of the abutment portion 732 of the cover 7 and the front end face of the fitting protrusion 513 of the outer contact 5 are approximately on the same plane. Furthermore, the cylindrical portion 72 of the cover 7 covers the first cylindrical portion 52 of the outer contact 5 from the outside through the gap.

[0102] Return to Figure 17 In step S150, the outer contact 5 and the cover 7 are held by the base plate 2. Specifically, four protrusions 74 of the cover 7 are inserted into the four fixing holes 23 of the base plate 2, and the base 51 of the outer contact 5 is inserted into the through hole 22 of the base plate 2. The cover 7 and the outer contact 5 are placed on the front end face of the main body 21 of the base plate 2 from the front end side in this position. Then, a heat-pressing process is performed to flatten the portions of the four protrusions 74 protruding from the main body 21 towards the base end side, and the cover 7 is fixedly held by the base plate 2. Next, the riveting area 26 of the base plate 2 is riveted inward, and the outer contact 5 is fixedly held by the base plate 2. In this state, the gasket 6 installed in the retaining groove 512 of the outer contact 5 liquid-tightly seals the gap between the base 51 and the through hole 22.

[0103] Next, in step S160, a second sealing member 8b is formed in each of the four circular recesses 25 of the base plate 2. A curable material is applied from the base end side to the bottom surface of each of the four circular recesses 25, filling the gap between the fixing hole 23 in each circular recess 25 and the corresponding protrusion 74 of the base plate 2. Then, the applied curable material is cured to solidify, thereby forming the second sealing member 8b in each of the four circular recesses 25 to seal the gap between the fixing hole 23 and the corresponding protrusion 74 in each circular recess 25. The gap between the base plate 2 and the cover 7 is liquid-tightly sealed by the second sealing member 8b.

[0104] Next, in step S170, a third sealing member 8c is formed inside the cylindrical portion 72 of the cover 7. A sufficient amount of curable material is applied from the front end side to the front end face of the mating protrusion 513 of the outer contact 5, as well as the front end face of the base 71 and the abutment portion 732 of the cover 7, filling the gap between the mating protrusion 513 of the outer contact 5 and the abutment portion 732 of the cover 7. Then, the applied curable material is cured to form the third sealing member 8c, thereby sealing the gap between the mating protrusion 513 and the abutment portion 732. The third sealing member 8c liquid-tightly seals the gap between the outer contact 5 and the cover 7 inside the cylindrical portion 72 of the cover 7. The execution order of steps S160 and S170 is not particularly limited; steps S160 and S170 can be executed in any order, or simultaneously. When the formation of the first sealing component 8a, the second sealing component 8b, and the third sealing component 8c is completed, the manufacturing method S100 ends.

[0105] The electrical connector and its manufacturing method according to the present invention have been described above based on the illustrated embodiments, but the present invention is not limited thereto. The various structures of the present invention can be replaced with any structure capable of performing the same function, or any structure can be added to the various structures of the present invention.

[0106] For those skilled in the art to which this invention pertains, modifications to the structure of the electrical connector of this invention can be made without intentionally departing from the principles, ideas, and scope of this invention, and the electrical connector with the modified structure is also within the scope of this invention.

[0107] and, Figures 4 to 16 The number and type of components of the electrical connector shown are merely illustrative examples, and the present invention is not necessarily limited thereto. Adding or combining any component, or deleting any component, without departing from the principles and intent of the invention is also within the scope of this invention. Figure 17The number and types of steps in the manufacturing method of the electrical connector shown are merely illustrative examples, and the present invention is not necessarily limited thereto. Any addition or combination of steps, or deletion of steps, for any purpose without departing from the principles and intent of the present invention are also within the scope of this invention.

Claims

1. An electrical connector for providing a coaxial connection between a first plug connector inserted from a front end side and a second plug connector inserted from a base end side, characterized in that, It includes a contact pin, an insulating housing, an outer contact, and a first sealing component. The aforementioned contact pin includes: a first contact portion that extends linearly along the insertion / removal direction of the first plug connector and the second plug connector and contacts the contact pin of the first plug connector; a press-in portion that extends from the first contact portion toward the base end side; and a second contact portion that extends linearly from the press-in portion toward the base end side and contacts the contact pin of the second plug connector. The aforementioned insulating housing comprises: a retaining portion into which the pressing portion of the stylus is pressed; a protrusion that protrudes from the front end face of the retaining portion toward the front end side and covers the base end side portion of the first contact portion of the stylus from the outside; and a through hole that passes through the retaining portion and the protrusion in the insertion / removal direction, and the stylus is inserted through the through hole. The aforementioned external contact includes: a base that internally holds the aforementioned retaining portion of the aforementioned housing; and a first cylindrical portion that extends linearly from the front end face of the aforementioned base toward the aforementioned front end side and contacts the external contact of the aforementioned first plug connector. The second cylindrical portion extends linearly from the base toward the base end and contacts the outer contact of the second plug connector; and a through hole penetrates the base, the first cylindrical portion, and the second cylindrical portion in the insertion / removal direction, with the contact pin and the housing located inside. The first sealing component is disposed inside the second cylindrical portion of the outer contact and seals the gap between the contact pin and the housing, as well as the gap between the housing and the outer contact.

2. The electrical connector according to claim 1, characterized in that, The first sealing component seals the gap between the press-in portion of the stylus and the through hole of the housing, and the gap between the retaining portion of the housing and the through hole of the outer contact.

3. The electrical connector according to claim 1, characterized in that, Also includes: A metal base plate having a plate-shaped main body and a through hole formed in the main body and through the base of the external contact in the aforementioned insertion / removal direction; and A circular gasket is mounted on the outer peripheral surface of the base of the aforementioned outer contact. The gap between the base of the external contact and the through hole of the base plate is sealed by the gasket.

4. The electrical connector according to claim 1, characterized in that, It also includes a cover that covers the first cylindrical portion of the outer contact from the outside in a separated state. The cover has a plate-shaped base, a cylindrical portion extending from the front end face of the base toward the front end side, and a through hole formed in the base in such a way as to penetrate the base in the insertion / removal direction. The base of the outer contact is inserted into the through hole of the cover such that the first cylindrical portion of the outer contact protrudes from the through hole of the cover toward the front end.

5. The electrical connector according to claim 4, characterized in that, It also includes a metal base plate, which has a plate-shaped main body, a through hole formed in the main body and through the base of the external contact in the insertion / removal direction, a fixing hole formed in the main body in the insertion / removal direction, and a circular recess formed on the base end face of the main body to surround the fixing hole. The aforementioned cover also has a protrusion that protrudes from the base end face toward the base end side. The protrusion of the cover is inserted into the fixing hole of the base plate.

6. The electrical connector according to claim 5, characterized in that, It also includes a second sealing component, which is disposed in the circular recess of the base plate and seals the gap between the protrusion of the cover and the fixing hole of the base plate.

7. The electrical connector according to claim 4, characterized in that, It also includes a third sealing component, which is disposed inside the cylindrical portion of the cover and seals the gap between the base of the outer contact and the through hole of the cover.

8. A method for manufacturing an electrical connector, characterized in that, it provides a coaxial connection between a first plug connector inserted from a front end side and a second plug connector inserted from a base end side. The process includes the following steps: The process of pressing a stylus into a cylindrical housing, thereby holding the stylus in place by the housing; The process of pressing the housing into the outer contact to hold the housing is described. The outer contact includes a base that holds the housing internally; a first cylindrical portion extending linearly from the front end face of the base toward the front end side and contacting the outer contact of the first plug connector; a second cylindrical portion extending linearly from the base toward the base end side and contacting the outer contact of the second plug connector; and a through hole penetrating the base, the first cylindrical portion, and the second cylindrical portion in the insertion / removal direction of the first and second plug connectors, with the contact pin and the housing located inside. The process of forming a first sealing member within the second cylindrical portion of the outer contact to seal the gap between the stylus and the housing, and the gap between the housing and the outer contact.

9. The method for manufacturing an electrical connector according to claim 8, characterized in that, The aforementioned contact pin includes: a first contact portion that extends linearly along the insertion / removal direction and contacts the contact pin of the first plug connector; a press-in portion that extends from the first contact portion toward the base end side; and a second contact portion that extends linearly from the press-in portion toward the base end side and contacts the contact pin of the second plug connector. The housing includes: a retaining portion into which the pressing portion of the stylus is pressed; a protrusion that protrudes from the front end face of the retaining portion toward the front end side and covers the base end side portion of the first contact portion of the stylus from the outside; and a through hole that passes through the retaining portion and the protrusion in the insertion / removal direction, and the stylus is inserted through the through hole. The first sealing member seals the gap between the press-in portion of the stylus and the through hole of the housing, and the gap between the retaining portion of the housing and the through hole of the external contact, within the second cylindrical portion of the external contact.

10. The method for manufacturing an electrical connector according to claim 9, characterized in that, The aforementioned press-in portion of the stylus has a small-diameter portion extending from the first contact portion toward the base end side and a large-diameter portion extending linearly from the small-diameter portion toward the base end side. The retaining portion of the aforementioned housing includes a small-diameter portion located at the aforementioned front end side and a large-diameter portion extending from the base end of the aforementioned small-diameter portion toward the aforementioned base end side. The through hole of the aforementioned housing includes a section in which the large-diameter portion of the aforementioned stylus is pressed in. The through hole of the aforementioned external contact includes a section into which the large-diameter portion of the aforementioned housing is pressed. The first sealing member seals the gap between the large-diameter portion of the stylus and the section of the through hole of the housing, and the gap between the large-diameter portion of the housing and the section of the through hole of the external contact, within the second cylindrical portion of the external contact.

11. The method for manufacturing an electrical connector according to claim 8, characterized in that, It also includes the following processes: The process of installing a cover that separates the outer portion of the first cylindrical part from the outside onto the outer contact; and The process of holding the aforementioned outer contact and the aforementioned cover by a metal base plate.

12. The method for manufacturing an electrical connector according to claim 11, characterized in that, The aforementioned base plate comprises: a plate-shaped main body portion; a through hole formed in the main body portion such that it is inserted through the main body portion in the insertion / removal direction, and the base portion of the external contact is inserted through the through hole; a fixing hole formed in the main body portion such that it is inserted through the main body portion in the insertion / removal direction; and a circular recess formed on the base end face of the main body portion such that it surrounds the fixing hole. The cover comprises: a plate-shaped base; a cylindrical portion extending from the front end face of the base toward the front end side; a through hole formed in the base in such a way as to penetrate the base in the insertion / removal direction; and a protrusion protruding from the base end face of the base toward the base end side.

13. The method for manufacturing an electrical connector according to claim 12, characterized in that, The process of holding the outer contact and the cover by the base plate includes the following steps: The process of placing the cover and the outer contact onto the front end face of the main body of the base plate from the front end side in such a manner that the protrusion of the cover is inserted into the fixing hole of the base plate and the base of the outer contact is inserted into the through hole of the base plate; and The process involves performing a heat-pressing process to flatten the portion of the protrusion of the cover protruding from the fixing hole of the base plate toward the base end, thereby fixing the cover in place by the base plate.

14. The method for manufacturing an electrical connector according to claim 12, characterized in that, Before the step of installing the outer contact and the cover onto the outer contact, the method further includes a step of installing an annular gasket on the outer peripheral surface of the base of the outer contact. The aforementioned gasket seals the gap between the base of the aforementioned external contact and the aforementioned through hole in the aforementioned base plate.

15. The method for manufacturing an electrical connector according to claim 14, characterized in that, The base of the aforementioned external contact has a cylindrical main body and a retaining groove formed on the outer peripheral surface of the main body. The aforementioned gasket is installed within the aforementioned retaining groove.

16. The method for manufacturing an electrical connector according to claim 12, characterized in that, It also includes the step of forming a second sealing member in the above-mentioned circular recess to seal the gap between the above-mentioned fixing hole and the above-mentioned protrusion.

17. The method for manufacturing an electrical connector according to claim 16, characterized in that, The aforementioned base plate has four of the aforementioned fixing holes. The aforementioned cover has four protrusions that are respectively inserted into the four aforementioned fixing holes. The second sealing component seals the gap between each of the four fixing holes and the corresponding protrusion.

18. The method for manufacturing an electrical connector according to claim 12, characterized in that, It also includes the step of forming a third sealing member inside the cylindrical portion of the cover to seal the gap between the base of the outer contact and the through hole of the cover.

19. The method for manufacturing an electrical connector according to claim 18, characterized in that, The base of the aforementioned external contact has a cylindrical main body and a fitting protrusion protruding from the front end face of the main body toward the front end side. The through hole of the cover has a straight section extending from the base end of the base towards the front end and an annular abutment portion formed to protrude inward from the inner circumferential surface of the straight section. The main body of the outer contact abuts against the abutting portion from the base end side in a state of being fitted into the straight-in portion, and the fitting protrusion of the outer contact engages with the abutting portion. The third sealing component seals the gap between the fitting protrusion and the abutment.

20. An electrical connector, characterized in that, The aforementioned electrical connector is manufactured using the manufacturing method described in claim 8.

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