Electrical connector component, in particular data and power connector component and method for manufacturing the connector component

Abstract

A connector component (1), preferably a data and / or power connector component, particularly preferably an SPE connector component, comprising a housing (6) and at least one contact (14) of a cable (11) for establishing an electrical connection and / or a data connection; as well as a contact sleeve (2) for shielding the contact (14); and a contact carrier for positioning the contact (14) within the contact sleeve (2); wherein the contact sleeve (2) is designed as a deep-drawn part, preferably manufactured by progressive deep drawing, and has at least two different wall thicknesses along its longitudinal axis.

Description

[0001] The present invention relates to an electrical connector component, in particular a data and power connector component, and a method for manufacturing the connector component.

[0002] In the field of connectors, especially data and power connectors, the contact partners for contacting the two connection partners have contact areas containing precious metals.

[0003] Especially with data and power connector components, i.e., in the high-frequency range, there are critical limits regarding contact resistance requirements, which should neither be exceeded nor fallen below. Furthermore, stringent requirements are placed on the shielding of the connector.

[0004] Another important aspect is the reliable connection of the cable to the other components of a connector assembly.

[0005] Based on this preliminary consideration, the object of the present invention is to ensure a readily manufacturable and stable connection of the cable to the other components of the connector assembly and at the same time to achieve an optimization of the structural design of the connector assembly with regard to shielding.

[0006] The invention solves this problem by means of a connector component that can transmit data and / or power and preferably both, with the features of claim 1 and by a method for manufacturing it with the features of claim 12.

[0007] A connector component according to the invention can preferably be configured as a data and / or power connector component, and particularly preferably as an SPE connector component. The connector component comprises a housing and at least one contact of a cable for establishing an electrical connection and / or a data connection.

[0008] Furthermore, the connector component includes a contact sleeve for shielding the contact(s); and a contact carrier for positioning the contact(s) within the contact sleeve.

[0009] The contact sleeve can be used in particular for shielding the contact(s).

[0010] According to the invention, the contact sleeve is designed as a deep-drawn part and has at least two different wall thicknesses along its longitudinal axis. The contact sleeve can particularly preferably be formed by progressive deep drawing.

[0011] The two different wall thicknesses allow for a suitably thin wall in the contact area and a thicker wall, thus providing a more secure mechanical connection of the cable in the cable termination area. Overall, the contact sleeve improves both the insulation and fixation properties of the connector component. The thinner the wall of the contact sleeve in the contact area, the better and thicker it can be overmolded with a plastic material, as the maximum wall thickness is often specified by standards.

[0012] Further advantageous properties are the subject of the dependent claims.

[0013] It is advantageous if the contact sleeve is divided into at least three areas: a contact area, a contact carrier area, and a cable connection area, with the contact sleeve extending over all three areas. This results in particularly good overall mechanical strength and effective shielding.

[0014] The at least one contact can be flush with the contact sleeve for further improved shielding, or it can be recessed in the contact sleeve relative to an opening of the contact sleeve.

[0015] The ratio of the length of the contact sleeve to the maximum opening diameter of the end opening of the contact sleeve in the contact area should be at least 3:1, preferably at least 4:1, and particularly preferably at least 6:1. This allows the connector component to have a comparatively compact mating face while still being shielded by the contact sleeve along its entire length.

[0016] For increased mechanical stability, the terminal opening of the contact sleeve can advantageously be ellipsoidal. Furthermore, the rounded geometry exhibits better wave resistance than comparable angular sleeves.

[0017] It is also advantageous for mechanical stability if the ratio of the maximum to the minimum opening diameter of the terminal opening of the contact sleeve is a maximum of 2:1, preferably a maximum of 1.8:1.

[0018] The connector component can advantageously have a mating face which is bounded by the end opening of the contact sleeve, wherein the mating face is symmetrical, preferably mirror-symmetrical, and particularly preferably mirror-symmetrical by two mutually perpendicular mirror planes whose line of intersection is the longitudinal axis of the connector component. This ensures that the contacts are equidistant from the contact sleeve, resulting in optimal shielding.

[0019] The contact sleeve can advantageously be made of brass and / or a brass alloy, as this material exhibits particularly good deep-drawing properties for progressive deep drawing while simultaneously providing good mechanical properties for the deep-drawn part. Other conductive and deep-drawable metals are also conceivable.

[0020] The contact sleeve can have at least one, preferably several crimp deformations, particularly preferably at least three crimp deformations in the cable shield connection area, wherein said crimp deformations are each designed as a concave depression, in particular a concave embossing.

[0021] The respective concave recess, in particular the concave embossing, has a longitudinal extension perpendicular to the concave curvature, which extends parallel to the longitudinal axis of the contact sleeve. This achieves a particularly secure connection of the cable to the contact sleeve without requiring localized deformation of the contact sleeve, which would negatively affect the characteristic impedance. Thus, good shielding transmission and a high degree of sealing to the cable are ensured.

[0022] In the case of multiple crimp deformations, these can be designed to be shield-optimized and axially symmetric to the longitudinal axis of the contact sleeve, and such that two contact sleeves can be brought into alignment by rotation of less than 190°, preferably less than 95°.

[0023] A method according to the invention for manufacturing a connector component of a connector according to the invention comprising at least the following steps: I. Providing the aforementioned contact sleeve; II. Providing a cable; III. Fixing the contact sleeve to the cable, forming the plug connection component, wherein The provision of the contact sleeve comprises a progressive deep drawing process, preferably with several forming steps using several differently shaped drawing punches and dies.

[0024] Advantageous embodiments of the process are the subject of the dependent claims.

[0025] The provision can include at least one, preferably at least two, cutting operations for cutting the contact sleeve as the completion of the progressive deep drawing.

[0026] Advantageously, after fixing, a plastic injection molding process can be carried out to form a plastic coating of a contact area, a contact carrier area and a cable connection area, thus forming the plug connection component.

[0027] The shield connection from the contact sleeve of the connector component to the shield of the mating connector can be achieved, for example, via contact lamellae pushed onto the front edge of the shield sleeve or by contact tabs embossed during deep drawing. However, corresponding contact tabs can also be located only on the shield of the mating connector.

[0028] An electrical connector component according to the invention, serving as a data and power connector, is described in more detail below with reference to the following figures, using a Single Pair Ethernet connector – also called an SPE connector – as an example. The SPE connector in question is a particularly preferred embodiment of the invention. The figures show: Fig. 1 a side view of an end section of a two-core cable for data and power transmission; Fig. 2 a side view of the end area of ​​the Fig. 1 in modified form; Fig. 3 a side view of a contact sleeve placed on the end area; Fig. 4 a partial section view of the end area of ​​the Fig. 3; Fig. 5 a perspective view of the end area of ​​the Fig. 3 and Fig. 4; Fig. 6 a front view of an electrical connector component according to the invention; Fig. 7 a side view of the connector component of the Fig. 6; Fig. 8 a rear view of the plug connector component of the Fig. 7; Fig. 9 a front view of a plug connection comprising the plug connection component of the Fig. 6 and a mating connector; Fig. 10 a side view of the connector of the Fig. 9; Fig. 11 a sectional view of the plug connection of the Fig. 9 and Fig. 10; and Fig. 12 a perspective view of the plug connection of the Fig. 9-11. Fig. 13 a process scheme of a manufacturing process according to the invention.

[0029] Fig. Figure 1 shows the end section of a cable 11 for data and / or power transmission. This cable 11 has exactly two inner conductors 12, each with insulation 13 and a contact 14, in particular as a metal wire. The inner conductors 12 are preferably twisted together in pairs along the length of the cable 11. They may optionally have pair shielding, e.g., a metal shield.

[0030] The cable 11 has a typical overall shield 15, also called cable shield, e.g., in the form of a metallic or metal-containing foil or a metallic or metal-containing braid. Furthermore, the cable has a jacket 16 made of an insulating material. The aforementioned construction describes a known SPE cable.

[0031] In Fig. 2. This is prepared for connection to a connector component. For this purpose, a section of the cable is fitted with a contact carrier 17 at its end, and the protruding overall shielding 15 is folded over the outer sheath 16 as a collar.

[0032] The inner conductors 12 of the cable 11 are stripped at their ends and have the stripped metal wire in the apical region of each inner conductor 12, to which a contact 14 is crimped. The contact 14 is arranged in a contact carrier 17, which accommodates all crimped contacts. This carrier is preferably made of plastic. It serves to define the spacing and positioning of the contacts 14 of the two inner conductors 12.

[0033] The area of ​​contacts 14 projecting from contact carrier 17 is also referred to as contact area 18. The area in which the contacts 14 are arranged in contact carrier 17 is hereinafter referred to as contact carrier area 19. This in turn transitions into a cable shield connection area 20, in which the inverted overall shield 15 is arranged.

[0034] In Fig. 3-5 A metallic contact sleeve 2, designed as a shielding plate, is arranged above the in Fig. 2 prepared cables 11. The contact sleeve 2 is designed as a deep-drawn part within the scope of the present invention. It has a rear opening 3 in the plug-in direction for receiving the cable 11 and a front opening 4 for receiving a contact area of ​​a mating connector.

[0035] The contact area 18 of the cable 11 is covered by this contact sleeve 2, so that the ends of the inner conductors 12 are covered by the contact sleeve 2 in the side view of the connector component 1.

[0036] How to get directly from the Fig. 3 detects that the contact sleeve 2 extends from the cable shield connection area 20 via the contact carrier area 19 to the contact area 18.

[0037] The deep-drawing process allows the contact sleeve 2 to have varying wall thicknesses along its length. Thus, the contact sleeve can have a thinner wall thickness in the contact area 18 than in the cable shield connection area 20. This has the advantage that the contact sleeve 2 in the cable connection area 20, due to its increased wall thickness, exhibits higher mechanical resistance to deformation and therefore higher cable pull-out resistance. This enables a secure connection between the contact sleeve and the cable shield 15 through clamping or crimping.

[0038] In contrast, due to the reduction in the wall thickness of the contact sleeve 2 in the terminal area of ​​the connector component 1 or in the contact area 18, more plastic material can be used for overmolding the connector component according to the invention than with a connector component with a comparable geometric design and a contact sleeve with a uniform wall thickness, which simplifies the injection molding process and ensures a better bond of the overmolded plastic to the contact carrier area.

[0039] Another special feature of the in Fig. The advantage of the contact sleeve 2 shown in Figure 3 is that it is circumferentially closed at least in the contact area 18, and particularly preferably over its entire longitudinal extent, so that optimal shielding, in particular with optimal force distribution over the entire circumference, is achieved.

[0040] The contact sleeve 2 has one or preferably several elongated, preferably groove-like, crimp deformations 5 in the cable shield connection area 20, which extend parallel to the longitudinal axis of the cable 11. If several crimp deformations 5 are provided, the crimp area with said crimp deformations 5 is axially symmetrical to the longitudinal axis of the cable. Preferably, the crimp deformation 5 is designed as one or more concave indentations for connecting the contact sleeve to the cable shield. Particularly preferably, the crimp deformation 5 comprises at least three concave surfaces.

[0041] In contact area 18, the contact sleeve 2 has an oval cross-section perpendicular to its longitudinal axis. The contact sleeve 2, together with the end faces of the contacts 14 of the two inner conductors 12, defines a so-called mating face, which is bounded by the contact sleeve 2. The ratio of the length of the contact sleeve to the maximum opening diameter of the mating face is at least 3:1, preferably at least 4:1, and particularly preferably at least 6:1.

[0042] As previously explained, the contact sleeve 2 has a thinner wall in contact area 18 than in other areas of the contact sleeve 2. This leaves more wall thickness available for overmolding material, assuming the same target wall thickness of the connector component. Thicker walls are easier to injection mold than thinner ones, resulting in a more stable plastic overmolding of the connector component. Manufacturing requirements sometimes also necessitate a minimum overmolding thickness for the contact sleeve 2. This minimum thickness can be more easily achieved with a thinner contact sleeve 2.

[0043] Furthermore, the contact sleeve 2 has a conical transition between the contact area 18 and the contact carrier area 19.

[0044] The contact sleeve 2 is preferably made of an electrically conductive material, preferably a brass alloy. The brass alloy is particularly suitable for deep drawing and crimping.

[0045] The contact sleeve 2 can have a chamfer at the end of the contact area 18 for connection with a mating connector.

[0046] The contact sleeve 2 can be completely closed along its entire longitudinal axis. Furthermore, the contact sleeve 2 can be designed with retaining contours, such as retaining grooves or retaining lugs, in the contact area 18 for locking or clamping with the mating connector.

[0047] The plug-in face or the oval opening area of ​​the contact sleeve 2 has a preferred ratio of maximum to minimum opening diameter of not greater than 2:1.

[0048] In Fig. 6-8 is a connector component designed as a plug of an SPE data connector. In the Fig. 9-12 also shows the corresponding mating connector 30, here in the form of a socket.

[0049] The preferred variant of a plug connection formed by the plug connection component is a so-called SPE plug connection, in which the shielding and the design of the contact sleeve 2 offer particular advantages.

[0050] In the Fig. In the front view shown in Figure 6, one can first recognize the so-called plug-in face 7, encompassing the end areas of the contacts 14 and the oval opening area of ​​the contact sleeve 2 arranged around it.

[0051] Beyond the contact sleeve 2, a plastic sheath 8 is arranged, which, due to the design of the contact sleeve 2 and the resulting increased wall thickness of the plastic sheath itself, is easier to overmold. At the same time, the plastic sheath 8 exhibits higher mechanical stability and better insulation due to its greater wall thickness.

[0052] The plastic casing 8 is formed from an injection-molded material. At its edge in the contact area 18, the connector component has a locking element 9 that projects radially from the contact sleeve 2 and the plastic casing 8.

[0053] The resting agent 9 is in the variant of the Fig. 6-12 are arranged on a spring arm 10a projecting from the plastic sheath 8. An actuating element 10b, also designed as a spring arm, is arranged on the plastic sheath 8 in the opposite direction to the spring arm 10a. The spring arms and the plastic sheath form the housing 6, which encloses the contact sleeve 2, the contacts 14, and, in some areas, the entire cable 11 and the contact carrier 17.

[0054] Manual actuation of the actuating element 10b causes the spring arm 10a to be elastically deformed in the direction of the plastic sheath, generating restoring forces. This results in a deformation or relative movement of the locking element 9 and consequently in a release of the positive locking connection with a further plug-in component 30 designed as a mating connector.

[0055] The in Fig. The preferred embodiment of the invention shown in Figures 6-8 as an SPE data connector thus comprises a cable with exactly two conductors or inner conductors 12, a contact carrier 17, the contact sleeve 2 designed as a shielding plate, and the housing 20 enclosing this arrangement, which includes the plastic sheathing 8.

[0056] The contact sleeve extends from the contacts 14 of the inner conductors 12, across the contact carrier 17 and across the cable connection 20, over which the cable 11 is secured to the rest of the connector component, in particular by clamping or crimping. Both the aforementioned contacts 14 and the cable connection are covered by the contact sleeve 2.

[0057] The mating face of the connector component 1 according to the invention is preferably symmetrical. Thus, the distance between the individual contacts 14 and the contact sleeve 2 is essentially the same at the respective mirrored positions. This uniform distance is advantageous for the characteristic impedance of the connector component 1.

[0058] Fig. Figures 9-11 show a plug connection comprising the plug connection component 1 according to the invention. Fig. 6-8, which is connected to a mating connector 30 by a snap-fit ​​connection.

[0059] The mating connector 30 is partially inserted into the contact sleeve 2. The mating connector 30 also has a housing 31 and, in turn, an opening 32 corresponding to the locking element 9, into which the spring arm 10a dips and engages. The mating connector 30 has contacts 34 that protrude radially from the housing 31 relative to the longitudinal axis of the mating connector 30.

[0060] Fig. Figure 13 shows a process diagram of a method for manufacturing a plug-in connector component 1 according to the invention.

[0061] The process initially comprises the production 101 of the contact sleeve 2 by a deep drawing process in which the contact sleeve 2 is manufactured without any rework at the end of the process.

[0062] The deep drawing process comprises several forming steps with drawing punches and dies of different diameters, whereby the deformation always proceeds in the direction of the longitudinal axis.

[0063] Preferably, a metal strip serves as the starting point, the sheet thickness of which corresponds at least to the thickest point of the wall thickness of the finished shielding sheet.

[0064] In the first drawing stage 101a, a round, circular or elliptical disc is punched out of the sheet metal and deep-drawn directly into a cup shape by a first drawing die.

[0065] In a second stage 101b, the cup is then reshaped once or several times by applying a second drawing die and die, and possibly a third, fourth, etc. drawing die and die, to the deep-drawn part of the previous forming stage.

[0066] The individual forming steps of the deep drawing process can be carried out at cycle times of more than 100 strokes / minute.

[0067] The characteristic drawing ratio and the resulting number of drawing stages enable the shaping of the in Fig. 3-12 describes the geometry of the contact sleeve 2. This is also known as progressive deep drawing.

[0068] The deep drawing process can then include at least two cutting stages 101c for cutting off the base in the contact area 18 of the contact sleeve 2 and for cutting off the flange in the braid contact area 20. The flange is necessary in deep drawing to control the flow behavior of the deep drawing material during the process by means of a defined holding force.

[0069] After the final cutting stages, the contact sleeve 2 can advantageously be further processed directly into the plug connector component 1 without further processing by connecting it to the cable 11.

[0070] A special feature of the process is that the contact sleeve 2 has a higher strength than the starting material due to deep drawing, as the material is hardened during stretching.

[0071] The method further comprises providing 102 a cable, in particular an SPE cable with exactly two inner conductors 12. The provided cable 11 may already have a contact carrier 17, which is attached to or overmolded around the end-exposed contacts 14. This is in Fig. 1 shown.

[0072] Then the optional preparation 103 of the cable 11 takes place, for example by turning the cable shield inside out, so that the total shielding 15 rests on the outer surface of the jacket 16.

[0073] The contact sleeve 2 is then mounted and fixed to the cable 11, preferably by crimping or embossing.

[0074] Finally, the contact sleeve 2 is encased, preferably by injection molding, with an insulating material.

[0075] The production of the connector component 1 by deep drawing the contact sleeve 2 is thus characterized by cost-effective production in high quantities, as well as by high cycle times and output quantities and by seamless contact sleeves 2 in which the “material lines” of the structure are not destroyed or interrupted.

[0076] This is accompanied by comparatively low material usage. Furthermore, 100% inspection of a batch of contact sleeves 2 is not necessary. Process monitoring and random sampling are generally sufficient for quality assurance of these contact sleeves 2.

[0077] Costly downstream processes such as welding or die forming are generally eliminated in this manufacturing step. Since many metals are suitable for deep drawing due to their ductility, a wide range of metals can be deep drawn.

[0078] For the manufactured contact sleeves 2, comparatively high surface qualities can be achieved, so that a good bonding of the plastic material to these surfaces can take place.

[0079] Conventional deep drawing typically produces a sleeve-shaped element with a uniform wall thickness. However, progressive deep drawing allows for targeted thinning of the material in the contact area 18 and / or an increase in material strength through stretching and hardening in the cable shield connection area 20.

[0080] Typically, the raw material should be at least as thick as, or equal to, the thickest part of the deep-drawn portion after the deep-drawing process; all other areas can be thinned by stretching.

[0081] A wider strip of pre-material allows for a higher degree of material utilization. The deep-drawing process is a comparatively stable process, enabling the production of contact sleeves 2 with high precision and high cycle rates. Processes such as welding or die casting, which achieve comparable shielding, are significantly more expensive than deep drawing.

[0082] The aforementioned variants of an electrical connector component 1 and a corresponding manufacturing process with an integrated deep-drawing process are only preferred variants within the scope of an exemplary embodiment. Based on the illustrated example, a person skilled in the art can make numerous further modifications, which also fall within the scope of the invention. Reference symbol list 1 plug connector component 2 Contact sleeve 3 Opening 4 Opening 5 Crimp deformation 6 cases 7 Steckgesicht 8 plastic coating 9 Resting agents 10a Spring arm 10b Actuating element 11 cables 12 inner conductors 13 Insulation 14 Contact 15 Total shielding / cable shield 16 coat 17 contact carriers 18 Contact area 19 Contact carrier area 20 Cable shield connection area 30 Plug connector component 31 cases 32 Opening 34 contacts 101 Provision of the contact sleeve 101a first stage (cutting out and cup forming) 101b second stage (multiple transformations) 101c cutting stage 102 Providing a cable 103 Preparing a cable 104 Fixing the contact sleeve to the cable SPE Single Pair Ethernet

Claims

[1] Connector component (1), preferably a data and / or power connector component, particularly preferably an SPE connector component, comprising a housing (6) and at least one contact (14) of a cable (11) for establishing an electrical connection and / or a data connection; a contact sleeve (2) for shielding the connector component (1); and a contact carrier (17) for positioning the contact (14) within the contact sleeve (2); characterized by , that the contact sleeve (2) is designed as a deep-drawn part, preferably manufactured by progressive deep drawing, and has at least two different wall thicknesses along its longitudinal axis. [2] Plug connector component (1) according to claim 1, characterized by, that the connector component (1) has at least three areas, a contact area (18), a contact carrier area (19) and a cable connection area (20), and that the contact sleeve (2) extends over the three said areas. [3] Plug connector component (1) according to claim 1 or 2, characterized by that the contacts (14) are flush with the contact sleeve (2) or are set back in the contact sleeve (2) relative to an opening (4) of the contact sleeve (2). [4] Plug connector component (1) according to any one of the preceding claims, characterized by , that the ratio of the length of the contact sleeve (2) to the maximum opening diameter of the terminal opening (4) of the contact sleeve (2) is at least 3:1, preferably at least 4:1, particularly preferably at least 6:

1. [5] Plug connector component (1) according to any one of the preceding claims, characterized by, that the terminal opening (4) of the contact sleeve (2) is ellipsoidal. [6] Plug connector component (1) according to claim 5, characterized by , that the ratio of the maximum to the minimum opening diameter of the terminal opening (4) of the contact sleeve (2) is a maximum of 2:1, preferably a maximum of 1.8:

1. [7] Plug connector component (1) according to any one of the preceding claims, characterized by , that the connector component (1) has a plug-in face (6) which is limited by the terminal opening (4) of the contact sleeve (2), wherein the plug-in face (6) is symmetrical, preferably mirror-symmetrical, particularly preferably mirror-symmetrical by two mirror planes arranged perpendicular to each other, the intersection line of which is identical to the longitudinal axis of the contact sleeve (2). [8] Plug connector component (1) according to any one of the preceding claims, characterized by, that the contact sleeve (2) is made of brass and / or a brass alloy. [9] Plug connector component (1) according to any one of the preceding claims, characterized by , that the connector component (1) in the cable shield connection area (20) has at least one, preferably several crimp deformations (5), particularly preferably at least three crimp deformations (5), wherein said crimp deformation or said crimp deformations (5) are each designed as a concave depression, in particular a concave embossing. [10] Plug connector component (1) according to any one of the preceding claims, characterized by , that the respective concave depression, in particular the concave embossing, has a longitudinal extent perpendicular to the concave curvature, which extends parallel to the longitudinal axis of the contacting sleeve (2). [11] Plug connector (1) according to any one of the preceding claims, characterized by, that the crimp deformations (5) are axially symmetric to the longitudinal axis of the contact sleeve (2). [12] Method for manufacturing a plug connector component of a plug connection (1) according to one of the preceding claims characterized at least by the following steps: I. Providing (101) the contact sleeve (2) according to one of the preceding claims; II Providing (102) a cable (11); III. Fixing (104) the contact sleeve (2) to the cable (11), wherein the provision (101) of the contact sleeve (2) comprises a progressive deep drawing, preferably with several forming steps (101b) by several differently shaped drawing punches and dies. [13] Method according to claim 12, characterized by, that the provision (101) includes at least one, preferably at least two, cutting operations (101c) for cutting the contact sleeve (2) as completion of the progressive deep drawing. [14] Method according to one of the preceding claims 12 or 13, characterized by , that after fixing (104) a plastic injection molding forming a plastic sheath (8) of a contact area (18), a contact carrier area (19) and a cable connection area (20) forming the plug connection component (1) is included.

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