Connector system and method for manufacturing a connector system

Abstract

The present invention relates to a connector system (1) comprising a connector (10) having at least one mating face (11) and a contact section (12), wherein the contact section (12) has a plurality of spring contacts (14) forming a receptacle (13) and a ribbon cable (20) comprising a plurality of conductors (24), wherein the conductors (24) are exposed to the outside in an end section (22) of the ribbon cable (20) and the spring contacts (14), when the ribbon cable (20) is joined in the receptacle (13) of the connector (10), clamp onto the conductors (24) in the end section (22) and electrically contact the conductors (24) under a clamping voltage (K). The invention further relates to a method for manufacturing a connector system (1).

Description

Technical field

[0001] The invention relates to a connector system and a method for manufacturing a connector system, wherein the method can in particular be carried out fully automatically. State of the art

[0002] In the automotive sector, several established connectors are used for electrical data transmission within a vehicle. Data transmission typically occurs via a wiring harness constructed from round cables (i.e., single wires, two-wire cables, and / or multicore cables) and / or individual conductors. However, these state-of-the-art wiring harnesses have disadvantages, such as non-automated manufacturing, a high weight due to the bulk of the conductors, and / or the ever-increasing number and size of connectors required, which is undesirable. Furthermore, individual conductors are connected to individual sockets or plugs via crimp contacts.

[0003] Document US 10,651,613 B2 relates to a connector assembly comprising at least a housing, a printed circuit board, a cable, and a cable management block. The cable, a multicore cable in the form of a round cable, is first braided into individual branches and then connected to a connector via the printed circuit board.

[0004] US Patent 10,348,032 B2 relates to a connector that is attached to the ends of multicore cables and comprises a substrate and a locator connected to the substrate. The conductors of the cables are braided and connected to the substrate.

[0005] In current technology, automated manufacturing is either nonexistent or insufficiently automated. Particularly when attempting to connect tiny multi-core cables to a substrate, such as a PCB, in an automated process, cable assemblers repeatedly encounter the limits of feasibility. As a result, the connection between the cable and the PCB is often made using conventional manual assembly. However, manual assembly is time-consuming and prone to errors. For the future, established connectors will continue to be used. However, the production of connector systems and cable harnesses should be automated to a high degree. Description of the invention

[0006] It is therefore an object of the present invention to provide a connector system including a manufacturing process that is simple in design and can be assembled or manufactured fully automatically.

[0007] The aforementioned problem is solved by a connector system according to claim 1 and a method for manufacturing a connector system according to claim 8. Further advantageous embodiments of the invention can be found in the dependent claims, the description, and the drawings.

[0008] In particular, the above-mentioned problem is solved by a connector system comprising a connector having at least one mating face and a contacting section, wherein the contacting section has a plurality of spring contacts forming a receptacle and a ribbon cable comprising a plurality of conductors, wherein the conductors in an end section of the ribbon cable are exposed to the outside and the spring contacts, in the joined state of the ribbon cable in the receptacle of the connector, clamp onto the conductors in the end section and electrically contact the conductors under a clamping voltage.

[0009] The present connector system uses a flat ribbon cable, preferably with a multi-layered construction, instead of a round cable. The conductors of the flat ribbon cable are specifically designed to function as shielded signal conductors through an outer shield and / or individual shields within the cable. Using a flat ribbon cable has the advantage that the conductors in the end section are arranged in a fixed position, allowing the flat ribbon cable to be connected to the spring contacts on the connector without the need for complex positioning of the individual conductors. The end section of the flat ribbon cable is dimensionally stable and can be easily and automatically inserted into the receptacle on the connector. Preferably, the pinout of the spring contacts is matched to the pinout of the conductors, and vice versa.In the prior art, it would be difficult to connect each individual conductor directly to a contact on the connector, especially automatically. Therefore, a substrate and / or an alignment aid is usually interposed. For the present connection, no additional component, such as a paddle card (PCB) as in the prior art, is necessary. Furthermore, the present connector system reverses the mechanical connection compared to the prior art. It is no longer necessary to fully expose all conductors of the cable and then individually arrange and connect them on a substrate. Instead, the individual conductors remain firmly connected to the ribbon cable, and the spring contacts of the connector make contact with the conductors, i.e., they press against the conductors and / or are attached to them. Exposing the conductors to the outside means that the conductors are located towards the cable sheath.are exposed from the outer sheath of the cable.

[0010] Preferably, the flat ribbon cable comprises at least a two-layer flat ribbon cable, and the flat ribbon cable extends with the majority of conductors along a first direction. The conductors are arranged in a row in a first and a second conductor layer within the flat ribbon cable. In the two-layer construction, the conductors are arranged in two layers along a second direction, transverse to the longitudinal direction or first direction. By relatively simple removal of the surrounding sheath and insulation, the conductors of the two layers can be exposed from the outside, preferably automatically, and then electrically connected.

[0011] Preferably, the mating face is configured for connection with a matching mating connector for transmitting electrical signals, and the contact section is located on a side facing away from the mating face. A side facing away from the mating face can be an opposite side or a side oriented perpendicular to the mating face, for example, rotated by 90 degrees.

[0012] Preferably, the majority of spring contacts are arranged opposite each other in a first and a second contact plane, so that the spring contacts surround the receiving area on at least two opposite sides. This surround allows the spring contacts to clamp the end section of the ribbon cable at least partially between them – which increases the clamping force and thus the pull-out force.

[0013] Preferably, the flat ribbon cable forms an insulating rib in its end section. The conductors in the first conductor layer are arranged on one side of the insulating rib, and the conductors in the second conductor layer are arranged on the opposite side of the insulating rib. The insulating rib is constructed from the insulation of the flat ribbon cable (between the conductors of the first and second conductor layers). The insulating rib provides dimensional stability to the end section, and each conductor is securely fixed. This eliminates the need to connect each conductor individually, which is a complex and time-consuming process that can only be performed manually. Instead, all conductors can be connected simultaneously, which is simpler and saves time.

[0014] Preferably, connectors and ribbon cables are directly connected without an intermediate component. Eliminating an intermediate component, such as a substrate, simplifies the design of the connector system and saves space.

[0015] Preferably, a shield contact establishes an electrical connection between the outer shield of the ribbon cable and the outer shield of the connector. The shield contact is preferably attached after the ribbon cable and connector have been joined, thus electrically connecting the outer shields. The outer shield allows, in particular, the (shielded) transmission of high-frequency signals.

[0016] The above-mentioned problem is further solved in particular by a method for manufacturing a connector system, wherein the method comprises at least the following steps: providing a connector with at least one mating face and a contacting section having a receptacle of spring contacts, providing a ribbon cable with a plurality of conductors, exposing the conductors from the outside in an end section of the ribbon cable and inserting the end section of the ribbon cable into the receptacle in the contacting section of the connector, such that the conductors in the end section are clamped by the spring contacts of the receptacle and electrically contacted under a clamping voltage.

[0017] The present method is simple and can be automated. The joining step involves inserting or sliding the ribbon cable into the receptacle on the connector, or vice versa. Due to the clamping force, the ribbon cable cannot be removed from the receptacle without considerable effort. Unintentional dislodging of the ribbon cable from the receptacle is therefore impossible.

[0018] Preferably, the method further comprises the step of permanently pressing the spring contacts onto the end section of the ribbon cable along a third direction using a pressing element, which is preferably clamped around the spring contacts after assembly. The pressing element is easy and automated to attach and prevents unintentional loosening of the connection due to material fatigue at the clamping contacts.

[0019] Preferably, the method further comprises the step of soldering the spring contacts of the connector to the conductors of the ribbon cable and / or overmolding the connector in the contact section and the ribbon cable in its end section. Soldering strengthens and secures the mechanical and electrical connection between the conductors and contacts. Overmolding secures the mechanical connection and protects the contact area and the end section from unwanted environmental influences.

[0020] The following description of embodiments is given with reference to the accompanying figures. These show: Fig. 1 a perspective view of an embodiment of a connector system in the plugged-in state; Fig. 2 a perspective view of an embodiment of a connector; Fig. 3 a perspective view of an embodiment of a flat ribbon cable; and Fig. 4 another embodiment of a connector system.

[0021] Preferred embodiments are described in detail below with reference to the accompanying figures.

[0022] Fig. Figure 1 shows an embodiment of a connector system 1 for transmitting high-frequency signals, in particular via shielded cables. The illustrated connector system 1 has at least one connector 10, which has at least one mating face 11 and a contact section 12 (see Figure 1). Fig. 2) The contacting section 12 has a plurality of spring contacts 14, which form a receptacle 13. The spring contacts 14 can, for example, include fork contacts or leaf springs. The illustrated connector system 1 further comprises a ribbon cable 20, which includes a plurality of conductors 24. The conductors 24 are exposed to the outside in an end section 22 of the ribbon cable 20 (see figure). Fig. 3) In the joined state of the ribbon cable 20 in the receptacle 13 of the connector 10, as shown in Fig. As shown in Figure 1, the spring contacts 14 clamp onto the conductors 24 in the end section 22 and electrically contact the conductors 24 under a clamping voltage K. As shown in Figure 1. Fig. As shown in Figure 1, the connector 10 and the ribbon cable 20 are directly connected to each other without an intermediate component.

[0023] Fig. Figure 2 shows an embodiment of the connector 10. In the illustrated connector 10, the mating face 11 is configured for connection with a matching mating connector for transmitting electrical signals. In the illustrated embodiment, the mating face 11 includes a USB-C interface. In other embodiments, the mating face 11 can include other interfaces. The contact section 12 is arranged on a side facing away from the mating face 11, more precisely, on the opposite side. In alternative embodiments, the contact section 12 can, for example, be oriented at a 90-degree angle to the mating face 11 and form an angled connector system. In the embodiment shown in Fig. In the connector 10 shown in Figure 2, the majority of spring contacts 14 are arranged opposite each other in a first and a second contact plane KE1, KE2. Due to this opposite arrangement, the spring contacts 14 surround the receptacle 13 from at least two opposite sides and press, in particular from two opposite sides, with a clamping force K onto the conductors 24 in the end section 22 of the ribbon cable 20.

[0024] Fig. Figure 3 shows an embodiment of a flat ribbon cable 20. The flat ribbon cable 20 shown comprises a two-layer flat ribbon cable 20, i.e., the conductors 24 are arranged in two layers along a third direction Z. The flat ribbon cable 20 extends with the majority of conductors 24 along a first direction X. The conductors 24 are arranged side by side in the flat ribbon cable 20, in a second direction Y, in a first and a second conductor plane LE1, LE2, along the third direction Z. The conductors 24 of the flat ribbon cable 20 are initially completely surrounded by insulation 26. The insulation 26 is in turn surrounded on the outside by a sheath 29, which forms the outer circumference of the flat ribbon cable 20. An outer shield 28 can be arranged between the insulation 26 and the sheath 29. The outer shield 28 can comprise a wire braid or a metallic foil or the like and serves to shield the conductors 24 from the outside.The original state of the flat ribbon cable 20 can be seen in . Fig. 3 downstream of the end section 22. The illustrated flat ribbon cable 20 forms an insulating rib 25 in the end section 22. The conductors 24 in the first conductor level LE1 are arranged on a first side S1 of the insulating rib 25, and the conductors 24 in the second conductor level LE2 are arranged on a second side S2 of the insulating rib 25 opposite the first side S1. The insulating rib 25 is formed from the insulation 26 of the flat ribbon cable 20 that has not been removed. In the illustrated embodiment, the insulation 26 between the conductors 24 of a conductor level LE1, LE2 is removed, so that the conductors 24 are only connected to the insulating rib 25 on one side. In alternative embodiments, it is sufficient for electrical contact if the conductors 24 of the first and second conductor levels LE1, LE2 are each exposed on one side from the sheath 29 and an insulation 26 is further arranged between the conductors 24 of a conductor level LE1, LE2.

[0025] In the Fig. In the alternative embodiment shown in Figure 4, the connector system 1 further comprises a shield contact 2, which establishes an electrical connection between the outer shield 28 of the ribbon cable 20 and an outer shield on the connector 10. In the illustrated embodiment, the shield contact 2 comprises a metal plate that is simply clamped to the ribbon cable 20 between the outer shield 28 and the jacket 29. In an alternative embodiment, two metal half-shells, which replicate the contour of a connector housing and the outer shield 28, can also be used.

[0026] A preferred embodiment of a method for manufacturing a connector system 1 is described below. The method comprises at least the following steps: providing a connector 10 with at least one mating face 11 and a contact section 12, which has a receptacle 13 made of spring contacts 14; providing a ribbon cable 20 with a plurality of conductors 24. The provision of the connector 10 and the ribbon cable 20 can be automated, for example, using manipulators; exposing the conductors 24 from the outside in an end section 22 of the ribbon cable 20. The exposure can be carried out using mechanical and / or thermal methods, such as milling and / or laser cutting. The ablation methods mentioned as examples, milling and laser cutting, can be carried out automatically using appropriate milling or laser devices.Exposing the conductors 24 means that the conductors 24 remain connected to the insulation 26 or the insulating web 25 of the ribbon cable 20 on at least one side. The conductors 24 are not fully exposed in the end section 22, as otherwise they would be arranged undefined in space and would not have a defined orientation and position. However, a defined position and orientation of the conductors 24 is important for automated processing. Finally, the end section 22 of the ribbon cable 20 is inserted into the receptacle 13 in the contacting section 12 of the connector 10, so that the conductors 24 in the end section 22 are clamped by the spring contacts 14 of the receptacle 13 and electrically contacted under a mechanical clamping tension K. The insertion preferably comprises pushing the end section 22 of the ribbon cable 20 into the receptacle 13 or, conversely, sliding the receptacle 13 onto the end section 22.The joining process can be automated, for example, using manipulators. The clamping tension K secures the end section 22 of the ribbon cable 20 in the receptacle 13 and prevents unintentional detachment of the ribbon cable 20 from the connector 10 and vice versa. The clamping tension K also ensures reliable electrical contact between the conductors 24 and the spring contacts 14. For the clamping tension K to be effective, it is important that a second height H2 between the conductors 24 of the first and second conductor levels LE1, LE2 at the end section 22 corresponds at least to a first height H1 between the spring contacts of the first and second contact levels K1, K2 at the receptacle 13. The method can further include the step of permanently pressing the spring contacts 14 along the third direction Z onto the end section 22 of the ribbon cable 20 using a clamping element, which is preferably clamped around the spring contacts 14 after joining.The contact element can, for example, comprise a suitably shaped metal ring. The contact pressure of the contact element is designed to ensure reliable electrical contact without damaging the conductors 24 or the spring contacts 14. Finally, the process can include one or both of the following steps: soldering the spring contacts 14 of the connector 10 to the conductors 24 of the ribbon cable 20. Soldering all spring contacts 14 to the conductors 24 can be performed simultaneously. The soldering can be automated. If the end section 22 is fixed in the receptacle 13 by the clamping force K, no manual soldering steps are required; instead, a soldering device can perform the soldering automatically. After soldering, or alternatively to soldering, the connector 10 in the contact section 12 and the ribbon cable 20 in its end section 22 can be overmolded.The ribbon cable 20 is pre-fixed to the connector 10 by the clamping force K. This pre-fixation remains in place during overmolding. The overmolding secures the spring contacts 14 to the conductors 24. In an alternative embodiment, the clamping element can be created by pre-molding after the conductors 24 of the ribbon cable 20 have been joined to the spring contacts 14 of the connector 10. The pre-molding process absorbs the forces of the main overmolding and protects the contacts. The overmolding also encloses the at least one optionally arranged shield contact 2. After overmolding, the ribbon cable 20 and the connector 10 are permanently bonded to each other and protected from environmental influences. The overmolding can serve as a base for applying a coding housing. The connector system 1 produced in this (fully automated) manner is robust and reliable. REFERENCE MARK LIST 1 connector system 2 shield contacts 10 connectors 11 Steckgesicht 12 Contact section 13th entry 14 spring contacts 20 flat ribbon cable 22 Final section 24 ladders 25 Insulation bridge 26 Insulation 28 External shielding 29 coat H1 first height H2 second height K clamping voltage KE1 first contact level KE2 second contact level LE1 first ladder level LE2 second ladder level S1 first page S2 second page X first direction Y second direction Z third direction QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 10,651,613

[0003] US 10,348,032

[0004]

Claims

Connector system (1) comprising: a. a connector (10) having at least one mating face (11) and a contact section (12); wherein b. the contact section (12) has a plurality of spring contacts (14) forming a receptacle (13); and c. a ribbon cable (20) comprising a plurality of conductors (24); wherein d. the conductors (24) are exposed to the outside in an end section (22) of the ribbon cable (20); and e. the spring contacts (14), when the ribbon cable (20) is joined in the receptacle (13) of the connector (10), clamp onto the conductors (24) in the end section (22) and electrically contact the conductors (24) under a clamping voltage (K). Connector system according to claim 1, wherein the ribbon cable (20) comprises at least a two-layer ribbon cable (20) and the ribbon cable (20) extends with the plurality of conductors (24) along a first direction (X) and the conductors (24) are arranged in the ribbon cable (20) in a first and a second conductor plane (LE1, LE2). Connector system according to claim 1 or 2, wherein the plug-in face (11) is configured for connection with a matching mating connector for transmitting electrical signals and the contacting section (12) is arranged on a side facing away from the plug-in face (11). Connector system according to one of claims 1 - 3, in which the plurality of spring contacts (14) are arranged opposite each other in a first and a second contact plane (KE1, KE2), such that the spring contacts (14) surround the receptacle (13) from at least two opposite sides. Connector system according to claim 2, wherein the flat ribbon cable (20) forms an insulating rib (25) in the end section (22) and the conductors (24) in the first conductor level (LE1) are arranged on a first side (S1) of the insulating rib (25) and the conductors (24) in the second conductor level (LE2) are arranged on a second side (S2) of the insulating rib (25) opposite the first side (S1). Connector system according to one of claims 1 - 5, wherein connector (10) and ribbon cable (20) are directly connected to each other without an intermediate component. Connector system according to one of claims 1 - 6, wherein a shield contact (2) establishes an electrical connection between an outer shield (28) of the ribbon cable (20) and an outer shield on the connector (10). A method for manufacturing a connector system (1), preferably according to one of claims 1-7, wherein the method comprises at least the following steps: a. Providing a connector (10) with at least one mating face (11) and a contact section (12) having a receptacle (13) made of spring contacts (14); b. Providing a ribbon cable (20) with a plurality of conductors (24); c. Exposing the conductors (24) from the outside in an end section (22) of the ribbon cable (20); and d. Inserting the end section (22) of the ribbon cable (20) into the receptacle (13) in the contact section (12) of the connector (10), such that the conductors (24) in the end section (22) are clamped by the spring contacts (14) of the receptacle (13) and electrically contacted under a clamping voltage (K). Method according to claim 8, further comprising the step: Permanently pressing the spring contacts (14) along a third direction (Z) onto the end section (22) of the flat ribbon cable (20) using a pressing element, which is preferably clamped around the spring contacts (14) after assembly. Method according to claim 8 or 9, further comprising the step of: soldering the spring contacts (14) of the connector (10) to the conductors (24) of the ribbon cable (20) and / or overmolding the connector (10) in the contacting section (12) and the ribbon cable (20) in its end section (22).

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