Angled subassembly for angled connector and method of assembling same - Patents.com

Abstract

The angled subassembly (100) of the angled connector (10) includes an angled shield (110) having a first shield portion (120) and a second shield portion (130) that extends at a bend angle (140) relative to the first shield portion (120), a cable (180) disposed on the first shield portion (120) and the second shield portion (130) of the angled shield (110), and an inner ferrule (200) disposed within the angled shield (110) around the cable (180). The cable (180) has a wire (183) and a foil (184) disposed around the wire (183). The inner ferrule (200) electrically connects the foil (184) to the angled shield (110).

Description

[Technical field]

[0001] The present invention relates to a subassembly for a connector, and more particularly to an angled subassembly for an angled connector. [Background technology]

[0002] Angled connectors generally include a housing, contacts disposed within the housing, a shield disposed about the housing, and a cable disposed within the housing and electrically connected to the contacts. Angled connectors are used in applications that require the contacts of the connector to be positioned at an angle relative to the direction that the cable extends into the connector. The cable extends unidirectionally into the angled connector and the contacts disposed within the housing have a bend that forms the angle required for the angled connector. The contacts may be formed as a single piece and then bent to the desired angle or may be formed as multiple pieces that are attached together to form the desired angle. Summary of the Invention [Problem to be solved by the invention]

[0003] However, these contact configurations result in high component costs, complex assembly, inconsistencies in forming the required angles, and difficult impedance control. [Means for solving the problem]

[0004] The angled subassembly of the angled connector includes an angled shield having a first shield portion and a second shield portion extending at a bent angle relative to the first shield portion, a cable disposed on the first and second shield portions of the angled shield, and an inner ferrule disposed within the angled shield and about the cable. The cable has a wire and a foil disposed about the wire. The inner ferrule electrically connects the foil to the angled shield.

[0005] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 illustrates a perspective view of an angled connector according to one embodiment. [Diagram 2] FIG. 2 is an exploded perspective view of the angled connector of FIG. 1. [Diagram 3] FIG. 2 is a perspective view of the angled shield of the angled connector of FIG. [Figure 4] FIG. 2 is a perspective view of an angled dielectric of the angled connector of FIG. [Diagram 5] FIG. 2 is a perspective view of the inner ferrule of the angled connector of FIG. 1. [Figure 6A] FIG. 2 is a perspective view of a cable of the angled connector of FIG. 1 connected to a contact of the angled connector. [Figure 6B] FIG. 2 is a perspective view of the cable, angled dielectric, and inner ferrule of the angled connector of FIG. 1 with the dielectric cover of the angled dielectric in the open dielectric position. [Figure 6C] FIG. 6C is a perspective view of the cable and angled dielectric of FIG. 6B with the dielectric cover in a closed dielectric position. [Figure 6D] FIG. 4 is a perspective view of a cable with an angled dielectric within the angled shield of FIG. 3 and with the shield cover of the angled shield in the open shield position. [Figure 6E]FIG. 6E is a perspective view of the cable in the angled shield of FIG. 6D with the shield cover in the closed shield position. [Figure 6F] FIG. 6F is a perspective view of the cable in the angled shield with the shield cover in the closed shield position of FIG. 6E and the braid of the cable disposed on the first shield portion of the angled shield. [Figure 7] FIG. 2 is a cross-sectional side view of the angled connector of FIG. [Figure 8] FIG. 2 is a cross-sectional top view of the angled connector of FIG. [Figure 9] FIG. 13 is an exploded perspective view of an angled connector according to another embodiment. [Figure 10] FIG. 10 is a perspective view of the inner ferrule of the angled connector of FIG. [Figure 11A] FIG. 10 is a perspective view of the cable and inner ferrule of the angled connector of FIG. [Figure 11B] FIG. 11B is a perspective view of the cable and inner ferrule of FIG. 11A, with the inner ferrule in a bent position. [Figure 11C] FIG. 11C is a perspective view of the cable with the inner ferrule of FIG. 11B in the angled shield and with the shield cover of the angled shield in the open shield position. [Figure 12] FIG. 10 is a cross-sectional side view of the angled connector of FIG. [Figure 13] FIG. 10 is a cross-sectional top view of the angled connector of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] As shown in FIG. 1, an angled connector 10 according to one embodiment includes an angled subassembly 100 and a mating subassembly 300 that is connected to the angled subassembly 100.

[0008] 1, 2, 7, and 8, the angled subassembly 100 includes an angled shield 110, an angled dielectric 150 disposed on the angled shield 110, a cable 180 disposed on the angled shield 110, a contact 190 electrically connected to the cable 180, an inner ferrule 200 disposed around the cable 180 within the angled shield 110, and an outer ferrule 210 disposed around the cable 180 and the angled shield 110.

[0009] 3, the angled shield 110 has a shield body 112 extending from a first end 114 to an opposite second end 116. The angled shield 110 has a first shield portion 120 and a second shield portion 130 extending from the first shield portion 120.

[0010] The first shield portion 120 extends from the first end 114 of the shield body 112, as shown in Figure 3. The first shield portion 120 has a first shield axis 122 that extends through a center of the first shield portion 120. In the illustrated embodiment, the first shield axis 122 extends along a vertical direction V.

[0011] 3, the second shield portion 130 extends from the first shield portion 120 to the second end 116 of the shield body 112. The second shield portion 130 has a second shield axis 132 that extends through a center of the second shield portion 130. In the illustrated embodiment, the second shield axis 132 extends along a longitudinal direction L that is perpendicular to the vertical direction V.

[0012] 3, due to the orientation of the second shield axis 132 relative to the first shield axis 122, the second shield portion 130 extends at a bend angle 140 relative to the first shield portion 120. In the illustrated embodiment, the bend angle 140 is 90° and the second shield portion 130 extends perpendicular to the first shield portion 120. In other embodiments, the bend angle 140 may be any angle greater than 90° and less than 180° and the second shield portion 130 may extend at an angle between 90° and 180° relative to the first shield portion 120. In other embodiments, the bend angle 140 may be less than 90° or equal to 180°.

[0013] 2 and 3, the angled shield 110 has a shield cover 124 attached to the shield body 112 at a shield hinge 128. The shield cover 124 is pivotable relative to the shield body 112 about the shield hinge 128 between an open shield position SO, shown in FIG. 2, and a closed shield position SC, as shown in FIG.

[0014] 2 and 3, the shield body 112 has a tab 123 on the first shield portion 120 and the shield cover 124 has a recess 126 extending into the shield cover 124. When the shield cover 124 is pivoted to the closed shield position SC as shown in FIG. 3, the tab 123 enters the recess 126 and secures the shield cover 124 in the closed shield position SC. In the illustrated embodiment, the shield body 112 has two tabs 123 corresponding to the two recesses 126 of the shield cover 124. In other embodiments, the shield body 112 may have more than one or two tabs 123 and the shield cover 124 may have more than one or two recesses 126, provided that the number of tabs 123 is equal to the number of recesses 126.

[0015] Shield body 112 has a shield latch 127 extending from shield body 112 at first shield portion 120, as shown in Figures 2 and 3. Shield cover 124 has a shield catch 125 extending from shield cover 124. When shield cover 124 is pivoted to closed shield position SC, as shown in Figure 3, shield catch 125 engages shield latch 127 to secure shield cover 124 in closed shield position SC.

[0016] 2 and 3, shield latch 127 is a tab having an opening extending therethrough, and shield catch 125 is a protrusion engageable with the opening. In this embodiment, shield latch 127 resiliently deflects under contact with shield catch 125 as shield cover 124 moves toward closed shield position SC, and resiliently returns to position shield catch 125 at shield latch 127 when shield cover 124 reaches closed shield position SC. In other embodiments, shield latch 127 and shield catch 125 may be any other type of mechanical latch, such as hooks that engage with each other in closed shield position SC. In the illustrated embodiment, the shield body 112 has two shield latches 127 and the shield cover 124 has two shield catches 125. In other embodiments, the shield body 112 may have more than one or two shield latches 127 and the shield cover 124 may have more than one or two shield catches 125, provided that the number of shield latches 127 is equal to the number of shield catches 125.

[0017] In the second shield portion 130, as shown in Figures 3, 7, and 8, the angled shield 110 has a transition portion 134 where the dimensions of the interior space 138 of the second shield portion 130 shown in Figures 7 and 8 decrease along the vertical direction V and along a width direction W perpendicular to the longitudinal direction L and the vertical direction V. In the illustrated embodiment, the transition portion 134 is formed by a plurality of spring members 136 that extend into the interior space 138 of the second shield portion 130 on opposite sides to each other in the vertical direction V. In the illustrated embodiment, two spring members 136 are located opposite each other in the vertical direction V, and two spring members 136 are located opposite each other in the width direction W. In other embodiments, the transition portion 134 may include fewer than three or more than four spring members 136. Each of the spring members 136 is resiliently deflectable and has a contact bend 137 at its maximum projection into the interior space 138.

[0018] The angled shield 110 is formed from a conductive material, such as aluminum, and in one embodiment is integrally formed as a single piece with at least the shield body 112, first portion 120, second portion 130, and shield cover 124. The angled shield 110 may be stamped and formed from a sheet of conductive material. In other embodiments, the angled shield 110 may be formed from multiple separate elements attached to one another.

[0019] The angled dielectric 150 has a dielectric body 152 extending from a first end 154 to an opposite second end 156, as shown in Figure 4. As shown in Figure 4, the angled dielectric 150 has a first dielectric portion 160 and a second dielectric portion 170 extending from the first dielectric portion 160.

[0020] The first dielectric portion 160 extends from the first end 154 of the dielectric body 152, as shown in Figure 4. The first dielectric portion 160 has a first dielectric axis 162 that extends through a center of the first dielectric portion 160. In the illustrated embodiment, the first dielectric axis 162 extends along a vertical direction V.

[0021] 4, the second dielectric portion 170 extends from the first dielectric portion 160 to the second end 156 of the dielectric body 152. The second dielectric portion 170 has a second dielectric axis 172 that extends through a center of the second dielectric portion 170. In the illustrated embodiment, the second dielectric axis 172 extends along a longitudinal direction L.

[0022] 4, due to the extension direction of the second dielectric axis 172 relative to the first dielectric axis 162, the second dielectric portion 170 extends with a bend angle 140 relative to the first dielectric portion 160. The bend angle 140 of the second dielectric portion 170 relative to the first dielectric portion 160 is the same as the bend angle 140 of the second shield portion 130 relative to the first shield portion 120, and the bend angle 140 of the second dielectric portion 170 relative to the first dielectric portion 160 is greater than or equal to 90° and less than 180°. In another embodiment, the bend angle 140 may be less than 90° or equal to 180°.

[0023] In the first dielectric portion 160, as shown in Figure 4, the angled dielectric 150 has a dielectric cover 164 attached to the dielectric body 152 at a dielectric hinge 168. The dielectric cover 164 is pivotable relative to the dielectric body 152 about the dielectric hinge 168 between an open dielectric position DO, shown in Figures 4 and 6B, and a closed dielectric position DC, shown in Figures 2 and 6C.

[0024] 4, the dielectric body 152 has a dielectric catch 158 on the first dielectric portion 160, and the dielectric cover 164 has a dielectric latch 166. When the dielectric cover 164 is pivoted to the closed dielectric position DC, the dielectric latch 166 engages with the dielectric catch 158 to secure the dielectric cover 164 in the closed dielectric position DC. In the illustrated embodiment, the dielectric catch 158 is a recess and the dielectric latch 166 is a protrusion complementary to the recess of the dielectric catch 158. In other embodiments, the dielectric catch 158 may be a protrusion and the dielectric latch 166 may be a recess complementary to the protrusion of the dielectric catch 158, or the dielectric catch 158 and the dielectric latch 166 may be any other elements capable of engaging with each other to secure the dielectric cover 164 in the closed dielectric position DC. In an alternative embodiment, the dielectric catch 158 and the dielectric latch 166 may be omitted.

[0025] The angled dielectric 150 is a dielectric material, such as plastic, and in one embodiment is integrally formed as a single piece with at least the dielectric body 152, the first dielectric portion 160, the second dielectric portion 170, and the dielectric cover 164. In this embodiment, the dielectric hinge 168 is a film hinge. In other embodiments, the angled dielectric 150 may be formed from multiple separate elements attached to one another.

[0026] As shown in Figures 2 and 6A, cable 180 has a wire 183, a foil 184 disposed around wire 183, a braid 185 disposed around foil 184, and a cable insulation 186 disposed around braid 185.

[0027] In the illustrated embodiment, the cable 180 includes a twisted pair of wires 183, each of which has a conductor 183a and a wire insulation 183b disposed around the conductor 183a. In the twisted pair embodiment, the wires 183 are wrapped around each other within the foil 184 such that the wire insulation 183b of each of the wires 183 abut each other. In another embodiment, the cable 180 includes a pair of wires 183 that run parallel to each other, each of the wires 183 having a conductor 183a and a wire insulation 183b. In another embodiment, the cable 180 may have a single wire 183 with one conductor 183a surrounded by one wire insulation 183b.

[0028] 2 and 6A, a foil 184 is disposed around the wires 183 or wires 183 in abutment with the wire insulation 183b. The foil 184 is formed from a conductive material. A braid 185 is disposed around and in abutment with the foil 184, the braid 185 being formed from a conductive material. A cable insulation 186, formed from an insulating material, is disposed around and in abutment with the braid 185.

[0029] The contact 190 has a mating portion 192 and a connecting portion 194 at an end opposite the mating portion 192, as shown in FIGS. 2 and 6A. The contact 190 is formed from a conductive material. In the illustrated embodiment, the mating portion 192 is a receptacle for a pin, while in other embodiments, the mating portion 192 can be a pin or any other type of contact element capable of mating with another contact element. In the illustrated embodiment, the connecting portion 194 is a crimp portion capable of being crimped to a conductor. In other embodiments, the connecting portion 194 can be a flat element capable of being welded to a conductor, or any other type of element capable of mechanically and electrically connecting the contact 190 to a conductor. The angled subassembly 100 has two contacts 190 in the illustrated embodiment. The number of contacts 190 corresponds to the number of wires 183 in the cable 180, and the angled subassembly 100 may alternatively have one contact 190 for embodiments in which the cable 180 has one wire 183.

[0030] The inner ferrule 200 has a base 210 extending from a first end 212 to a second end 214 along a longitudinal direction L, as shown in FIG. 5. The inner ferrule 200 has a first crimp portion 220 at the first end 212 and a second crimp portion 230 at the second end 214, the second crimp portion 230 being connected to the first crimp portion 220 by the base 210. The first crimp portion 220 has a pair of first crimp wings 222 extending from the base 210 and positioned opposite each other in the width direction W. The second crimp portion 230 has a pair of second crimp wings 232 extending from the base 210 and positioned opposite each other in the width direction W.

[0031] In the second crimped portion 230, as shown in FIG. 5, the base 210 has a sectoral projection 236 that extends at least partially between the second crimped wings 232 in the vertical direction V. The sectoral projection 236 has a generally triangular shape with a narrower portion at the base 210 adjacent the first crimped portion 220 and a wider portion at the second end 214 of the base 210. The sectoral projection 236 and the second crimped wings 232 form a flare shape 238 of the second crimped portion 230 that opens toward the second end 214 of the base 210. In another embodiment, the sectoral projection 236 may be omitted and the second crimped portion 230 may extend linearly from the first crimped portion 220 along the longitudinal direction L.

[0032] 5, the first end 212 of the base 210 is connected to a carrier strip 240. Multiple inner ferrules 200 may be connected to the carrier strip 240 for transporting the inner ferrules 200 during manufacturing or for other uses, and the inner ferrules 200 are separated from the carrier strip 240 at the first end 212 of the base 210 prior to use of the inner ferrules 200 as described below.

[0033] The inner ferrule 200 is formed from a conductive material such as aluminum or copper and in one embodiment is integrally formed as a single piece with at least the base 210, the first crimp portion 220, and the second crimp portion 230. In the illustrated embodiment, the inner ferrule 200 is also integrally formed with the carrier strip 240 prior to separation from the carrier strip 240. The inner ferrule 200 may be formed by stamping and bending from a sheet of conductive material. In other embodiments, the inner ferrule 200 may be formed from multiple separate elements that are attached to one another. In another embodiment, the inner ferrule 200 may have multiple first crimp portions 220 and multiple second crimp portions 230 for connecting to multiple wires.

[0034] The outer ferrule 210 is a generally cylindrical element formed from a conductive material, as shown in the embodiment of Figures 1 and 2. In one embodiment, the outer ferrule 210 is formed by bending or rolling a sheet of conductive material.

[0035] The mating subassembly 300 includes a mating shield 310 and a mating dielectric 320 disposed within the mating shield 310, as shown in FIGS. 1 and 2. The mating shield 310, formed from a conductive material, extends from a first end 312 to an opposite second end 314 along a longitudinal direction L. The mating shield 310 has a plurality of contact springs 316 disposed adjacent the first end 312. In one embodiment, the mating shield 310 is integrally formed as a single piece. The mating dielectric 320, formed from a dielectric material, has a plurality of contact receiving passages 322 extending through the mating dielectric 320 along the longitudinal direction L, as shown in FIG. 8. The mating dielectric 320 may alternatively have one or more than two contact receiving passages 322, the number of contact receiving passages 322 corresponding to the number of wires 183 and the number of contacts 190 of the cable 180.

[0036] Assembly of angled connector 10 will now be described primarily with reference to Figures 6A-6F.

[0037] In a first step, shown in Figure 6A, the cable insulation 186, braid 185, and foil 184 are stripped to expose the wires 183. For each of the wires 183, a portion of the wire insulation 183b is stripped to expose a portion of the conductors 183a. A connection portion 194 of each of the contacts 190 is electrically and mechanically connected to one of the exposed conductors 183a. In the embodiment shown in Figure 6A, the connection portion 194 is crimped to the conductors 183a.

[0038] In the next step shown in Figure 6B, with the dielectric cover 164 in the open dielectric position DO, the cable 180 is inserted and threaded through the angled dielectric 150. In the step shown in Figure 6B, the cable 180 extends through the angled dielectric 150 along the second dielectric axis 172 shown in Figure 4.

[0039] The inner ferrule 200 is moved to a position around the cable 180 in the step shown in FIG. 6B. The first crimp portion 220 is placed around the foil 184 and the wire 183, and the first crimp wings 222 are crimped around the foil 184 and the wire 183. The first crimp wings 222 of the first crimp portion 220 press the foil 184 against the wire 183 to hold the foil 184 in place and electrically connect the inner ferrule 200 to the foil 184. The second crimp portion 230 is placed around the wire 183, and the second crimp wings 232 are crimped around the wire 183. The crimped second crimp wings 232 and the scallops 236 are at least partially between the wires 183 in the width direction W. The second crimping wings 232 press against the wire insulation 183b of the wire 183 and form a flare shape 238 with the scallops 236. The wires 183 are positioned adjacent to one another in the first crimp portion 220, as shown in FIG. 8, and the flare shape 238 holds the wires 183 at a pitch 189 separating them from one another at the second end 214 of the inner ferrule 200. In another embodiment, the second crimping wings 232 and scallops 236 may position the wires 183 parallel to one another throughout the second crimp portion 230, and the wires 183 may move outward in the space between the first crimp portion 220 and the second crimp portion 230 along the longitudinal direction L to the pitch 189 before reaching the second crimp portion 230. The pitch 189 is predetermined and selected for optimal impedance control.

[0040] In the next step, shown in Figure 6C, the cable 180 is bent within the angled dielectric 150. Once the cable 180 is bent, it has a first portion 187 and a second portion 188 that extends at a bend angle 140 relative to the first portion 187. The first portion 187 is disposed in the first dielectric portion 160 and the second portion 188 is disposed in the second dielectric portion 170. As shown in Figure 6C, an inner ferrule 200 is disposed adjacent to the second dielectric portion 170.

[0041] Cable 180 is fully inserted into the angled dielectric 150 and bent into the shape described above and shown in FIG. 6C. With the dielectric cover 164 moved from the open dielectric position DO to the closed dielectric position DC shown in FIG. 6C. In one embodiment, the dielectric catch 158 engages the dielectric latch 166 to fix the dielectric cover 164 in the closed dielectric position DC. In another embodiment, instead of or in addition to the dielectric catch 158 and the dielectric latch 166, the dielectric cover 164 is fixed to the dielectric body 152 at the closed dielectric position DC by plastic welding the dielectric cover 164 to the dielectric body 152. In another embodiment, the angled dielectric 150 does not have a rotatable dielectric cover 164 relative to the dielectric body 152, but is overmolded as a single piece onto the foil 184 of the cable 180 at the position shown in FIG. 6C.

[0042] The angled dielectric 150 at the position shown in FIG. 6C fixes the cable 180 at the position shown in FIG. 6C such that the first portion 187 has the same bend angle 140 with respect to the second portion 188 due to the structure and bend angle 140 of the first dielectric portion 160 with respect to the second dielectric portion 170. In the illustrated embodiment, the cable 180 is inserted into and bent and held by the angled dielectric 150 with the contacts 190 already connected to the wires 183, and the inner ferrule 200 is crimped to the cable 180 after the cable 180 is inserted through the angled dielectric 150. In another embodiment, the cable 180 may be inserted into, bent by, and held by the angled dielectric 150 before connecting the contacts 190 to the wires 183.

[0043] In the step shown in FIG. 6D, with the shield cover 124 in the open shield position SO, the cable 180 bent and held by the angled dielectric 150 is inserted into the angled shield 110. At the position shown in FIG. 6D, the braid 185 spreads outward from the cable 180.

[0044] Shield cover 124 is then moved from the open shield position SO, shown in FIG. 6D, to the closed shield position SC, shown in FIG. 6E, to encase cable 180 in shield body 112. In the illustrated embodiment, tab 123 is disposed in recess 126 to secure shield cover 124 in the closed shield position SC. As shown in FIG. 3 and described above, shield catch 125 engages shield latch 127 to secure shield cover 124 in the closed shield position SC. In other embodiments including tab 123 and recess 126 or omitting tab 123 and recess 126, in addition to or in lieu of engaging shield catch 125 with shield latch 127, shield cover 124 may be welded or molded to shield body 112 to secure shield cover 124 in the closed shield position SC.

[0045] With the shield cover 124 in the closed shield position SC shown in Figure 6E, the braid 185 is placed or folded over the first shield portion 120 of the angled shield 110, as shown in Figure 6F. An outer ferrule 210 is then placed over the exposed portion of the braid 185 and a portion of the cable insulation 186 and crimped to the braid 185, first shield portion 120, and cable insulation 186, as shown in Figures 1 and 7.

[0046] 6D-6F, the mating subassembly 300 is already connected to the angled shield 110 when the angled dielectric 150 and cable 180 are inserted into the angled shield 110. As shown in FIGS. 7 and 8, the second end 116 of the angled shield 110 at the second shield portion 130 is inserted into and positioned on the second end 314 of the mating shield 310. The angled shield 110 is mechanically and electrically connected to the mating shield 310 through the second shield portion 130. 7 and 8 , the mating dielectric 320 is disposed within the interior space 138 of the second shield portion 130. The mating dielectric 320 extends from a position adjacent to the transition portion 134 to an outside of the second shield portion 130 along the longitudinal direction L. In another embodiment, the mating subassembly 300 may be connected to the angled shield 110 after the angled dielectric 150 and the cable 180 are inserted into the angled shield 110.

[0047] The angled connector 10 is shown in FIGS. 1, 7 and 8 in a fully assembled state with the cable 180 positioned and held within the angled shield 110 and angled dielectric 150.

[0048] 7, the first portion 187 of the cable 180 is located in the first shield portion 120 of the angled shield 110 and the first dielectric portion 160 of the angled dielectric 150. The foil 184 is disposed around the wire 183 in the first portion 187 and held against the wire insulation 183b of the wire 183. The braid 185 in the first portion 187 is crimped to the first shield portion 120 by the outer ferrule 210 and is disposed between the first shield portion 120 and the outer ferrule 210. In one embodiment, the first shield portion 120 provides an aid in crimping the outer ferrule 210 around the braid 185 and cable 180 that prevents the crimping of the outer ferrule 210 from damaging the foil 194 or the wire 183.

[0049] The second portion 188 of the cable 180 is located in the second shield portion 130 of the angled shield 110 and the second dielectric portion 170 of the angled dielectric 150, as shown in Figures 7 and 8. The foil 184 is disposed around the wire 183 in the second portion 188 and is held against the wire insulation 183b of the wire 183 by the first crimp portion 220 of the inner ferrule 200. The first crimp portion 220 and the second crimp portion 230 are disposed in the second shield portion 130. The wire 183 and the foil 184 are disposed in the first portion 187 and the second portion 188 of the cable 180, respectively.

[0050] The first crimp portion 220 of the inner ferrule 200 is electrically and mechanically connected to the foil 184 by crimping the first crimp wings 222. As shown in Figures 7 and 8, when the cable 180 with the inner ferrule 200 crimped thereon is positioned within the interior space 138 of the second shield portion 130, the spring members 136 extending into the interior space 138 contact the inner ferrule 200. Each contact bend 137 of the spring members 136 contacts the second crimp portion 230 of the inner ferrule 200, and the spring members 136 resiliently deflect to apply pressure that maintains the spring members 136 in contact with the second crimp portion 230. The spring member 136 forms and maintains an electrical connection between the angled shield 110 and the inner ferrule 200. The inner ferrule 200 electrically connects the angled shield 110 to the foil 184 by crimping the first crimp portion 220.

[0051] 8 , each of the contacts 190 is positioned and held in one of the contact-receiving passages 322 of the mating dielectric 320 within the second shield portion 130 of the angled shield 110. The conductor 183a of the wire 183 electrically and mechanically connected to the connecting portion 194 of the contact 190 is disposed within the mating dielectric 320, and the mating portion 192 of the contact 190 opposite the connecting portion 194 is disposed adjacent to the first end 312 of the mating shield 310.

[0052] 1, 7 and 8, the foil 184, angled shield 110, braid 185, inner ferrule 200, outer ferrule 210, and mating shield 310 of the cable 180 are electrically connected. The conductor 183a of the wire 183 is electrically connected to the contact 190 and is electrically isolated from the foil 184, angled shield 110, braid 185, inner ferrule 200, and mating shield 310 by the wire insulation 183b and mating dielectric 320. When the angled connector 10 is connected to a mating connector, the contact springs 316 of the mating shield 310 resiliently abut and electrically connect with the shield of the mating connector, and the contacts 190 mate with and electrically connect with the contacts of the mating connector.

[0053] In the angled connector 10, the cable 180 runs through a bend where a first portion 187 is held at a bend angle 140 relative to a second portion 188 by the angled shield 110 and angled dielectric 150. Having a bend in the cable 180 itself allows the foil 184 to remain over a longer portion of the cable 180 in the angled connector 10, allowing for advanced impedance control and improved shielding performance. The first crimped portion 220 of the inner ferrule 200 crimped to the foil 184 maintains intimate contact of the wire or wires 183 within the angled shield 110 and tight wrapping of the foil 184 around the wire 183 at the second portion 188. The contact of the second crimped portion 230 with the angled shield 110 at the spring member 136 forms a reliable electrical connection between the angled shield 110 and the foil 184 via the inner ferrule 200, further aiding in advanced impedance control and improved shielding performance.

[0054] The foil 184 extending through the bend over the majority of the cable 180 also prevents the crimping of the outer ferrule 210 from significantly affecting impedance control. The outer ferrule 210 can be crimped as tightly as necessary for mechanical robustness and, as described above, can press against the first shield portion 120 without potentially damaging the foil 184. The simplified design of the contacts 190 used with the angled connector 10 can save component costs and reduce assembly complexity.

[0055] In the illustrated embodiment, the angled dielectric 150 maintains the intimate contact of the wire or wires 183 within the angled shield 110 and the tight wrapping of the foil 184 around the wires 183 at the first portion 187 and the second portion 188. In another embodiment, the angled dielectric 150 may be omitted. In an embodiment that omits the angled dielectric 150, the other elements of the angled connector 10 are still positioned as described above, and the cable 180 extends through the angled shield 110 with the first portion 187 and the second portion 188 still at the bend angle 140, relying on the inner ferrule 200 to maintain the intimate contact of the wires 183 with each other and the tight wrapping of the foil 184.

[0056] The angled connector 10 in the illustrated embodiment holds a first portion 187 of the cable 180 at a bend angle 140 of 90° relative to a second portion 188 of the cable 180 opposite the bend. In other embodiments, the bend angle 140 may be any angle greater than 90° and less than 180°, or any angle less than 90° or equal to 180°. The cable 180 in the illustrated embodiment also has a specific rotational position relative to the contacts 190 about the longitudinal axis of rotation L. The angled connector 10 is not limited to the rotational positions of the illustrated embodiment, and the cable 180 may be positioned and held by the angled subassembly 100 in any rotational position about the longitudinal axis L relative to the contacts 190.

[0057] An angled connector 10' according to another embodiment includes an angled subassembly 100' and a mating subassembly 300 that connects to the angled subassembly 100', as shown in Figure 9. Like reference numbers refer to like elements as in the embodiment of the angled connector 10 described above with respect to Figures 1-8, and differences in the embodiment of the angled connector 10' will now be primarily described with reference to Figures 9-13.

[0058] In the angled subassembly 100', as shown in Figure 9, the angled shield 110, cable 180, contacts 190, and outer ferrule 210 are the same as shown and described in detail above with respect to the angled subassembly 100 of Figures 1-8. The angled dielectric 150 has been omitted in this embodiment of the angled subassembly 100', with the differences in the inner ferrule 200' of the angled subassembly 100' being described in more detail below.

[0059] The inner ferrule 200' has a base 210 extending along a longitudinal direction L from a first end 212 to a second end 214, as shown in Figure 10. The inner ferrule 200' has a third crimp portion 240 at the first end 212, a second crimp portion 230 at the second end 214, and a first crimp portion 220 between the third crimp portion 240 and the second crimp portion 230, the third crimp portion 240 being connected to the first crimp portion 220 and the second crimp portion 230 by the base 210. The first crimp portion 220 has a pair of first crimp wings 222 extending from the base 210 and positioned opposite each other in a width direction W. The second crimping portion 230 extends from the base 210 and has a pair of second crimping wings 232 located opposite each other in the width direction W. The third crimping portion 240 extends from the base 210 and has a pair of third crimping wings 242 located opposite each other in the width direction W.

[0060] As shown in FIG. 10, the third crimp portion 240 is separated from the first crimp portion 220 and the second crimp portion 230 by a bending region 216 of the base 210. The bending region 216 has a weakening element 218 that reduces the force required to bend the bending region 216. In the illustrated embodiment, the weakening element 218 is a thinning of the material of the base 210 in the vertical direction V, which may be achieved by removing material of the base 210 or forming the weakening element 218 in a thinner dimension. In other embodiments, the weakening element 218 may be any other structure, such as various arrangements of openings in the base 210, that reduces the force required to bend the bending region 216. If the bending region 216 can be sufficiently bent without the weakening element, the weakening element 218 may be omitted.

[0061] 5 embodiment, in the second crimp portion 230, as shown in FIG. 10, the base 210 has a sectoral projection 236 that extends at least partially between the second crimp wings 232 in the vertical direction V. The sectoral projection 236 has a generally triangular shape with a narrower portion at the base 210 adjacent the first crimp portion 220 and a wider portion at the second end 214 of the base 210. The sectoral projection 236 and the second crimp wings 232 form a flared shape 238 of the second crimp portion 230 that opens towards the second end 214 of the base 210. In another embodiment, the second crimping wing 232 and the scalloped portion 236 may position the multiple wires 183 parallel to one another throughout the second crimping portion 230, and the multiple wires 183 may move outward to a pitch 189 along the longitudinal direction L in the space between the first crimping portion 220 and the second crimping portion 230 before reaching the second crimping portion 230.

[0062] 10 , the first end 212 of the base 210 is connected to a carrier strip 240. A plurality of inner ferrules 200′ may be connected to the carrier strip 240 for transporting the inner ferrules 200′ during manufacturing or for other uses, and the inner ferrules 200′ are separated from the carrier strip 240 at the first end 212 of the base 210 prior to use of the inner ferrules 200′ as described below.

[0063] The inner ferrule 200' is formed from a conductive material, such as aluminum or copper, and in one embodiment is integrally formed as a single piece with at least the base 210, the first crimp portion 220, the second crimp portion 230, and the third crimp portion 240. In the illustrated embodiment, the inner ferrule 200' is also integrally formed with the carrier strip 240 prior to separation from the carrier strip 240. The inner ferrule 200' may be formed by stamping and bending from a sheet of conductive material. In other embodiments, the inner ferrule 200' may be formed from multiple separate elements that are attached to one another.

[0064] Assembly of the angled connector 10' will now be described primarily with respect to Figures 11A-11C, with only the differences from the assembly shown and described in Figures 6A-6F being described in detail here.

[0065] Following the step shown in Figure 6A, the inner ferrule 200' is moved into position around the cable 180, as shown in Figure 11A. The first crimp portion 220 and the second crimp portion 230 are positioned and crimped onto the cable 180 as described above with respect to Figure 6B. The third crimp portion 140 is positioned around the foil 184 and the wire 183 at a location spaced apart from the first crimp portion 220 and the second crimp portion 230 along the longitudinal direction L. In the state shown in Figure 11A, the first crimp portion 220 and the second crimp portion 230 are crimped, while the third crimp wing 242 of the third crimp portion 240 remains uncrimped.

[0066] In a next step, the inner ferrule 200' is bent at the bend region 216 of the base 210, as shown in Figure 11B. The bend region 216 is bent until the third crimp portion 240 extends at the bend angle 140 described above relative to the first crimp portion 220 and the second crimp portion 230. With the third crimp portion 240 positioned at the bend angle 140 as shown in Figure 11B, the third crimp wing 242 of the third crimp portion 240 is crimped. The third crimp wing 242 presses the foil 184 against the wire 183, holding the foil 184 in place and electrically connecting the inner ferrule 200' to the foil 184. The bending and crimping of the third crimp portion 240 causes the cable 180 to bend at the bend angle 140. In another embodiment, the third crimp portion 240 may be crimped before the bend region 216 is bent and / or may be crimped such that the third crimp wings 242 provide coarse positioning and strain relief rather than primarily holding the foil 184 in place and electrically connecting the inner ferrule 200′ to the foil 184.

[0067] Following bending of the inner ferrule 220' and crimping of the third crimped portion 240, the cable 180 and crimped inner ferrule 200' are inserted into the angled shield 110 with the shield cover in the open shield position SO as shown in Figure 11C. In the position shown in Figure 11C, the braid 185 spreads outwardly from the cable 180. At this point, assembly of the angled connector 10' is complete, similar to that described above with respect to Figures 6E and 6F.

[0068] The angled connector 10' is shown in a fully assembled state in Figures 12 and 13 with the cable 180 positioned and retained within the angled shield 110. Only the location of the elements of the inner ferrule 200' will be described in detail with respect to Figures 12 and 13. The location and function of the other elements of the angled connector 10' are the same as described above with respect to Figures 7 and 8.

[0069] 12, the foil 184 is disposed around the wire 183 in the first portion 187 and the second portion 188 of the cable 180 and is held against the wire insulation 183b of the wire 183 by the first crimp portion 220 and the third crimp portion 240 of the inner ferrule 200'. The first crimp portion 220 and the second crimp portion 230 are disposed on the second shield portion 130. The third crimp portion 240 is disposed on the first shield portion 120.

[0070] The first crimp portion 220 and the third crimp portion 240 of the inner ferrule 200' are electrically and mechanically connected to the foil 184 by crimping the first crimp wing 222 and the third crimp wing 242. As shown in Figures 12 and 13, when the cable 180 with the inner ferrule 200' crimped thereon is positioned within the interior space 138 of the second shield portion 130, the spring members 136 extending into the interior space 138 contact the inner ferrule 200'. Each of the contact bends 137 of the spring members 136 contacts the second crimp portion 230 of the inner ferrule 200', and the spring members 136 elastically deflect to apply pressure that maintains the spring members 136 in abutment with the second crimp portion 230. The spring member 136 forms and maintains an electrical connection between the angled shield 110 and the inner ferrule 200'. The inner ferrule 200' electrically connects the angled shield 110 to the foil 184 by the crimp of the first crimp portion 220 and the third crimp portion 240.

[0071] In the angled connector 10', the first crimp portion 220 and the third crimp portion 240 of the inner ferrule 200' crimped to the foil 184 maintain intimate contact of the wire or wires 183 within the angled shield 110 and tight wrapping of the foil 184 around the wire 183 at the first portion 187 and the second portion 188. The bend region 216 of the inner ferrule 200' positions the cable 180 at the bend angle 140 as it extends through the angled shield 110. The contact of the second crimp portion 230 with the angled shield 110 at the spring member 136 forms a reliable electrical connection between the angled shield 110 and the foil 184 via the inner ferrule 200', aiding in advanced impedance control and improved shielding performance.

Claims

1. An angled subassembly (100) for an angled connector (10), comprising: The angled subassembly (100) comprises: - an angled shield (110) having a first shield portion (120) and a second shield portion (130) extending at a bend angle (140) relative to said first shield portion (120); - a cable (180) disposed on the first shield portion (120) and the second shield portion (130) of the angled shield (110), the cable (180) having a wire (183) and a foil (184) disposed around the wire (183); an inner ferrule (200) disposed within said angled shield (110) around said cable (180) and electrically connecting said foil (184) to said angled shield (110); An angled subassembly (100) comprising:

2. The inner ferrule (200) has a first crimp portion (220) and a second crimp portion (230) connected to the first crimp portion (220) by a base (210); the first crimp portion (220) is disposed around the foil (184) and the wire (183); The second crimped portion (230) is disposed around the wire (183). The angled subassembly (100) of claim 1.

3. the wire (183) is one of a pair of wires (183) disposed within the foil (184) of the cable (180); the base (210) has a scalloped protrusion (236) at the second crimp portion (230) that extends partially between the pair of wires (183); The angled subassembly (100) of claim 2.

4. the pair of wires (183) are positioned adjacent to one another in the first crimped portion (220); The second crimp portion (230) has a flare shape (238) that holds the pair of wires (183) at a pitch (189) separating them from each other at the end (214) of the inner ferrule (200). The angled subassembly (100) of claim 3.

5. 3. The angled subassembly (100) of claim 2, wherein the first crimp portion (220) and the second crimp portion (230) are disposed on the second shield portion (130) of the angled shield (110).

6. the inner ferrule (200) has a third crimp portion (240) connected to the first crimp portion (220) and the second crimp portion (230) by the base (210); the third crimp portion (240) is disposed around the foil (184) and the wire (183); The angled subassembly (100) of claim 5.

7. the third crimp portion (240) is separated from the first crimp portion (220) and the second crimp portion (230) by a bend region (216) of the base (210); said third crimped portion (240) extends at said bend angle (140) relative to said first crimped portion (220) and said second crimped portion (230); the third crimp portion (240) is disposed on the first shield portion (120) of the angled shield (110); The angled subassembly (100) of claim 6.

8. 2. The angled subassembly (100) of claim 1, wherein the angled shield (110) has a plurality of spring members (136) in the second shield portion (130) that resiliently contact the inner ferrule (200).

9. The angled shield (110) includes a shield body (112) and a shield cover (124) attached to the shield body (112); The shield cover (124) is rotatable with respect to the shield body (112) between an open shield position (SO) in which the cable (180) can be inserted into the shield body (112) and a closed shield position (SC) in which the cable (180) is enclosed in the shield body (112). The angled subassembly (100) of claim 1.

10. further comprising an angled dielectric (150) disposed within the angled shield (110); The wires (183) and the foil (184) of the cable (180) extend through the angled dielectric (150); the angled dielectric (150) has a first dielectric portion (160) and a second dielectric portion (170) that extends at the bend angle (140) relative to the first dielectric portion (160); The inner ferrule (200) is disposed adjacent to the second dielectric portion (170). The angled subassembly (100) of claim 1.

11. An angled connector (10), comprising: The angled connector (10) comprises: - an angled subassembly (100) comprising an angled shield (110), a cable (180) disposed on said angled shield (110), and an inner ferrule (200) disposed within said angled shield (110) around said cable (180), The angled shield (110) has a first shield portion (120) and a second shield portion (130) that extends at a bend angle (140) relative to the first shield portion (120); the cable (180) is disposed on the first shield portion (120) and the second shield portion (130), and has a wire (183) and a foil (184) disposed around the wire (183); an angled subassembly (100), wherein the inner ferrule (200) electrically connects the foil (184) to the angled shield (110); a counter subassembly (300) connected to said angled subassembly (100); An angled connector (10) comprising:

12. The mating subassembly (300) includes a mating shield (310) electrically connected to the angled shield (110) and a mating dielectric (320) disposed within the mating shield (310). Angled connector (10) according to claim 11.

13. A method of assembling an angled sub-assembly (100) of an angled connector (10), comprising: - providing a cable (180) having a wire (183) and a foil (184) arranged around said wire (183); - crimping an inner ferrule (200) around said cable (180); - inserting the cable (180) with the inner ferrule (200) crimped around the cable (180) into an angled shield (110) having a first shield portion (120) and a second shield portion (130) extending at a bend angle (140) relative to the first shield portion (120), the cable (180) is placed into the first shield portion (120) and the second shield portion (130), and the inner ferrule (200) electrically connects the foil (184) to the angled shield (110); The method includes:

14. The angled shield (110) includes a shield body (112) and a shield cover (124) attached to the shield body (112); The cable (180) having the inner ferrule (200) is inserted into the shield body (112) with the shield cover (124) in an open shield position (SO); further comprising pivoting the shield cover (124) relative to the shield body (112) to a closed shield position (SC). The method of claim 13.

15. and further comprising bending the inner ferrule (200) to the bend angle (140) before inserting the cable (180) having the inner ferrule (200) into the angled shield (110). The method of claim 13.

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