electrical connectors

Abstract

An electrical connector (1) comprising: an insulating housing (3) having a contact-receiving cavity (4) extending between a mating side (13) and a cable routing side (14) of the housing; and a plurality of electrical contacts (2) contained within the contact-receiving cavity, the electrical contacts having a bayonet end section (12), a central body section (10), and a wiring end section (9), the wiring end section (9) protruding from the housing beyond the cable routing side (14) for connection to a conductor (22) of an electrical wire (8). The contact receiving cavity includes a cable wiring side tube receiving section (15) having a diameter larger than a portion of the electrical contact so as to form a tubular gap between the electrical contact and the housing, and the connector further includes an insulating tube sleeve (5) that is slidably inserted onto the electrical wire, the insulating sleeve tube having a section that extends into the cable wiring side tube receiving section (15) and a section that extends from the housing beyond the cable wiring side (15) covering the insulating layer (23) on the conductor (22).

Description

[Technical Field]

[0001] The present invention relates to electrical connectors. [Background technology]

[0002] There are many applications that require electrical contacts with a high contact density or compact structure, whereby the distance between the contacts depends, among other things, on the specific voltage difference between the contacts, taking into account the safety margin required for the particular application. Electrical connectors typically have an insulating housing with a cavity in which the electrical contacts are placed and held apart. Within the housing, the contacts are separated by the insulating material of the housing, but on the cable-wiring side and mating side of the connector, where portions of the contacts may extend beyond the housing, the electrical path between the electrical contacts is reduced, and electrical breakdown can occur between the contacts outside the housing.

[0003] In mating connectors, the male or pin contacts typically protrude from the mating side of the connector housing, while in the complementary connector into which the receptacle is inserted, the mating side of the receptacle contacts is within the insulating housing. During mating, the pin contacts are inserted into the receptacle contacts and are therefore separated by the insulating housing of the receptacle contacts, except at the interface between the housings of the mating connectors.

[0004] To increase the electrical path, and thus the resistance to electrical breakdown, it is known to overmold sections of pin contacts that are configured to be inserted into cavities in the insulating housing of a mating connector in a plugged configuration, thereby increasing the electrical path. Overmolding the sections of the contacts that extend from the mating side of the electrical connector is an expensive and complicated technique in terms of the molds required to ensure that the material is injected around the contacts. Furthermore, the thickness of the insulating layer molded onto the contacts is very difficult to control with the precision required to ensure that there is enough insulating material to avoid electrical breakdown through the insulating material layer.

[0005] On the cabling side, it is known to fill the spaces between the electrical contacts with an insulating resin or potting material after the contacts have been connected to the cable conductors by various known means, such as crimping, soldering, or welding, but care must be taken to avoid air bubbles in the resin or potting material, as these bubbles can shorten the electrical path between the electrical contacts.

[0006] Shrink-fit tubes fitted around the contacts to provide an insulating layer are also known, but these also suffer from problems of non-uniform thickness and electrical insulation. Also, the tubes shrink somewhat uncontrollably, resulting in slight variations in longitudinal positioning of the sleeve. Traditional solutions that separately assemble sleeves over the contacts after assembly within the housing do not provide the consistent and precise axial positioning and / or thickness that would allow connector size and contact spacing to be reduced to the theoretical minimum for the connector material, voltage, and geometry.

[0007] Therefore, especially for demanding applications requiring very compact connectors and high reliability and safety, there is a need to ensure that the connectors have specifications to withstand high relative voltage differences in a consistent, safe and reliable manner. Summary of the Invention [Problem to be solved by the invention]

[0008] SUMMARY OF THE INVENTION In view of the above, it is an object of the present invention to provide an electrical connector that is compact yet capable of withstanding high voltage differentials between electrical contacts in a consistent and reliable manner.

[0009] It would be advantageous to provide an electrical connector that is economical to manufacture and assemble.

[0010] In certain applications, it would be advantageous to provide an electrical connector that has a high contact density and is capable of transmitting high voltage electrical signals in a safe and reliable manner.

[0011] It would be advantageous to provide a high density electrical connector that has a well-defined or well-controlled mating force. [Means for solving the problem]

[0012] The object of the present invention has been achieved by providing an electrical connector as claimed in claim 1. The dependent claims set out various advantageous features of embodiments of the invention.

[0013] Disclosed herein is an electrical connector that includes an insulating housing having a contact-receiving cavity extending between a mating side and a cable routing side of the housing, and a plurality of electrical contacts received within the contact-receiving cavity and secured in direct contact engagement with the contact-receiving cavity, the electrical contacts having a bayonet end section, a central body section, and a wiring end section that protrudes from the housing beyond the cable routing side for connection to the conductors of an electrical wire.

[0014] The contact receiving cavity includes a cable wiring side tube receiving section having a diameter larger than a portion of the electrical contact so as to form a tubular gap between the electrical contact and the housing, and the connector further includes an insulating tube sleeve slidably inserted onto the electrical wire, the insulating sleeve tube having a section extending within the cable wiring side tube receiving section and a section extending from the housing beyond the cable wiring side, covering the insulating layer on the conductor.

[0015] In an advantageous embodiment, the insulating tube sleeve is made of polyimide.

[0016] In an advantageous embodiment, the connector further includes an insulating filler deposited on the cabling side of the housing between and around the insulating tube sleeves inserted in the cabling-side tube-receiving section of the housing.

[0017] In an advantageous embodiment, the connector further includes a filler containment ring mounted around the cable routing side of the housing to form a well for injection, pouring or molding of an insulating filler material.

[0018] In an advantageous embodiment, the length of the insulating tube sleeve is at least eight times the distance between adjacent contacts.

[0019] In an advantageous embodiment, the contact includes a mating section extending beyond the mating side of the housing and a reduced diameter body section having a rearwardly facing shoulder, the contact further including a second insulating tube sleeve having a length inserted over the reduced diameter central body section, a portion of the insulating tube sleeve extending beyond the mating side of the housing and configured to be inserted into a contact receiving cavity of a mating connector.

[0020] In an advantageous embodiment, the diameter of the portion of the contact point adjacent the shoulder is substantially the same as the diameter of the second insulating tube sleeve such that the second insulating tube sleeve is flush with the contact point at the interface between the insulating tube sleeve and the shoulder.

[0021] In an advantageous embodiment, the electrical contact comprises a pin contact including a reduced diameter body section having a rearwardly facing shoulder and a second insulating tube sleeve inserted over the reduced diameter central body section, a portion of the second insulating tube sleeve having a length thereof extending beyond the mating side of the housing and configured to be inserted into a receptacle contact receiving cavity of a mating connector.

[0022] In an advantageous embodiment, the receptacle contacts have a plug end section positioned within a receptacle contact receiving cavity of the second housing spaced a first length from the mating side of the second housing, said first length being at least twice the diameter of the receptacle contact receiving cavity.

[0023] In one embodiment, the electrical contacts include a receptacle contact that includes a reduced diameter body section having a rearwardly facing shoulder and a second insulating tube sleeve inserted over the reduced diameter central body section, a portion of the second insulating tube sleeve having a length that extends beyond the mating side of the housing and is configured to be inserted into a pin contact receiving cavity of a mating connector.

[0024] In an advantageous embodiment, the insulating tube sleeve has a tube wall thickness of less than 0.3 mm.

[0025] Also disclosed herein is an electrical connector structure including a first connector and a second connector pluggably connectable to each other, the first connector and the second connector having the characteristics of the electrical connector according to any one or more of the above embodiments, wherein the first connector includes pin contacts and the second connector includes receptacle contacts.

[0026] Also disclosed herein is a method of assembling an electrical connector according to any of the preceding embodiments, comprising: -inserting or overmolding the electrical contacts into an insulating housing; -inserting an insulating tubing sleeve over at least a portion of the electrical wire; - connecting the conductors of the wires to the respective wire-receiving portions of the contacts; - sliding an insulating tube sleeve over each wire-receiving portion of the contacts and into the contact-receiving cavity; - depositing an insulating filler on the cabling side of the housing between and around the insulating tube sleeve.

[0027] Further objects and advantageous features of the present invention will become apparent from the appended claims, detailed description and accompanying drawings. [Brief explanation of the drawings]

[0028] [Figure 1a] Perspective view of the inner part (without outer casing) of the first (male) connector according to an embodiment of the present invention. [Figure 1b] Perspective view of the inner part (without outer casing) of the first (male) connector according to an embodiment of the present invention. [Figure 1c] Cross-sectional view of the inner part of FIGS. 1a and 1b. [Figure 2a] Perspective view of the electrical contacts (pin contacts) of the first connector. [Figure 2b] Exploded perspective view of the electrical contacts of FIG. 2a, showing the insulating tube sleeve assembled to the contacts. [Figure 3a] Perspective view of the inner part (without outer casing) of the second (female) connector according to an embodiment of the present invention for insertion connection to the first connector of FIGS. 1a to 1c. [Figure 3b] Perspective view of the inner part (without outer casing) of the second (female) connector according to an embodiment of the present invention for insertion connection to the first connector of FIGS. 1a to 1c. [Figure 3c] Cross-sectional view of the inner part of FIGS. 3a and 3b. [Figure 4a] Cross-sectional view through the first connector (including the insulating housing and contacts according to FIGS. 1a to 1c) and the mating second connector (including the insulating housing and contacts according to FIGS. 3a to 3b). [Figure 4b] Detailed cross-sectional view of a part of the connector according to an embodiment of the present invention, showing the cable wiring side of the connector. [Figure 5] Cross-sectional view through the first connector having pin contacts and the mating second connector having receptacle contacts according to another embodiment of the present invention, wherein the mating section of the pin contacts is positioned within the contact receiving cavity of the first insulating housing and the receptacle contacts project from the second insulating housing. [Figure 6a] Perspective view of the connector provided with the receptacle contacts of the embodiment of FIG. 5. [Figure 6b]6 is a perspective view of a connector having receptacle contacts of the embodiment of FIG. 5. FIG. [Figure 7a] 1 is a perspective view of a cable wiring structure for connecting to electrical contacts of an electrical connector according to an embodiment of the present invention; [Figure 7b] 7b is a diagram of the cabling structure of FIG. 7a in a first assembly step for connection to electrical contacts of a connector according to one embodiment of the present invention. [Figure 7c] 7b, showing a further assembly step. [Figure 7d] 7b, showing a further assembly step. DETAILED DESCRIPTION OF THE INVENTION

[0029] Referring to the figure, the electrical connector 1 includes an insulating housing 3 and a plurality of electrical contacts 2 mounted in corresponding contact-receiving cavities 4 formed in the housing.

[0030] The insulating housing 4 fixes the position of the electrical contacts and separates them by a distance necessary for electrical insulation. The electrical contacts may be secured substantially fixedly within the housing, typically by barbs or protrusions having an interference fit with the housing, or by other means known per se. The insulating housing may also be overmolded over certain sections of the electrical contacts. Alternatively, the electrical contacts may be inserted into cavities in an already formed housing.

[0031] Casings 19a, 19b may be provided around the insulating housing 3, the casings serving various functions such as guiding and locking the connector to a mating connector, gripping a cable connected to the connector, mounting the connector, and various structural and protective functions for the connector.

[0032] The electrical contact 2 generally comprises a wiring end section 9 for connection to a wire conductor 22 of an electrical conductor, for example an electrical wire 8, the wire being provided with an insulating layer 22 as known per se and with an end exposed for crimping, soldering or welding connection to the wiring end section 9 of the electrical contact. The electrical contact further comprises a central body section 10 at least partially received in and secured in direct contact with the contact-receiving cavity 4 of the housing, and a plug-in end section 12 for plug-in connection to a complementary contact.

[0033] A connector structure comprising a first connector 1a and a second connector 1b that can be pluggably mated with each other is shown in Figure 4a.

[0034] The first connector 1a may include pin contacts 2a, and the second connector 1b may include receptacle contacts 2b. The pin contacts 2a of the first connector 1a protrude beyond the mating side 13 of the first housing 3a. However, the receptacle contacts 2b of the second connector 1b have a plug end section 12b that extends a distance (first length) L1 from the mating side 13b of the second housing 3b into the receptacle contact receiving cavity 4b. The first length L1 is preferably at least twice the diameter of the receptacle contact receiving cavity 4b. Thus, when the pin contacts 2a are plugged into the receptacle contacts 2b, a section of the pin contact is inserted into the receptacle contact receiving cavity 4b, thereby providing insulation isolation between adjacent pin contacts.

[0035] 5, 6a, and 6b, a first connector 1a includes pin contacts 2a and a second connector 1b includes receptacle contacts 2b, whereby the pin contacts 2a of the first connector 1a have bayonet end sections 12a that are received within the pin contact-receiving cavities 4a, and the receptacle contacts 2b of the second connector 1b have bayonet end sections 12b that protrude beyond the mating side 13b of the second housing 3b. Thus, when the receptacle contacts 2b are bayoneted over the pin contacts 2a, a section of the receptacle contact is inserted into the pin contact-receiving cavities 4a, thereby providing insulating isolation between adjacent receptacle contacts.

[0036] The wiring end section 9 of the contact 2 projects outside the housing 3 beyond the cable routing side 14 of the housing 3 so that the connector can be connected to an electrical wire 8 after the contact 2 has been assembled to the housing 3.

[0037] 1a-2b, the pin contact 2a further includes a mating-side insulating tube sleeve 5a inserted over a portion of the central body section 10 of the pin contact 2a. The insulating tube sleeve 5a mounted over the pin contact 2a protrudes beyond the mating side 13a of the first housing 3a with a length configured to be partially inserted into the receptacle contact-receiving cavity 4b when the first and second connectors are mated with each other, thereby ensuring an extended electrical path between adjacent electrical pin contacts.

[0038] The pin contact 2a has a body section with a reduced diameter to allow for the positioning of an insulating tube sleeve 5a that is inserted over the reduced section diameter until it abuts the shoulder 24. The sleeve 5a preferably lies flush with the outer diameter of the pin contact forward of the shoulder 24.

[0039] 5-6b, the receptacle contact 2a of this variation includes a mating-side insulating tube sleeve 5b inserted over a portion of the central body section 10 of the receptacle contact 2b. The insulating tube sleeve 5b fitted over the receptacle contact 2b has a length configured to be partially inserted into the pin contact-receiving cavity 4a when the first and second connectors are mated with each other, and protrudes beyond the mating side 13b of the second housing 3b, thereby ensuring an extended electrical path between adjacent electrical pin contacts.

[0040] The receptacle contact 2b has a body section 10 with a reduced diameter to allow for the positioning of an insulating tubing sleeve 5b that is inserted over the reduced diameter section until it abuts shoulder 24. The sleeve 5b preferably lies flush with the outer diameter of the receptacle contact forward of shoulder 24.

[0041] The insulating tube sleeves 5a, 5b, which are assembled to the pin contacts or receptacle contacts (depending on the variant) by sliding them over the body section, advantageously ensure accurate positioning of the tube sleeves 5a, 5b relative to the contacts and also a constant, accurate thickness defined by the thickness of the tube sleeve, compared to overmolded insulating layers which may have varying thicknesses depending on manufacturing tolerances.

[0042] According to one aspect of the present invention, the insulating tube sleeves 5a, 5b are preferably made of polyimide tubing, which advantageously provides high insulation resistance to electric fields, and further, polyimide tubing can be formed to very precise dimensions, particularly in the tube thickness, which can be made with very thin walls, e.g., less than 0.3 mm. This ensures that the insulating layer has a precise, consistent thickness around the pin contact to ensure electrical breakdown resistance within small tolerances, despite the very thin walls of the insulating tube sleeves. Other suitable insulating tube materials that can be formed with very thin tube walls, particularly in the tube thickness of less than 0.3 mm, include polytetrafluoroethylene (PTFE), glass, or ceramic tubing.

[0043] The length L2 of the insulating tube sleeves 5a, 5b, which defines the length from the receptacle contact receiving cavity 4b to the pin contact receiving cavity 4a, can be easily changed to adjust the electrical path according to the required specifications by the position of the shoulder on the pin contact and the length of the insulating tube sleeves 5a, 5b, for example, compared to overmolding.

[0044] Thus, assembling the insulating tube sleeve onto the pin contacts or receptacle contacts (as the variant) allows greater flexibility in the manufacture of connectors with different specifications. Furthermore, insertion of the insulating tube sleeve 5a, 5b from the wire end section, as opposed to insertion from the bayonet end section, allows for easy and accurate positioning of the insulating tube sleeve onto the pin contacts or receptacle contacts (as the variant) in a secure manner, as the insulating tube sleeve is locked between the contact shoulder 24 and the shoulder 25 in the pin-receiving cavity 4a, 4b.

[0045] 4a and 4b, in accordance with one embodiment of the present invention, an electrical connector includes a cable-running side insulating tube sleeve 5 inserted over the wiring end section 9 of the electrical contact 2. The insulating tube sleeve 5 may advantageously be made of polyimide, which has the advantages discussed above in connection with the insulating tube sleeves 5a, 5b on the mating side of the contact.

[0046] The contact receiving cavity 4 includes a larger diameter section at the cable routing side 14 that extends into the housing over a tube insertion length L3 to form a gap between the housing and the outer surface of the receptacle contact wiring end section 9, which is configured to allow the insulating tube sleeve 5 to be inserted into the housing over the length L3. The insulating tube sleeve 5 has a length L4 that extends from the interior of the housing 3 to a position on the insulating layer 23 of the electrical wire 8 so that the interconnections between the conductors 22 and the electrical contact wiring end section 9 are completely covered, providing a long electrical path between adjacent conductors. The insulating tube sleeve length L4 is preferably at least eight times the distance between adjacent contacts 2 to ensure a sufficiently long electrical path between the contacts.

[0047] It should be noted that in certain embodiments, only a portion of the electrical contacts may include an insulating tube sleeve, for example, only the contacts configured to be connected to a high voltage may include an insulating tube sleeve.

[0048] 7a-7d show steps in the assembly of an insulating tube sleeve 5 onto an electrical contact 2. In this example, the wiring end section 9 is for a pin contact 2a, but the same procedure applies to the wiring end section for a receptacle contact 2b.

[0049] The insulating tube sleeves 5 are inserted over the electrical wires 8 and threaded through filler containment rings 7, which serve to contain the insulating filler 6, as described below. The insulating tube sleeves 5 are inserted over the wires 8 before the wires are connected to their respective contacts 2. FIG. 7b shows the electrical wires 8 connected (e.g., by soldering) to the wire-receiving sections 9 of their respective contacts 2. In a subsequent step, the insulating tube sleeves 5 are slid along the electrical wires toward the cable-running side 14 of the housing 3, and they are further inserted into their respective cable-running tube-receiving sections 15 until they abut the shoulders 26 of the tube-receiving sections 15.

[0050] The containment ring 7 may then be positioned against the cable routing side 14 of the housing 3, optionally held in place by locating members 18, 21 on the housing 3 and containment ring 7. An epoxy resin or other insulating filler 6 material may then be poured or injected into the well area formed by the containment ring 7 around and between the insulating tube sleeve 5. The insulating filler 6 is made of a resin (such as an acrylate or epoxy-based resin) configured to form a bond between the material of the insulating tube sleeve 5 and the material of the housing 3.

[0051] [List of references used] Electrical Connector 1 First connector 1a, second connector 1b Electrical Contact 2 Pin contact 2a, receptacle contact 2b Wiring End Section 9 Center Body Section 10 Sleeve Receiving Section 11 Plug-in end sections 12, 12a, 12b Shoulder 24 Housing 3 First housing 3a, second housing 3b Mating side 13, 13a, 13b Cable routing side 14 Contact receiving cavity 4 Pin contact receiving cavity 4a, receptacle contact receiving cavity 4b Cable wiring side tube receiving section 15 Shoulder 26 Mating tube receiving section 16 Shoulder 25 Center Retention Section 17 Ring positioning member 18 Wiring side insulating tube sleeve 5 Mating side insulating tube sleeves 5a, 5b Polyimide Tube Insulating filler 6 Filler Containment Ring 7 Positioning member 21 Electrical Wires / Cables8 Conductor 22 Insulating layer 23 Casing 19, 19a, 19b Distance L1 of receptacle contact from mating face Mating side insulating tube sleeve length L2 Cable wiring side tube receiving section length depth L3 Wiring side insulating tube sleeve length L4

[0052] [Embodiment] (1) An electrical connector (1), an insulating housing (3) having a contact-receiving cavity (4) extending between a mating side (13) and a cable routing side (14) of the housing; a plurality of electrical contacts (2) disposed within the contact-receiving cavities and fixed in direct contact engagement with the contact-receiving cavities; Including, the electrical contact has a plug end section (12), a central body section (10), and a wiring end section (9), the wiring end section (9) protruding from the housing beyond the cabling side (14) for connection to a conductor (22) of an electrical wire (8); the contact receiving cavity includes a cable wiring side tube receiving section (15) having a diameter larger than a portion of the electrical contact so as to form a tubular gap between the electrical contact and the housing, the connector further includes an insulating tube sleeve (5) slidably inserted onto the electrical wire, the insulating sleeve tube having a section extending into the cable wiring side tube receiving section (15) and a section extending from the housing beyond the cable wiring side (15) to cover an insulating layer (23) on the conductor (22). (2) The electrical connector according to embodiment 1, wherein the insulating tube sleeve (5) is made of polyimide. (3) The electrical connector of any one of claims 1 to 2, further comprising an insulating filler (6) deposited on the cable wiring side (14) of the housing (3) between and around the insulating tube sleeves (5) inserted into the cable wiring side tube receiving section (15) of the housing. (4) The electrical connector of embodiment 3, further comprising a filler containment ring (7) mounted around the cable routing side (14) of the housing (3) to form a well for injection, pouring or molding of the insulating filler (6). (5) An electrical connector according to any one of embodiments 1 to 4, wherein the length (L4) of the insulating tube sleeve is at least 8 times the distance between adjacent contacts.

[0053] (6) An electrical connector according to any one of embodiments 1 to 5, wherein the contacts include a mating section (12) extending beyond the mating side (13) of the housing and a small-diameter body section (10) having a rearward-facing shoulder (24), and the contacts further include a second insulating tube sleeve (5a, 5b) having a length (L2) inserted onto the small-diameter central body section, a portion of the insulating tube sleeve extending beyond the mating side (13) of the housing and configured to be inserted into a contact-receiving cavity (4) of a mating connector. (7) The electrical connector of embodiment 6, wherein the diameter of the portion of the contact adjacent the shoulder (24) is substantially the same as the diameter of the second insulating tube sleeve (5a, 5b) so that the second insulating tube sleeve is flush with the contact at the interface between the insulating tube sleeve and the shoulder. (8) The electrical connector according to embodiment 6 or 7, wherein the electrical contacts include pin contacts (2a), the pin contacts including the small-diameter body section (10) having a rearward-facing shoulder (24) and the second insulating tube sleeve (5a) inserted over the small-diameter central body section, the portion of the second insulating tube sleeve (5a) having a length (L2) of the second insulating tube sleeve (5a) extending beyond the mating side (13a) of the housing and configured to be inserted into the receptacle contact-receiving cavity (4b) of the mating connector (1b). (9) The electrical connector of embodiment 8, wherein the receptacle contacts have a plug end section (12b) positioned within the receptacle contact receiving cavity (4b) of the second housing (3b) at a first length (L1) from the mating side (13b) of the second housing, and the first length is at least twice the diameter of the receptacle contact receiving cavity (4b). (10) The electrical connector of embodiment 6 or 7, wherein the electrical contacts include receptacle contacts (2b), the receptacle contacts including the small-diameter body section (10) having a rearward-facing shoulder (24) and the second insulating tube sleeve (5b) inserted onto the small-diameter central body section, the portion of the second insulating tube sleeve (5b) having a length (L2) of the second insulating tube sleeve (5b) extending beyond the mating side (13b) of the housing and configured to be inserted into the pin contact receiving cavity (4a) of the mating connector (1a).

[0054] (11) An electrical connector according to any one of the preceding claims, wherein the insulating tube sleeve (5, 5a, 5b) has a tube wall thickness of less than 0.3 mm. (12) An electrical connector structure, The connector includes a first connector (1a) and a second connector (1b) that are pluggably connectable to each other; An electrical connector structure, wherein the first connector and the second connector have the characteristics of the electrical connector described in any one or more of embodiments 1 to 11, wherein the first connector (1a) includes pin contacts (2a) and the second connector (1b) includes receptacle contacts (2b). (13) A method for assembling the electrical connector (1) according to any one of the first to 12 embodiments, comprising the steps of: - inserting or overmolding said electrical contacts into said insulating housing (3); - inserting said insulating tube sleeve over at least a portion of said electrical wire (8); - connecting the conductors (22) of the wires (8) to the respective wire-receiving portions of the contacts; - sliding the insulating tube sleeve over the respective wire-receiving portions of the contacts and into the contact-receiving cavities; - depositing an insulating filler (6) on the cable wiring side (14) of the housing (3) between and around the insulating tube sleeves (5); A method comprising: (14) An electrical connector (1), an insulating housing (3) having a contact-receiving cavity (4) extending between a mating side (13) and a cable routing side (14) of the housing; a plurality of electrical contacts (2) received in the contact receptacle; Including, The electrical contact has a plug end section (12), a central body section (10), and a wiring end section (9); the wiring end section (9) protruding from the housing beyond the cabling side (14) for connection to a conductor (22) of an electrical wire (8); the contact-receiving cavity includes a cable-side tube-receiving section (15) having a diameter larger than a portion of the electrical contact so as to form a tubular gap between the electrical contact and the housing; The connector further includes an insulating tube sleeve (5) slidably inserted over the electrical wire; The insulating sleeve tube has a section that extends into the cable wiring side tube receiving section (15) and a section that extends out of the housing beyond the cable wiring side (15) to cover an insulating layer (23) on the conductor (22), The contact includes a mating section (12) extending beyond a mating side (13) of the housing and a reduced diameter body section (10) having a rearwardly facing shoulder (24); The electrical connector further includes a second insulating tube sleeve (5a, 5b) having a length (L2) inserted over the smaller diameter central body section, a portion of the insulating tube sleeve extending beyond the mating side (13) of the housing and configured to be inserted into the contact-receiving cavity (4) of a mating connector. (15) The electrical connector according to claim 14, wherein the insulating tube sleeve (5) is made of polyimide.

[0055] (16) The electrical connector of any one of claims 14 to 15, further comprising an insulating filler (6) deposited on the cable wiring side (14) of the housing (3) between and around the insulating tube sleeves (5) inserted into the cable wiring side tube receiving section (15) of the housing. (17) The electrical connector of claim 16, further comprising a filler containment ring (7) mounted around the cable routing side (14) of the housing (3) to form a well for injection, pouring or molding of the insulating filler (6). (18) An electrical connector according to any one of embodiments 14 to 17, wherein the length (L4) of the insulating tube sleeve is at least eight times the distance between adjacent contacts. (19) An electrical connector according to any one of embodiments 14 to 18, wherein the diameter of a portion of the contact adjacent the shoulder (24) is substantially the same as the diameter of the second insulating tube sleeve (5a, 5b) so that the second insulating tube sleeve is flush with the contact at the interface between the insulating tube sleeve and the shoulder. (20) An electrical connector according to any one of embodiments 14 to 19, wherein the electrical contacts include pin contacts (2a), the pin contacts including the small-diameter body section (10) having a rearward-facing shoulder (24) and the second insulating tube sleeve (5a) inserted over the small-diameter central body section, the portion of the second insulating tube sleeve (5a) having a length (L2) of the second insulating tube sleeve (5a) extending beyond the mating side (13a) of the housing and configured to be inserted into a receptacle contact-receiving cavity (4b) of a mating connector (1b).

[0056] (21) The electrical connector of embodiment 20, wherein the receptacle contacts have a plug end section (12b) positioned within the receptacle contact receiving cavity (4b) of the second housing (3b) at a first length (L1) from the mating side (13b) of the second housing, and the first length is at least twice the diameter of the receptacle contact receiving cavity (4b). (22) An electrical connector according to any one of embodiments 14 to 21, wherein the electrical contacts include a receptacle contact (2b), the receptacle contact including the small-diameter body section (10) having a rearward-facing shoulder (24) and the second insulating tube sleeve (5b) inserted onto the small-diameter central body section, the portion of the second insulating tube sleeve (5b) having a length (L2) of the second insulating tube sleeve (5b) extending beyond the mating side (13b) of the housing and configured to be inserted into the pin contact receiving cavity (4a) of the mating connector (1a). (23) An electrical connector according to any one of embodiments 14 to 22, wherein the insulating tube sleeve (5, 5a, 5b) has a tube wall thickness of less than 0.3 mm. (24) An electrical connector structure, The connector includes a first connector (1a) and a second connector (1b) that are pluggably connectable to each other; An electrical connector structure, wherein the first connector and the second connector have the characteristics of the electrical connector described in any one or more of embodiments 14 to 23, wherein the first connector (1a) includes pin contacts (2a) and the second connector (1b) includes receptacle contacts (2b). (25) A method for assembling the electrical connector (1) according to any one of the embodiments 14 to 24, comprising the steps of: - inserting or overmolding said electrical contacts into said insulating housing (3); - inserting said insulating tube sleeve over at least a portion of said electrical wire (8); - connecting the conductors (22) of the wires (8) to the respective wire-receiving portions of the contacts; - sliding the insulating tube sleeve over the respective wire-receiving portions of the contacts and into the contact-receiving cavities; - depositing an insulating filler (6) on the cable wiring side (14) of the housing (3) between and around the insulating tube sleeves (5); A method comprising:

Claims

1. An electrical connector (1), an insulating housing (3) having contact-receiving cavities (4) extending between a mating side (13) and a cable routing side (14) of the housing; a plurality of electrical contacts (2) disposed within the contact receiving cavities and fixed in direct contact engagement with the contact receiving cavities; Including, the electrical contact has a plug end section (12), a central body section (10), and a wiring end section (9), the wiring end section (9) protruding from the housing beyond the cabling side (14) for connection to a conductor (22) of an electrical wire (8); the contact receiving cavity includes a cable wiring side tube receiving section (15) having a diameter larger than a portion of the electrical contact so as to form a tubular gap between the electrical contact and the housing, the connector further includes an insulating tube sleeve (5) slidably inserted onto the electrical wire, the insulating sleeve tube having a section extending into the cable wiring side tube receiving section (15) and a section extending out of the housing beyond the cable wiring side (15) to cover an insulating layer (23) on the conductor (22).

2. 2. The electrical connector of claim 1, wherein said insulating tube sleeve (5) is made of polyimide.

3. 2. The electrical connector of claim 1, further comprising an insulating filler (6) deposited on the cable routing side (14) of the housing (3) between and around the insulating tube sleeves (5) inserted into the cable routing side tube receiving section (15) of the housing.

4. 4. The electrical connector of claim 3, further comprising a filler containment ring (7) mounted around the cable routing side (14) of the housing (3) to form a well for injection, pouring or molding of the insulating filler (6).

5. 2. The electrical connector of claim 1, wherein the length (L4) of the insulating tube sleeve is at least eight times the distance between adjacent contacts.

6. 2. The electrical connector of claim 1, wherein the contacts include a mating section (12) extending beyond the mating side (13) of the housing and a reduced diameter body section (10) having a rearwardly facing shoulder (24), and the contacts further include a second insulating tube sleeve (5a, 5b) having a length (L2) inserted over the reduced diameter central body section, a portion of the insulating tube sleeve extending beyond the mating side (13) of the housing and configured to be inserted into a contact-receiving cavity (4) of a mating connector.

7. 7. The electrical connector of claim 6, wherein a diameter of a portion of the contact adjacent the shoulder is substantially the same as a diameter of the second insulating tube sleeve such that the second insulating tube sleeve is flush with the contact at the interface between the insulating tube sleeve and the shoulder.

8. 7. The electrical connector of claim 6, wherein the electrical contacts include pin contacts (2a), the pin contacts including the small diameter body section (10) having a rearwardly facing shoulder (24) and the second insulating tube sleeve (5a) inserted over the small diameter central body section, the portion of the second insulating tube sleeve (5a) having a length (L2) of the second insulating tube sleeve (5a) extending beyond the mating side (13a) of the housing and configured to be inserted into a receptacle contact receiving cavity (4b) of a mating connector (1b).

9. 9. The electrical connector of claim 8, wherein the receptacle contacts have plug end sections (12b) positioned within the receptacle contact receiving cavities (4b) of the second housing (3b) spaced a first length (L1) from a mating side (13b) of the second housing, the first length being at least twice the diameter of the receptacle contact receiving cavities (4b).

10. 7. The electrical connector of claim 6, wherein the electrical contacts include receptacle contacts (2b), the receptacle contacts including the small diameter body section (10) having a rearwardly facing shoulder (24) and the second insulating tube sleeve (5b) inserted over the small diameter central body section, the portion of the second insulating tube sleeve (5b) having a length (L2) of the second insulating tube sleeve (5b) extending beyond the mating side (13b) of the housing and configured to be inserted into the pin contact receiving cavity (4a) of the mating connector (1a).

11. 2. The electrical connector of claim 1, wherein the insulating tube sleeve (5, 5a, 5b) has a tube wall thickness of less than 0.3 mm.

12. An electrical connector structure, comprising: The connector includes a first connector (1a) and a second connector (1b) that are pluggably connectable to each other; 12. An electrical connector structure, wherein the first connector and the second connector have the characteristics of the electrical connector described in any one of claims 1 to 11, wherein the first connector (1a) includes pin contacts (2a) and the second connector (1b) includes receptacle contacts (2b).

13. A method for assembling an electrical connector (1) according to any one of claims 1 to 11, comprising the steps of: - inserting or overmolding said electrical contacts into said insulating housing (3); - inserting said insulating tube sleeve over at least a portion of said electrical wire (8); - connecting the conductors (22) of the wires (8) to the respective wire-receiving portions of the contacts; - sliding the insulating tube sleeve over the respective wire-receiving portions of the contacts into the contact-receiving cavities; - depositing an insulating filler (6) on the cabling side (14) of the housing (3) between and around the insulating tube sleeves (5); A method comprising:

14. An electrical connector (1), an insulating housing (3) having contact-receiving cavities (4) extending between a mating side (13) and a cable routing side (14) of the housing; a plurality of electrical contacts (2) received in the contact receptacle; Including, The electrical contact has a plug end section (12), a central body section (10), and a wiring end section (9); the wiring end section (9) protruding from the housing beyond the cabling side (14) for connection to the conductor (22) of the electrical wire (8); the contact receiving cavity includes a cable-side tube receiving section (15) having a diameter larger than a portion of the electrical contact so as to form a tubular gap between the electrical contact and the housing; The connector further includes an insulating tube sleeve (5) slidably inserted over the electrical wire; The insulating sleeve tube has a section that extends into the cable wiring side tube receiving section (15) and a section that extends out of the housing beyond the cable wiring side (15) to cover an insulating layer (23) on the conductor (22), The contact includes a mating section (12) that extends beyond a mating side (13) of the housing, and a reduced diameter body section (10) having a rearwardly facing shoulder (24); The electrical connector further includes a second insulating tube sleeve (5a, 5b) having a length (L2) inserted over the smaller diameter central body section, a portion of the insulating tube sleeve extending beyond the mating side (13) of the housing and configured to be inserted into a contact-receiving cavity (4) of a mating connector.

15. 15. The electrical connector of claim 14, wherein the insulating tube sleeve (5) is made of polyimide.

16. 15. The electrical connector of claim 14, further comprising an insulating filler (6) deposited on the cable routing side (14) of the housing (3) between and around the insulating tube sleeves (5) inserted into the cable routing side tube receiving section (15) of the housing.

17. 17. The electrical connector of claim 16, further comprising a filler containment ring (7) mounted around the cable routing side (14) of the housing (3) to form a well for injection, pouring or molding of the insulating filler (6).

18. 15. The electrical connector of claim 14, wherein the length (L4) of the insulating tube sleeve is at least eight times the distance between adjacent contacts.

19. 15. The electrical connector of claim 14, wherein a diameter of a portion of the contact adjacent the shoulder (24) is substantially the same as a diameter of the second insulating tube sleeve (5a, 5b) such that the second insulating tube sleeve is flush with the contact at the interface between the insulating tube sleeve and the shoulder.

20. 15. The electrical connector of claim 14, wherein the electrical contacts include pin contacts (2a), the pin contacts including the small diameter body section (10) having a rearwardly facing shoulder (24) and the second insulating tube sleeve (5a) inserted over the small diameter central body section, the portion of the second insulating tube sleeve (5a) having a length (L2) of the second insulating tube sleeve (5a) extending beyond a mating side (13a) of the housing and configured to be inserted into a receptacle contact receiving cavity (4b) of a mating connector (1b).

21. 21. The electrical connector of claim 20, wherein the receptacle contacts have plug end sections (12b) positioned within the receptacle contact receiving cavities (4b) of the second housing (3b) spaced a first length (L1) from a mating side (13b) of the second housing, the first length being at least twice the diameter of the receptacle contact receiving cavities (4b).

22. 15. The electrical connector of claim 14, wherein the electrical contacts include receptacle contacts (2b), the receptacle contacts including the small diameter body section (10) having a rearwardly facing shoulder (24) and the second insulating tube sleeve (5b) inserted over the small diameter central body section, the portion of the second insulating tube sleeve (5b) having a length (L2) of the second insulating tube sleeve (5b) extending beyond the mating side (13b) of the housing and configured to be inserted into the pin contact receiving cavity (4a) of the mating connector (1a).

23. 15. The electrical connector of claim 14, wherein the insulating tube sleeve (5, 5a, 5b) has a tube wall thickness of less than 0.3 mm.

24. An electrical connector structure, comprising: The connector includes a first connector (1a) and a second connector (1b) that are pluggably connectable to each other; 24. An electrical connector structure, wherein the first connector and the second connector have the characteristics of the electrical connector of any one of claims 14 to 23, wherein the first connector (1 a) includes pin contacts (2 a) and the second connector (1 b) includes receptacle contacts (2 b).

25. A method for assembling an electrical connector (1) according to any one of claims 14 to 23, comprising the steps of: - inserting or overmolding said electrical contacts into said insulating housing (3); - inserting said insulating tube sleeve over at least a portion of said electrical wire (8); - connecting the conductors (22) of the wires (8) to the respective wire-receiving portions of the contacts; - sliding the insulating tube sleeve over the respective wire-receiving portions of the contacts into the contact-receiving cavities; - depositing an insulating filler (6) on the cabling side (14) of the housing (3) between and around the insulating tube sleeves (5); A method comprising:

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