Electrical connector with right-angle contacts

Abstract

This provides an effective and reliable assembly process for electrical connectors with right-angle contacts. [Solution] The electrical connector comprises a dielectric housing (200) extending between a front and a rear section. The dielectric housing includes a front contact channel, a rear contact channel, and a molded anvil between the front and rear contact channels. The rear contact channel extends in a direction intersecting the front contact channel. The electrical connector comprises a contact (150), the contact (150) having a contact body between a mating portion configured to mate with a mating contact and a termination portion configured to terminate with a wire (104). The contact body has a transition portion molded along the molded anvil to position the termination portion in the rear contact channel. The termination portion is oriented in a direction intersecting the mating portion.

Description

Technical Field

[0001] The subject matter of this specification generally relates to electrical connectors.

Background Art

[0002] Electrical connectors generally include contacts held in a housing. The contacts are configured to mate with mating contacts of a mating electrical connector. The connector generally includes a cable or wire terminated at an end of the contact. Some known connectors are right-angle connectors and have contacts configured such that the termination end is 90° relative to the mating end so that the cable can exit the housing at 90° relative to the mating axis. The contacts have to be carefully bent by a machine or a person. If bent inappropriately, the fit into the housing may be improper and scrap may occur.

Summary of the Invention

Problems to be Solved by the Invention

[0003] An effective and reliable assembly process for electrical connectors having right-angle contacts is still needed.

Means for Solving the Problems

[0004] In one embodiment, an electrical connector is provided, comprising a dielectric housing extending between a front and a rear portion. The front portion is configured to mate with a mating electrical connector. The dielectric housing includes a front contact channel, a rear contact channel, and a molded anvil between the front and rear contact channels. The rear contact channel extends in a direction intersecting (lateral, transverse to) the front contact channel. The electrical connector comprises contacts, each contact including a contact body between a mating portion and a termination portion of the contact. The termination portion is configured to terminate with a wire. The mating portion is configured to mate with a mating contact of a mating electrical connector. The mating portion is received by the front contact channel. The contact body has a transition section that is molded along the molded anvil and positions the terminal portion in the rear contact channel. The terminal portion is oriented in a direction that intersects the mating portion (lateral, transverse).

[0005] The present invention will be described using the attached drawings as an example. [Brief explanation of the drawing]

[0006] [Figure 1] This is a perspective view of an electrical connector according to an exemplary embodiment. [Figure 2] This is a front perspective view of a cable assembly according to an exemplary embodiment. [Figure 3] This is a front view of a portion of a cable assembly according to an exemplary embodiment. [Figure 4] This is a partial rear view of a cable assembly according to an exemplary embodiment. [Figure 5] This is an exploded view of a cable assembly according to an exemplary embodiment. [Figure 6] This is a rear perspective view of an exemplary embodiment of a cable assembly, showing the housing cover and shield cover in the open position. [Figure 7] This is a rear perspective view of an exemplary embodiment of a cable assembly, showing the housing cover in the closed position and the shield cover in the open position. [Figure 8] This is a rear view of an exemplary embodiment of a cable assembly, showing the housing cover and shield cover in the open position. [Figure 9] This is a rear view of a cable assembly according to an exemplary embodiment, showing the housing cover in the closed position and the shield cover in the open position. [Figure 10] This is a cross-sectional view of a portion of a cable assembly according to an exemplary embodiment. [Figure 11] This is a partial rear perspective cross-sectional view of a portion of a cable assembly according to an exemplary embodiment. [Modes for carrying out the invention]

[0007] Figure 1 is a perspective view of an exemplary embodiment of an electrical connector 100. The electrical connector 100 is configured to mate with a mating electrical connector (not shown). In the illustrated embodiment, the electrical connector 100 is a receptacle connector configured to mate with a plug connector. In an alternative embodiment, the electrical connector 100 may be a plug connector configured to mate with a receptacle connector. In an exemplary embodiment, the electrical connector 100 is a cable connector provided at the end of one or more cables 102. The mating electrical connector may also be a cable connector. Alternatively, the mating electrical connector may be a board connector mounted on a printed circuit board. In various embodiments, the electrical connector 100 may be a header connector configured to be attached to another component, such as a panel, wall, chassis, circuit board, or other component.

[0008] The electrical connector 100 comprises a connector housing 110 that holds one or more cable assemblies 120. In the illustrated embodiment, the connector housing 110 holds a pair of cable assemblies 120. However, in alternative embodiments, the connector housing 110 may be designed to hold more or fewer cable assemblies 120. In the illustrated embodiment, the cable assemblies 120 are arranged side by side. In alternative embodiments, other arrangements are possible, such as the cable assemblies 120 being stacked on top of each other.

[0009] The connector housing 110 includes a wall 112 that forms a cavity 114 for receiving the cable assembly 120. The mating electrical connector can be inserted into the cavity 114 to mate with the cable assembly 120. For example, the connector housing 110 can open at the front to provide access to the cavity 114 and the cable assembly 120 and to receive the mating electrical connector. The cable 102 extends from the connector housing 110. For example, the cable 102 may extend from the rear and / or bottom of the connector housing 110. The connector housing 110 includes a latching mechanism, such as a connector latch 116, used to secure the mating electrical connector in the cavity 114. In the illustrated embodiment, the connector latch 116 is a latch pocket configured to receive a flexible latch of a mating electrical connector. In alternative embodiments, other types of latching mechanisms may be provided, such as a flexible latch used for electrical coupling to the mating electrical connector. In various embodiments, the connector housing 110 may include a guiding mechanism and / or a keying mechanism for controlling mating with the mating electrical connector.

[0010] Figure 2 is a front perspective view of a cable assembly 120 according to an exemplary embodiment. Figure 3 is a partial front view of the cable assembly 120 according to an exemplary embodiment. Figure 4 is a partial rear view of the cable assembly 120 according to an exemplary embodiment. In an exemplary embodiment, the cable assembly 120 is a signal assembly configured to transmit data signals. However, in addition to or instead, the cable assembly may be a power assembly configured to transmit power. In various embodiments, the cable assembly 120 includes a plurality of signal lines for connecting the cable 102 to a mating electrical connector. For example, the cable assembly 120 may include a pair of signal lines configured to transmit differential pair signals. However, the cable assembly 120 may include more or fewer signal lines than two. In exemplary embodiments, the cable assembly 120 is a high-speed cable assembly. For example, the cable assembly 120 may be a multi-gigabit cable assembly. In various embodiments, the cable assembly 120 can provide a bandwidth of 15 GHz or more. In various embodiments, the cable assembly 120 can support data transmission of 56 Gbps or more.

[0011] The cable assembly 120 is terminated at the end of the cable 102. For example, the cable assembly 120 may be terminated at the end of the wire 104 of the cable 102. In the illustrated embodiment, the cable 102 includes differential pair wires such as twisted pair wires 104 or parallel pair wires 104. However, in alternative embodiments, the cable 102 may include more or fewer wires 104, such as including multiple twisted pair wires 104. In other alternative embodiments, the wires 104 may be single-ended wires instead of twisted pair wires. In various other embodiments, the cable 102 may include a single conductor. In an exemplary embodiment, the cable 102 is a shielded cable having a cable shield 106 that surrounds the wire 104 and provides electrical shielding for the wire 104. The cable 102 includes an outer jacket 108 that surrounds the cable shield 106.

[0012] In an exemplary embodiment, the cable assembly 120 includes one or more contacts 150, a dielectric housing 200 that holds the contacts 150, and an outer shield 300 that surrounds at least a portion of the dielectric housing 200 and provides electrical shielding around the dielectric housing 200 and the contacts 150 held by the dielectric housing 200. In an exemplary embodiment, the outer shield 300 completely surrounds the dielectric housing 200 and the contacts 150, completely shielding the contacts 150 between the cable 102 and a mating interface configured to mate with a mating electrical connector. The outer shield 300 provides 360° shielding around the ends of the cable 102 and the contacts 150. For example, the outer shield 300 shields along the top, bottom, sides, front, and rear of the cable assembly 120, providing efficient electrical shielding along the signal transmission line.

[0013] In the illustrated embodiment, the cable assembly 120 includes a pair of contacts 150. The contacts 150 are configured to terminate at the corresponding ends of the wires 104 of the cable 102. The outer shield 300 is configured to terminate directly or via a ferrule or other connecting element on the cable shield 106 of the cable 102, forming a common grounding path between the cable 102 and the cable assembly 120.

[0014] In an exemplary embodiment, the cable assembly 120 is a right-angle cable assembly. The contact 150 is a right-angle contact and has a 90° bend along the contact 150 for transitioning between the mating ends of the terminal ends of the contact 150. In the illustrated embodiment, the cable 102 extends from the bottom of the cable assembly 120. The cable 102 generally extends along a cable axis that is perpendicular to the mating axis of the cable assembly 120. In an alternative embodiment, the cable 102 can extend from other parts such as the side or top of the cable assembly 120. In an alternative embodiment, the cable 102 can extend at other angles other than a right angle.

[0015] FIG. 5 is an exploded view of a cable assembly 120 according to an exemplary embodiment. FIG. 5 shows the contact 150, the dielectric housing 200, and the outer shield 300. In the illustrated embodiment, the outer shield 300 is a multi-component shield having a front shield 302, a rear shield 304, and a ferrule 306 for the cable 102 configured to be coupled to the rear shield 304 to mechanically and electrically connect the cable 102 to the outer shield 300. The rear shield 304 is separate from the front shield 302 and is configured to be electrically coupled to the front shield 302 by means such as crimping, laser welding, or other connection processes. However, in an alternative embodiment, the outer shield 300 may be a single-component shield rather than a multi-component shield.

[0016] Each contact 150 includes a contact body 152 that extends between a mating portion 160 and a terminal end 180. In an exemplary embodiment, the contact body 152 is a press-formed structure formed from a metal sheet by pressing into a desired shape. For example, the contact body 152 is a single structure having a mating portion 160 integral with the terminal end 180.

[0017] The fitting portion 160 is configured to fit into the mating contacts of the mating electrical connector. In the illustrated embodiment, the fitting portion 160 includes a socket 162 configured to receive pins that define the mating contacts of the mating electrical connector. In an alternative embodiment, other types of fitting portions can be provided, such as pins, spring beams, blades, or other types of fitting portions. In an exemplary embodiment, the fitting portion 160 is formed in a cylindrical or tubular structure so as to define the socket 162. In an alternative embodiment, the fitting portion 160 can have other shapes.

[0018] The termination portion 180 is configured to be terminated to the wire 104 of the cable 102. In the illustrated embodiment, the termination portion 180 includes a crimp barrel 182 configured to crimp to the wire 104. In an alternative embodiment, other types of termination portions can be provided, such as welding pads or solder pads configured to be welded or soldered to the wire 104, or pressure contact.

[0019] In an exemplary embodiment, the contact body 152 includes a transition portion 170 between the fitting portion 160 and the termination portion 180. The transition portion 170 includes a bend or a fold that turns the termination portion 180 in a direction intersecting the fitting portion 160. For example, the transition portion 170 can have a 90° bend so as to form a right-angle contact. In the illustrated embodiment, the termination portion 180 is oriented perpendicular to the fitting portion 160. For example, the fitting portion 160 is generally horizontally oriented, and the termination portion 180 is generally vertically oriented.

[0020] The dielectric housing 200 is used to hold the contacts 150 relative to each other, for example, to mate into a mating electrical connector. The dielectric housing 200 is manufactured from a dielectric material such as a plastic material. In an exemplary embodiment, the dielectric housing 200 is manufactured by a molding process such as an injection molding process. The dielectric housing 200 extends between a front portion 202 and a rear portion 204. The dielectric housing 200 includes an upper portion 206 and a bottom portion 208. The dielectric housing 200 includes a first side portion 210 and a second side portion 212. In an exemplary embodiment, the dielectric housing 200 includes a base 214, a front portion 216 extending forward from the base 214, and a rear portion 218 extending backward from the base 214. In an exemplary embodiment, the front portion 216 receives and supports the mating portion 160 of the contact 150, and the rear portion 218 receives and supports the termination portion 180 of the contact 150. The front portion 216 can define a nose cone configured to surround and support the mating portion 160 of the contact 150 on the front portion 202 of the dielectric housing 200. The rear portion 218 can define a platform or tray configured to support the termination portion 180 of the contact 150.

[0021] In an exemplary embodiment, the dielectric housing 200 includes contact channels 220 configured to receive corresponding contacts 150. Depending on the particular application, the dielectric housing 200 may include multiple contact channels 220 or a single contact channel 220. In the illustrated embodiment, the dielectric housing 200 includes a pair of contact channels 220 for receiving a pair of contacts 150. In alternative embodiments, more or fewer contact channels 220 may be provided. In an exemplary embodiment, the contact channels 220 are arranged in a row between a first side 210 and a second side 212. For example, the contact channels 220 are arranged side by side with a separating wall 222 between them. The separation wall 222 is a contact separator between contacts. The separation wall 222 may also be a wire separator between wires. The separation wall 222 electrically insulates the contacts 150 from each other within the contact channel 220.

[0022] In an exemplary embodiment, each contact channel 220 includes a front contact channel 226 and a rear contact channel 228. The front contact channel 226 passes through a front portion 216 and receives the mating portion 160 of the corresponding contact 150. The rear contact channel 228 passes through a rear portion 218 and receives the end portion 180 of the corresponding contact 150. The rear contact channel 228 extends along a path in a direction intersecting the path of the front contact channel 226. For example, in the illustrated embodiment, the rear contact channel 228 is oriented approximately perpendicular to the front contact channel 226. In an alternative embodiment, the rear contact channel 228 may be oriented at other angles.

[0023] In an exemplary embodiment, each contact channel 220 includes a molded anvil 230 between a front contact channel 226 and a rear contact channel 228. The molded anvil 230 is located at the intersection of the front contact channel 226 and the rear contact channel 228. The molded anvil 230 is defined by the inner corner 232 of the contact channel 220. In an exemplary embodiment, the molded anvil 230 is curved according to an arc-shaped path. In an exemplary embodiment, the molded anvil 230 includes a molded surface 234 used to mold the transition portion 170 of the contact 150. For example, the body of the contact 150 can be molded in the molded anvil 230 by bending the body of the contact 150 against the molded surface 234 to form the transition portion 170. The smooth curved shape of the molded anvil 230 provides a support surface for forming the bend or curved portion of the transition 170 of the contact 150.

[0024] In an exemplary embodiment, the front contact channel 226 is completely enclosed by the dielectric housing 200. For example, the front contact channel 226 may be a generally cylindrical tube or bore passing through the front portion 216 of the dielectric housing 200, and the dielectric housing 200 covers the front contact channel 226 360° along its entire length. However, in various embodiments, the front contact channel 226 may include an opening that provides access to the front contact channel 226. In an exemplary embodiment, the contact 150 can be loaded into the front contact channel 226 from the rear through the rear portion 204 of the dielectric housing 200.

[0025] In an exemplary embodiment, the rear contact channel 228 is open at the rear 204 of the dielectric housing 200. For example, the rear contact channel 228 may be surrounded by the dielectric housing 200 on three sides, for example, the front, right, and left sides of the rear contact channel 228, but the rear of the rear contact channel 228 may be open. The rear contact channel 228 is open at the rear to receive the contact 150.

[0026] In an exemplary embodiment, the dielectric housing 200 includes a housing cover 240 at its rear 204. The housing cover 240 is coupled to the rear 204 to close the rear contact channel 228. The housing cover 240 is used to cover the end portion 180 of the contact 150 and the rear contact channel 220. In an exemplary embodiment, the housing cover 240 is connected to the base 214 of the dielectric housing 200 by a hinge 242. In an exemplary embodiment, the hinge 242 and the housing cover 240 are integral with the dielectric housing 200. For example, the dielectric housing 200, the hinge 242, and the housing cover 240 can be co-molded during a common molding process to form a single monolithic structure. The hinge 242 may be an integral hinge. In the illustrated embodiment, the hinge 242 is located on the upper part 206 of the dielectric housing 200. The housing cover 240 is supported on the upper part 206 of the dielectric housing 200 and is configured to close by rotating the housing cover 240 downward, connecting the housing cover 240 to the rear part 204 of the dielectric housing 200. In alternative embodiments, other mounting positions and other closing processes may be used.

[0027] The housing cover 240 includes an inner surface 244 and an outer surface 246 with an outer wall 248 in between. The housing cover 240 may include a support mechanism 250 along the side wall 248 for supporting the housing cover 240 and the dielectric housing 200. The support mechanism 250 may be a projection, ridge, tab, rail, groove, slot, or other mechanism formed in or protruding from the side wall 248, configured to contact a complementary mechanism of the rear portion 204 of the dielectric housing 200. The support mechanism 250 can be used to position and / or guide the housing cover 240 relative to the dielectric housing 200. The support mechanism 250 can secure the housing cover 240 to the dielectric housing 200 by means of a tight fit or a latching connection, etc.

[0028] When the housing cover 240 is closed, the inner surface 244 faces the rear contact channel 220. The inner surface 244 supports the end portion 180 of the contact 150 and the rear contact channel 228. In an exemplary embodiment, the housing cover 240 can be used to form the contact 150 during assembly. For example, as the housing cover 240 moves from the open position to the closed position, the housing cover 240 engages with the end portion 180 of the contact 150 (for example, if it is in a straight configuration or a pre-bent configuration), and while closing the housing cover 240, the contact 150 can be bent to form the transition portion 170. When the housing cover 240 is closed, the transition portion 170 is bent around the forming anvil 230. Alternatively, before closing the housing cover 240, the contact 150 can be bent around the molding anvil 230 by hand or with a tool.

[0029] The outer shield 300 provides shielding for the contact 150. The dielectric housing 200 is used to position the contact 150 relative to the outer shield 300 and to electrically isolate the contact 150 from the outer shield 300. In the illustrated embodiment, the outer shield 300 includes a front shield 302 and a rear shield 304. The front shield 302 extends along the front portion 216 of the dielectric housing 200 and provides shielding for the front portion 216 of the dielectric housing 200. The rear shield 304 extends along the rear portion 218 of the dielectric housing 200 and provides shielding for the rear portion 218 of the dielectric housing 200.

[0030] In an exemplary embodiment, the front shield 302 is a press-formed part formed from a metal sheet into a desired shape. The front shield 302 includes a shield body 310 press-formed from a metal sheet. The front shield 302 extends between a front portion 312 and a rear portion 314. The front shield 302 includes an upper portion 316 and a bottom portion 318. The front shield 302 includes a first side portion 320 and a second side portion 322. The front shield 302 includes a cavity 324 surrounded by the shield body 310. In the illustrated embodiment, the cavity 324 is open at the front portion 312 and the rear portion 314. The opening at the front portion 312 provides access to the mating portion 160 of the dielectric housing 200 and contact 150 for mating with the mating electrical connector. The opening at the rear 314 allows the rear shield 304 and dielectric housing 200 to be loaded into the cavity 324 from the rear.

[0031] In an exemplary embodiment, the front shield 302 includes a connecting beam 326 adjacent to the front portion 312. The connecting beam 326 is configured to be electrically connected to the shielding structure of the mating electrical connector to form a grounding path between the outer shield 300 and the mating electrical connector.

[0032] In an exemplary embodiment, the front shield 302 includes a fastening element 328 used to secure the outer shield 300 to the connector housing 110 (shown in Figure 1). In the illustrated embodiment, the fastening element 328 is defined by latches extending outward from the front shield 302 at the top 316, the first side 320, and the second side 322, among others. The fastening element 328 is located near the rear 314. In alternative embodiments, other positions are possible. In alternative embodiments, other types of fastening elements may be used.

[0033] In an exemplary embodiment, the front shield 302 includes common elements 330 used to electrically connect the front shield 302 to the rear shield 304. In the illustrated embodiment, the common elements 330 include interference ridges or dimples which extend into the cavity 324 and contact the rear shield 304 when the rear shield 304 is inserted into the cavity 324. In an alternative embodiment, other types of common elements may be used to electrically connect the front shield 302 and the rear shield 304. Optionally, the front shield 302 may be soldered or welded to the rear shield 304 during assembly.

[0034] In an exemplary embodiment, the rear shield 304 is a press-formed part formed from a metal sheet into a desired shape. The rear shield 304 includes a shield body 350 press-formed from a metal sheet. The rear shield 304 extends between a front portion 352 and a rear portion 354. The rear shield 304 includes an upper portion 356 and a bottom portion 358. The rear shield 304 includes a first side portion 360 and a second side portion 362. The rear shield 304 includes a cavity 364 surrounded by the shield body 350. In the illustrated embodiment, the cavity 364 is open at the front portion 352 and the rear portion 354. The opening at the front portion 352 allows the front portion 216 of the dielectric housing 200 to pass through the rear shield 304. The opening at the rear portion 354 allows the dielectric housing 200 to be loaded into the cavity 364 from the rear.

[0035] In an exemplary embodiment, the cavity 364 includes a main section 366 and a cable section 368 extending from the main section 366. The cable section 368 is defined by a front wall 370. The main section 366 is configured to receive the front section 216 of the dielectric housing 200. The cable section 368 is configured to receive the rear section 218 of the dielectric housing 200 and a portion of the cable 102 (shown in Figure 1). In an exemplary embodiment, the cable section 368 is configured to terminate to the cable shield 106 of the cable 102. For example, the cable section 368 can be terminated to the cable shield 106 by crimping, soldering, welding, or other means.

[0036] In the illustrated embodiment, the cable portion 368 extends in a direction intersecting the main portion 366. In various embodiments, the cable portion 368 can be oriented perpendicular to the main portion 366. For example, the main portion 366 can extend generally horizontally, and the cable portion 368 can extend generally vertically. In alternative embodiments, other orientations are possible. In the illustrated embodiment, the front wall 370 is oriented vertically. In alternative embodiments, other orientations are possible. The front wall 370 may be curved to match the curvature of the cable 102.

[0037] In an exemplary embodiment, the rear shield 304 includes a fixing mechanism 372 along the main portion 366, for example, along the side walls and / or top walls. The fixing mechanism 372 may be a projection, ridge, tab, latch, rail, groove, slot, or other mechanism formed in or protruding from the wall, configured to contact a complementary mechanism at the rear of the front shield 302. During assembly, the fixing mechanism 372 can be used to position and / or guide the rear shield 304 relative to the front shield 302. The fixing mechanism 372 is used to secure the rear shield 304 to the front shield 302 by interference fit or latching connection, etc.

[0038] In an exemplary embodiment, the rear shield 304 includes a shield cover 380 at the rear portion 354. The shield cover 380 is configured to be coupled to the rear portion 354 to close the cavity 364. The shield cover 380 is used to cover the rear portion of the dielectric housing 200, such as the housing cover 240, when the shield cover 380 is closed. In an exemplary embodiment, the shield cover 380 is connected to the rear shield 304 by a hinge 382. In an exemplary embodiment, the hinge 382 and the shield cover 380 are integral with the rear shield 304. For example, the rear shield 304, the hinge 382, ​​and the shield cover 380 can be press-formed and formed as a single monolithic structure from a common metal sheet. The hinge 382 may be a single hinge. In the illustrated embodiment, the hinge 382 is located on the upper part 356 of the rear shield 304. The shield cover 380 is supported on the upper part 356 of the rear shield 304 and is configured to close by rotating the shield cover 380 downward, connecting the shield cover 380 to the rear part 354 of the rear shield 304. In alternative embodiments, other mounting positions and other closing processes may be used.

[0039] The shield cover 380 includes a rear cover wall 384 used to cover and close the cavity 364. The shield cover 380 may include a fastening mechanism 390 along the rear cover wall 384 for fastening the shield cover 380 to the rear shield 304. The fastening mechanism 390 may be a projection, ridge, tab, rail, groove, slot, or other mechanism formed in or protruding from the rear cover wall 384, configured to contact a complementary mechanism on the rear 354 of the rear shield 304. The fastening mechanism 390 can be used to position and / or guide the shield cover 380 relative to the rear shield 304. The fastening mechanism 390 can fasten the shield cover 380 to the rear shield 304 by means of a interference fit or a latching connection, etc.

[0040] When the shield cover 380 is closed, the rear cover wall 384 faces the front wall 370 to form a pocket for receiving the ends of the cable 102 and / or wire 104. The shield cover 380 supports the dielectric housing 200 in the cavity 364. For example, when the shield cover 380 is closed, it prevents the dielectric housing 200 from coming loose. The shield cover 380 provides shielding along the rear of the dielectric housing 200 and the contact 150.

[0041] In an exemplary embodiment, the shield cover 380 can be used to form the contact 150 during assembly. For example, when the shield cover 380 moves from an open position to a closed position, the shield cover 380 engages with the housing cover 240 so that the housing cover 240 can automatically close when the shield cover 380 is closed. Such a closing action presses the housing cover 240 against the end portion 180 of the contact 150 (for example, if it is in a straight configuration or a pre-bent configuration), and while the housing cover 240 is closed together with the shield cover 380, the contact 150 can be bent to form the transition portion 170. When the shield cover 380 is closed, the transition portion 170 is bent around the forming anvil 230. Alternatively, before closing the shield cover 380, the contact 150 can be bent around the molding anvil 230 by hand or with a tool. The housing cover 240 may be closed before closing the shield cover 380.

[0042] Figure 6 is a rear perspective view of an exemplary embodiment of a cable assembly 120, showing the housing cover 240 and shield cover 380 in the open position. Figure 7 is a rear perspective view of an exemplary embodiment of a cable assembly 120, showing the housing cover 240 in the closed position and the shield cover 380 in the open position. Figure 8 is a rear view of an exemplary embodiment of a cable assembly 120, showing the housing cover 240 and shield cover 380 in the open position. Figure 9 is a rear view of an exemplary embodiment of a cable assembly 120, showing the housing cover 240 in the closed position and the shield cover 380 in the open position.

[0043] During assembly, the contacts 150 are loaded into the contact channels 220 of the dielectric housing 200. In various embodiments, the contacts 150 can be pre-formed into right-angle contacts before being loaded into the contact channels 220. In alternative embodiments, the contacts 150 can be formed into right-angle contacts after being loaded into the contact channels 220. For example, after loading the contacts 150 into the contact channels 220, the contacts 150 can be pressed against the forming anvil 230 for forming. For example, after loading the mating portion 160 into the front portion 216 of the contact channel 220, the end portion 180 can be bent downward into the rear contact channel 228 of the contact channel 220 to form the transition portion 170 between the mating portion 160 and the end portion 180. During the assembly process, the end portion 180 can be bent downward by hand or using a tool or fixing device. In various other embodiments, the end portion 180 can be bent downward by the housing cover 240 as it moves from the open position to the closed position. For example, the inner surface of the housing cover 240 can press the end portion 180 of the contact 150, bending the contact 150 in the transition portion 170 and loading the end portion 180 into the rear contact channel 228.

[0044] During assembly, the outer shield 300 is assembled by inserting the rear shield 304 into the cavity 324 of the front shield 302. The fixing mechanism 372 is fixed to the front shield 302, fixing the rear shield 304 to the front shield 302. The front shield 302 is electrically connected to the rear shield 304 using a common element 330 of the front shield 302. For example, the common element 330 engages with the main part 366 by an interlocking fit. Optionally, during assembly, the common element 330 can be soldered to the rear shield 304 or welded by a laser welding process or the like.

[0045] During assembly, the dielectric housing 200 is loaded into the outer shield 300. Before loading the dielectric housing 200 into the outer shield 300, the contacts 150 can be pre-loaded into the dielectric housing 200. Alternatively, the contacts 150 can be loaded into the dielectric housing 200 after the dielectric housing 200 has been loaded into the outer shield 300. Before loading the contacts 150 into the dielectric housing 200, the wire 104 (shown in Figure 1) can be terminated at the end portion 180 of the contact 150. The wire 104 is configured to extend through the cable portion 368 of the cavity 364 of the rear shield 304 after being bent downwards at a 90° configuration at the end portion 180. In various embodiments, the housing cover 240 can be closed before the dielectric housing 200 is loaded into the outer shield 300. Alternatively, the housing cover 240 can be closed after the dielectric housing 200 has been loaded into the outer shield 300. In various embodiments, the housing cover 240 can be closed using the shield cover 380. For example, the housing cover 240 can be automatically closed when the shield cover 380 moves from an open position to a closed position. Optionally, if the contact 150 is in a linear configuration (rather than a right-angle configuration), the contact 150 can be formed into a right-angle configuration by closing the shield cover 380. For example, by closing the shield cover 380, the housing cover 240 closes, compressing the termination portion 180 of the contact 150 downwards and allowing the transition portion 170 of the contact 150 to be pressed against the forming anvil 230 for forming. After closing the shield cover 380, the outer shield 300 provides a 360° periphery shield for the contact 150. After closing the shield cover 380, the rear shield 304 can be terminated to the cable 102 by fastening, welding, or soldering it to the cable shield 106 of the cable 102.

[0046] Figure 10 is a partial cross-sectional view of a portion of the cable assembly 120 according to an exemplary embodiment. Figure 11 is a rear perspective partial cross-sectional view of a portion of the cable assembly 120 according to an exemplary embodiment. Figures 10 and 11 show the cable assembly 120 in the assembled position, showing that the contact 150 is received in the dielectric housing 200, and the dielectric housing 200 is received in the outer shield 300. The wire 104 is shown terminated at the end portion 180 of the contact 150. The contact 150 is shown in a right-angle configuration with the end portion 180 oriented perpendicular to the mating portion 160. The transition portion 170 forms a 90° bend between the mating portion 160 and the end portion 180. The forming anvil 230 supports the transition portion 170. In an exemplary embodiment, the transition portion 170 can be formed against the forming surface 234 of the forming anvil 230 by bending the contact body 152 of the contact 150 around the curved surface of the forming anvil 230. For example, the contact 150 is formed in a predetermined position in the dielectric housing 200 to ensure that the mating portion 160 is properly fitted into the front contact channel 226 and the termination portion 180 is properly fitted into the rear contact channel 228. The housing cover 240 holds the contact 150 in the contact channel 220. The housing cover 240 electrically insulates the contact 150 from the shield cover 380.

Claims

1. An electrical connector (100), A dielectric housing (200) extending between a front portion (202) and a rear portion (204), wherein the front portion is configured to mate into a mating electrical connector, and the dielectric housing includes a front contact channel (226), a rear contact channel (220), and a molded anvil (230) between the front contact channel and the rear contact channel, wherein the rear contact channel extends in a direction intersecting the front contact channel, and the dielectric housing (200) A contact (150) comprising a contact body (152) between a mating portion (160) and a terminal portion (180) of the contact, wherein the terminal portion is configured to terminate on an electric wire (104), the mating portion is configured to mate into the mating contact of the mating electrical connector, the mating portion is received into the front contact channel, the contact body has a transition portion (170) formed along the molded anvil that positions the terminal portion in the rear contact channel, and the terminal portion is oriented in a direction intersecting the mating portion, and the contact (150) and An electrical connector (100) equipped with [a specific feature].

2. The transition portion (170) follows an arc-shaped path, as described in claim 1, for the electrical connector (100).

3. The electrical connector (100) according to claim 1, wherein the molded anvil (230) includes a molded surface (234), and the transition portion (170) is molded on the molded surface.

4. The electrical connector (100) according to claim 1, wherein the mating portion (160) is received in the front contact channel (226), and the terminal portion (180) enters the rear contact channel (220).

5. The electrical connector (100) according to claim 1, wherein the rear contact channel (220) is oriented perpendicular to the front contact channel (226).

6. The dielectric housing (200) includes a housing cover (240) of the rear portion (204) of the dielectric housing for covering the contact (150) in the rear contact channel, wherein the housing cover is movable between an open position and a closed position, the electrical connector (100) according to claim 1.

7. The electrical connector (100) according to claim 6, wherein the housing cover (240) is configured to press the end portion (180) of the contact (150) and form the transition portion (170) when the housing cover moves from the open position to the closed position.

8. The electrical connector (100) according to claim 6, wherein the housing cover (240) includes a contact pocket for receiving the end portion (180) of the contact (150).

9. The electrical connector (100) according to claim 6, wherein the housing cover (240) is connected to the dielectric housing (200) by a hinge (242), and the housing cover rotates between the open position and the closed position by the hinge.

10. The electrical connector (100) according to claim 6, wherein the housing cover (240) is integrated with the dielectric housing (200) and has a monolithic single structure.

11. The electrical connector (100) according to claim 6, further comprising an outer shield (300) surrounding at least a portion (160) of the dielectric housing (200) to provide an electrical shield around the dielectric housing, wherein the outer shield includes a shield cover (380) that covers the housing cover (240).

12. The electrical connector (100) according to claim 11, wherein the shield cover (380) is movable between an open position and a closed position, and the shield cover is configured to move the housing cover (240) from the open position to the closed position when the shield cover moves from the open position to the closed position.

13. The electrical connector (100) according to claim 1, further comprising an outer shield (300) surrounding at least a portion (160) of the dielectric housing (200) to provide an electrical shield around the dielectric housing.

14. The electrical connector (100) according to claim 13, wherein the outer shield (300) includes a front shield (302) and a rear shield (304), the rear shield being separate from the front shield and configured to be electrically coupled to the front shield, the front shield including a front cavity for receiving the front portion of the dielectric housing (200), and the rear shield including a rear cavity for receiving the rear portion (204) of the dielectric housing.

15. An electrical connector (100), A dielectric housing (200) extending between a front portion (312) and a rear portion (314), the dielectric housing including an upper portion (206) and a bottom portion (208), the dielectric housing including a first side portion (210) and a second side portion (212), the front portion forming a mating end of the dielectric housing configured to mate with a mating electrical connector, the bottom portion forming a cable end configured to receive a cable, the dielectric housing including contact channels (220, 226) between the front portion and the rear portion, each contact channel including a front contact channel (226), a rear contact channel, and a molded anvil (230) between the front contact channel and the rear contact channel, the rear contact channel extending between the front contact channel and the bottom portion of the dielectric housing, A contact (150) received in the corresponding contact channel, each contact including a contact body (152) between a mating portion (160) and a termination portion (180) of the contact, the termination portion extending to the cable end and configured to terminate on the wire (104) of the cable, the mating portion configured to mat with the mating contact of the mating electrical connector, the mating portion received in the front contact channel, the contact body having a transition portion (170) formed along the molded anvil to position the termination portion in the rear contact channel, and the termination portion oriented in a direction intersecting the mating portion, the contact (150) and An electrical connector (100) equipped with [a specific feature].

16. The electrical connector according to claim 15, wherein the contact channels (220) are aligned in a line between the first side portion (210) and the second side portion (212), and the contact channels are separated by a separation wall (222).

17. The electrical connector according to claim 15, wherein after the mating portion (160) is received in the front contact channel (226), the terminal portion (180) enters the rear contact channel (228).

18. The electrical connector according to claim 15, wherein the dielectric housing (200) includes a housing cover (240) of the rear portion (204) of the dielectric housing for covering the contact (150) in the rear contact channel, the housing cover is movable between an open position and a closed position, and the housing cover is configured to press the end portion (180) of the contact to form the transition portion when the housing cover moves from the open position to the closed position.

19. The electrical connector according to claim 18, further comprising an outer shield (300) surrounding at least a portion of the dielectric housing (200) and providing an electrical shield around the dielectric housing, wherein the outer shield includes a shield cover (380) covering the housing cover, the shield cover being movable between an open position and a closed position, and the shield cover being configured to move the housing cover from the open position to the closed position when the shield cover moves from the open position to the closed position.

20. An electrical connector (100), A dielectric housing (200) extending between a front portion (312) and a rear portion (314), the front portion configured to mate with a mating electrical connector, the dielectric housing includes a front contact channel (226), a rear contact channel (228), and a molded anvil (260) between the front contact channel and the rear contact channel, the rear contact channel extending in a direction intersecting the front contact channel, and the dielectric housing includes a housing cover (240) coupled to the rear portion of the dielectric housing and covering the rear contact channel, An outer shield (300) surrounds at least a portion of the dielectric housing and provides an electrical shield around the dielectric housing, the outer shield (300) includes a shield cover (380) that covers the housing cover, A contact (150) comprising a contact body (152) between a mating portion (160) and a termination portion (180) of the contact, wherein the termination portion is configured to terminate on a wire (104), the mating portion is configured to mate with the mating contact of the mating electrical connector, the contact body is positioned along the molded anvil (230) such that it forms a transition portion (170) according to the molded anvil by the cover which closes the rear contact channel and is coupled to the rear of the dielectric housing, the mating portion is received in the front contact channel, the termination portion is received in the rear contact channel, and the termination portion is oriented in a direction intersecting the mating portion, and the contact (150) and An electrical connector (100) equipped with [a specific feature].

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