Angled Connector
The single-piece angled connector design addresses robustness and impedance control issues by integrating shield and dielectric sections, enhancing connector performance and simplifying manufacturing.
Patent Information
- Application Number
- JP2025545080
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-02-07
- Filing Date
- 2024-02-02
- Publication Date
- 2026-01-29
AI Technical Summary
Current angled connector designs face issues with robustness and impedance control due to a two-part construction, particularly at the mating interface between the cable and contacts, which complicates manufacturing and increases component count.
A single-piece angled connector design featuring a shield and dielectric with integrated sections forming a continuous structure, eliminating the need for additional components like inner ferrules and improving shielding and impedance control.
Enhances connector robustness and simplifies manufacturing by reducing components, while maintaining effective shielding and impedance control.
Smart Images
Figure 2026503775000001_ABST
Abstract
Description
[Technical Field]
[0001] The subject matter herein relates to electrical connectors, and more particularly to angled subassemblies and associated angled connectors. [Background technology]
[0002] Angled connectors generally include a housing, contacts disposed within the housing, a shield disposed around the housing, and a cable disposed within the housing and electrically connected to the contacts. Angled connectors are used in applications where the contacts of the connector must be oriented at an angle relative to the direction of the cable extending into the connector. Summary of the Invention [Problem to be solved by the invention]
[0003] Current angled connector designs typically rely on two-part construction, with the mating interface between the cable and contacts at the corner of the connector's bend. These arrangements can lead to a loss of robustness due to the additional interface at the signal contacts and / or shield, and can make impedance control difficult. A simplified design that improves connector robustness and impedance control, while also reducing the number of required components, is desired. [Means for solving the problem]
[0004] The connector includes a shield, contacts, and a dielectric. The shield includes a first section extending in a first direction and a second section extending in a second direction at a bend angle from the first section. The dielectric is disposed within the shield and defines the first section extending in the first direction and the second section extending in the second direction at a bend angle from the first section. The contacts are disposed entirely within the dielectric and include a connecting end configured to connect to a conductor of a cable and a mating end configured to engage with a mating contact. The mating end extends in the first direction, and the connecting end extends in the second direction at a bend angle from the mating end.
[0005] The invention will now be described, by way of example, with reference to the accompanying drawings in which: [Brief explanation of the drawings]
[0006] [Figure 1] FIG. 1 is a rear perspective view of a connector assembly including an angled connector according to one embodiment of the present disclosure. [Figure 2] FIG. 2 is a front perspective view of the connector assembly of FIG. 1. [Figure 3] FIG. 2 is a partial side perspective view of an angled connector of the connector assembly of FIG. 1. [Figure 4] FIG. 2 is an exploded perspective view of the connector assembly of FIG. 1. [Figure 5] FIG. 2 is a bottom perspective view of a shield subassembly of the angled connector of FIG. 1. [Figure 6] FIG. 2 is a perspective view of the dielectric of the angled connector of FIG. 1. [Figure 7] 2 is a perspective view of the outer ferrule of the connector assembly of FIG. 1 in an uncrimped state. [Figure 8] FIG. 2 is a perspective view of a cable of the connector assembly of FIG. 1 connected to a contact of the angled connector. [Figure 9] FIG. 9 is a perspective view of the cable and angled dielectric of FIGS. 6 and 8 with the dielectric cover in the closed dielectric position. [Figure 10]1 is a perspective view of a connector assembly including a cable and an angled dielectric inserted into the shielding subassembly, with the shielding cover of the shielding subassembly in an open position; FIG. [Figure 11] 11 is a perspective view of the connector assembly of FIG. 10 with the shield cover in a closed position and the cable braid removed or unfolded. [Figure 12] 12 is a perspective view of the connector assembly shown in FIG. 11 with the cable braid disposed in the first shield section of the shield subassembly. [Figure 13] FIG. 2 is a top cross-sectional view of the connector assembly of FIG. 1. DETAILED DESCRIPTION OF THE INVENTION
[0007] A connector assembly 10 according to one embodiment of the present disclosure is shown in Figures 1-4. The assembly 10 includes an angled connector or angled connector subassembly 100 and a cable 180 electrically connected thereto. The connector 100 includes an angled shield or angled shield assembly 110, an angled dielectric 150 disposed within the shield assembly 110, a pair of contacts 190 electrically connected to conductors of the cable 180, and an outer ferrule 210 disposed around the cable 180 and the angled shield assembly 110.
[0008] As shown in FIGS. 3-5 , for example, angled shield or shield assembly 110 includes a first or front shield 120 and a second or rear shield 130 extending from the front shield. Front shield 120 includes a first body section 122 extending along the longitudinal axis of connector 100 in a first direction (i.e., longitudinal direction L). Front shield 120 further includes a second body section 124 extending from first body section 122 at a bend angle or in a second direction (i.e., perpendicular direction V) relative to the first direction. In an exemplary embodiment, this angle is approximately 90°, although other non-zero angles may be used without departing from the scope of the present disclosure. First body section 122 and second body section 124 of front shield 120 are preferably integrally formed, such as by stamping or forming sheet metal.
[0009] Second body section 124 of front shield 120 defines laterally extending locking surface 125 as well as vertically extending locking surface 126. Additional locking surfaces 123 may be formed on first body section 122. These protruding latches may serve, for example, to secure a cover to the shield during further processing or to secure connector 100 in an inserted position relative to other components.
[0010] The rear shield 130 includes a first body section 132 extending along the longitudinal direction L, or first direction, of the connector 100 and a second body section 134 extending at a generally curved angle from the first body section. Like the front shield 120, the first and second rear body sections 132, 134 may be formed from a single piece of stamped sheet metal, by way of example. As shown most clearly in FIG. 3 , when the shield cover 136 is in the closed position, the front shield 120 extends to the rearmost end of the shield assembly 110. More specifically, at least the front shield 120 includes a second body section 124 that overlaps or covers at least a portion of both the first and second rear body sections 132, 134. This rearward extension of the front shield 120 is a departure from the prior art and improves connector shielding due to overlapping components.
[0011] The rear shield 130 further includes a shield cover 136. The cover 136 is attached to the remainder of the rear shield 130 by a shield hinge 138. The shield cover 136 is pivotable about the shield hinge 138 relative to the remainder of the rear shield 130 between an open shield position, shown in FIGS. 4, 5, and 10, and a closed shield position, shown in FIGS. 1-3 and 11-13. In the closed position, the shield cover 136 forms part of the second rear body section 134 and extends in a vertical direction V at a bent angle from the first rear body section 132. As shown in FIG. 3, a detent 143 may be formed in or defined by the rear shield 130 and can engage with the second body section 124 of the front shield 120 to secure the front and rear shields together. The detent 143 further serves to provide an additional contact point, thereby improving the EMI / shielding performance of the shield assembly 110.
[0012] As shown in FIG. 5 , the cover 136 defines a protruding flange 140 on each side. Detents 141 are formed (e.g., stamped) in the flange 140. Corresponding recesses or openings 131 are formed in the rear shield 130 and act as latches for the detents, functioning as catches to selectively retain the shield cover 136 in a closed position. It should be understood that the reverse arrangement, as well as a different number of detents and latches, may be used without departing from the scope of this disclosure. In the exemplary embodiment, the openings 131 are formed in tabs 133 extending from the rear of the rear shield 130, although other locations are possible.
[0013] 5, both the second body section 134 and the shield cover 136 define ridge-like protrusions 135 and 137, respectively. Protrusions 135 and 137 each extend at a generally bent angle with the cover in the closed position and function to maintain separation of the wires of the cable 180 and / or the contacts 190 in the assembled state of the connector 100. Protrusions 135 and 137 also provide support during crimping of the outer ferrule 210, instead of the inner ferrule used in the prior art, to prevent excessive deformation (i.e., crushing) of the rear shield 130 and the cable 180 and / or the contacts 190. In the embodiment shown in FIG. 5, the end of the cover 136 of the rear shield 130 is connected to a carrier strip 300. Multiple rear shields 130 may be connected to a carrier strip 300 for transporting the shields 130 during manufacturing or for other uses. As will be understood by those skilled in the art, the carrier strip 300 is removed prior to use of the rear shields 130 as described below.
[0014] As described above, the angled shield assembly 110 of the exemplary embodiment is formed from two components (i.e., a front shield and a rear shield) that are secured together after fabrication, for example, by crimping and / or welding. The components of the angled shield assembly 110 are formed from a conductive material, such as aluminum. The angled shield assembly 110 may be formed by stamping and bending sheet metal. In other embodiments, the shield assembly 110 may be integrally formed.
[0015] As shown in Figures 4, 6, 9, and 13, the angled dielectric 150 has a body comprised of a first dielectric section 152 and a second dielectric section 154. The first dielectric section 152 has a longitudinal axis that extends generally in a first direction, or longitudinal direction L, in the assembled state of the connector 100. The second dielectric section 154 extends generally at a bend angle, or perpendicular to a vertical direction V, from the first dielectric section 152. As with the shield assembly 110, the bend angle of the second dielectric section 154 relative to the first dielectric section 152 may be varied in other embodiments of the present disclosure. As shown in Figure 6, the angled dielectric 150 has a dielectric cover 156 attached to it with a dielectric hinge 158. The dielectric cover 156 is pivotable relative to the remainder of the body of the dielectric 150 about a dielectric hinge 158 between an open position shown in FIGS. 4 and 6 and a closed position shown in FIGS. 9, 10 and 13.
[0016] In the embodiment shown in FIG. 6 , the dielectric 150 has a dielectric catch 159 formed in the second dielectric section 154, and the dielectric cover 156 defines a dielectric latch 160. When the dielectric cover 156 is pivoted to the closed dielectric position, the dielectric latch 160 engages with the dielectric catch 159 to secure the dielectric cover 156 in the closed position. In the exemplary embodiment, the dielectric catch 159 is a recess, and the dielectric latch 160 is a protrusion complementary to the recess in the dielectric catch. In other embodiments, the positions of the catch 159 and the latch 160 may be reversed compared to the illustrated arrangement, or the dielectric catch and dielectric latch may be replaced with any other elements capable of engaging with each other to secure the dielectric cover 156 in the closed dielectric position. In other embodiments, the dielectric catch 159 and dielectric latch 160 may be omitted entirely, and the dielectric cover 156 may be held closed by, for example, a friction fit.
[0017] Referring again to FIG. 6 , the second dielectric section 154 defines two channel-like recesses 162 separated by an elongated protrusion 164. The recesses 162 are sized to receive a portion of a pair of contacts 190, as seen in FIG. 13 . Similarly, the first dielectric section 152 defines two enclosed elongated terminal openings or passages 166 divided or separated by a wall 168. The terminal passages 166 are sized and shaped to retain the remaining portions of the pair of contacts 190, including their mating ends. A rounded transition 169 between each recess 162 and each passage 166 may include a radius that matches the radius of a bend 193 of the contact 190, as shown in FIGS. 6 and 8 .
[0018] As shown in FIGS. 2, 9, and 13, the first dielectric section 152 extends in the longitudinal direction L beyond the mating end or portion 192 of each contact 190, and the second dielectric section 154 extends beyond the connection (or crimp) end 194 of each contact 190. In this manner, the dielectric 150 continuously covers or houses the contacts 190 along their entire length. This is an improvement over prior art embodiments. Furthermore, the dielectric 150 only receives the contacts 190. Specifically, because the connection between the wires and contacts occurs before bending of the connector 100, no inner ferrule is needed to support the wires of the cable 180 before, after, or between the bends 193 of the contacts 190.
[0019] Angled dielectric 150 is fabricated from a dielectric material, such as plastic, and in one embodiment is integrally formed in a single piece including at least first dielectric section 152, second dielectric section 154, and dielectric cover 156. In the illustrated embodiment, dielectric hinge 158 is a film hinge. In other embodiments, angled dielectric 150 may be formed from multiple separate elements attached to one another.
[0020] As shown most clearly in FIG. 8 , cable 180 includes a pair of wires 182, a braid 183 disposed around the wires, and a cable insulator 184 disposed around braid 183. In an embodiment, cable 180 may be, by way of example only, a twisted pair cable. Braid 183 is formed from a conductive material. Cable insulator 184, formed from an insulating material, is disposed around and abuts braid 183.
[0021] Each contact 190 includes a mating portion 192, a bent portion 193, and a connecting portion or connection section 194 at an end opposite the mating portion 192, as shown in FIGS. 8 and 13 . The contacts 190 are formed from a conductive material. In the exemplary embodiment, the mating portion 192 is a receptacle for a pin, and more specifically, a receptacle defining a split lead-in portion 196. In other embodiments, the mating portion 192 may be a pin or any other type of contact element capable of mating with another contact element. In the illustrated embodiment, the connecting portion 194 is a crimp portion having crimp wings that can be crimped to a conductor. In other embodiments, the connecting portion 194 may be a flat element that can be welded to the conductor or any other type of element that can mechanically and electrically connect the contact 190 to the conductor. The bend 193 of the contact 190 comprises a generally flat section of contact material bent about a single axis to achieve a desired bend angle (e.g., 90°). The connector 100, in the exemplary embodiment, has two contacts 190. The number of contacts 190 corresponds to the number of wires 182 in the cable 180. Alternatively, the angled subassembly 100 may have one contact 190 for embodiments of the cable 180 having one wire 182.
[0022] A crimpable outer ferrule 210 is shown in FIGS. 1, 2, 4, and 7. In its final state, the outer ferrule 210 is crimped to form a generally cylindrical section 212 around the cable 180 and a shaped section 214 that conforms to the outer contour of the second rear body section 134 of the rear shield 130. The outer ferrule 210 is formed from a conductive material. In one embodiment, the outer ferrule 210 is formed by bending or rolling a sheet of conductive material. The outer ferrule 210 is shown in its uncrimped form in FIG. 7. For transport of the outer ferrules 210 during manufacturing or for other uses, multiple outer ferrules 210 may be connected to a carrier strip 216 from which the outer ferrules 210 are separated prior to use of the outer ferrules 210 as described below.
[0023] Assembly of the angled connector 100 will now be described primarily with reference to Figures 1 and 8-12. Referring to Figure 8, a cable 180 is shown prepared by stripping away the cable insulation or jacket 184, braid 183, and foil 185 to expose the wires 182. For each wire 182, a portion of its insulation is stripped away to expose a portion of its conductor. A connection portion 194 of each contact 190 is electrically and mechanically connected (e.g., via a crimp, as shown) to one of the exposed conductors of each wire 182. After the contacts 190 are connected to the wires 182, the contacts 190 are bent to a desired bend angle in a flat region defined between the mating end 192 and the terminating end 194 to form a bend 193.
[0024] 9, in the following step, contact 190 is inserted into angled dielectric 150 in a first or longitudinal direction L with dielectric cover 156 in an open dielectric position (not shown). Cover 150 is then closed to assume the intermediate configuration shown in FIG. 9. Note that dielectric 150 extends in a downward / vertical direction V at least past the connection point between connection portion 194 and wire 182, or where the insulation on wire 182 is stripped.
[0025] 10 , the front shield 120 is pre-assembled with the rear shield 130 to form a shield assembly. The pre-assembled shield assembly 110 is then attached to the dielectric 150. More specifically, with the cover 136 of the rear shield 130 in the open position, the dielectric 150 and contacts 190 are inserted into the shield assembly 110 in the longitudinal direction L of the assembly. As shown in FIGS. 9 and 10 , the depth to which the dielectric 150 is inserted into the shield assembly 110 can be set by several mechanisms, including protruding mechanical stops 170 formed on the ends of the dielectric 150.
[0026] 11 , shield cover 136 is moved from the open shield position to the closed shield position, enclosing dielectric 150 and contacts 190 of shield assembly 110. Cover 136 is held in the closed position by, by way of non-limiting example, the detents described above. In other embodiments, in addition to or instead of engaging the latch and catch mechanism, shield cover 136 may be welded or otherwise bonded to the closed shield position. At this stage, braid 183 extends outward from cable 180.
[0027] With the shield cover 136 in the closed shield position shown in Figure 11, the braid 183 may be placed or folded over the second body section shield 134 of the angled shield assembly 110, as shown in Figure 12. An outer ferrule 210 is then placed over the exposed portion of the braid 183 and a portion of the cable insulation 184 and crimped to the braid, second shield body section 134 and cable insulation 184, as shown in Figures 1 and 2. Figures 1-3 show the angled connector assembly 10 in a fully assembled state.
Claims
1. An angled connector (100) comprising a shield assembly (110), The shield assembly (110) comprises: a front shield (120) having a first body section (122) extending in a first direction; a rear shield (130) fixed to the front shield (120); Including, The rear shield (130) a first rear body section (132) extending in said first direction; a second rear body section (134) extending from said first rear body section (132) at a bend angle relative to said first direction; Including, the forward shield (120) covers at least a portion of the first rear body section (132) and at least a portion of the second rear body section (134) of the rear shield (130); Angled connector (100).
2. The angled connector (100) of claim 1, wherein the forward shield (120) further comprises a second body section (124) extending from the first body section (122) at the bend angle.
3. 3. The angled connector (100) of claim 2, wherein the second body section (124) of the forward shield (120) defines a locking surface (125) protruding from a side of the second body section (124) in a direction away from the rearward shield (130).
4. 3. The angled connector of claim 2, wherein the rear shield includes a cover that is pivotable between an open position in which contacts are insertable into the shield assembly and a closed position in which the contacts are enclosed by the shield assembly.
5. 5. The angled connector (100) of claim 4, wherein the rear shield (130) has a latch (131) and the cover (136) defines at least one detent (141) for selectively engaging the latch to secure the cover in the closed position.
6. 5. The angled connector of claim 4, further comprising an outer ferrule disposed around the second rear body section of the rear shield and the cover.
7. The angled connector (100) of claim 1, further comprising an angled dielectric (150) disposed within the shield assembly (110).
8. The angled dielectric (150) a first dielectric section (152) extending in the first direction through at least a portion of the first rear body section (132) of the rear shield (130) and into the first body section (122) of the front shield (120); a second dielectric section (154) extending from the first dielectric section (152) at the bend angle; Including, 8. The angled connector (100) of claim 7.
9. further comprising at least one contact (190); The at least one contact (190) a connection portion (194) configured to connect to the cable (180); a mating portion (192) configured to engage with a mating contact; and the mating portion extends in the first direction, the connecting portion extends from the mating portion at the bent angle, and the angled dielectric (150) covers the at least one contact (190) over a length of the angled dielectric (150).
9. The angled connector (100) of claim 8.
10. A connector (100), a shield (110, 120, 130) having a first section (122, 132) extending in a first direction and a second section (124, 134) extending in a second direction at a bend angle from said first section; a dielectric (150) disposed within said shield (110, 120, 130) and having a first section (152) extending in said first direction and a second section (154) extending from said first section in said second direction at said bend angle; a contact (190) disposed entirely within said dielectric (150) and having a connecting end (194) configured to connect to a cable and a mating end (192) configured to engage a mating contact, said mating end (192) extending in said first direction and said connecting end extending from said mating end in said second direction at said bend angle; A connector (100) comprising:
11. The connection end (194) of the contact (190) includes a socket having a split lead-in portion (196); The mating end (192) of the contact (190) includes crimp wings; An intermediate portion (193) of the contact (190) forms the bend angle between the connecting end (194) and the mating end (192). The connector (100) of claim 10.
12. The shield (110, 120, 130) a front shield (120) having a first body section (122) extending in the first direction; a rear shield (130) fixed to the front shield (120); Including, The rear shield (130) a first rear body section (132) extending in said first direction; a second rear body section (134) extending from said first rear body section (124) in said second direction at said bend angle; Including, the forward shield (120) covers at least a portion of the first rear body section (132) and at least a portion of the second rear body section (134) of the rear shield (130); The connector (100) of claim 10.
13. 13. The connector (100) of claim 12, wherein the forward shield (120) further includes a second body section (124) extending from the first body section (122) in the second direction at the bend angle and at least partially covering the second rear body section (134).
14. A method of assembling an angled connector (100), comprising: - providing a cable (180) having wires (182); - crimping contacts (190) onto said wires (182); - bending said contacts (190) after said step of crimping them; - inserting the bent contact (190) into a dielectric (150), the dielectric covering the contact over its entire length; - inserting said dielectric (150) into the shield (110, 120, 130); - crimping an outer ferrule (210) onto said cable (180) and said shield (110, 120, 130); A method comprising:
15. forming said shield (110, 120, 130) further comprising The step of forming the shield (110, 120, 130) comprises: forming a front shield (120) having a first body section (122) extending in a first direction; forming a rear shield (130) including a first rear body section (132) extending in the first direction and a second rear body section (134) extending at a bend angle from the first rear body section (132), wherein the front shield (120) covers at least a portion of the first rear body section (132) and at least a portion of the second rear body section (134) of the rear shield (130); before the step of inserting the dielectric (150) into the shields (110, 120, 130), fixing the front shield (120) to the rear shield (130) by at least one of crimping or welding; 15. The method of claim 14, comprising: